Vauxhall Workshop Service and Repair Manuals

Replace (fixed) rear quarter window - L35

Note:   This document describes the procedure for removing the glass from the rear quarter window (fixed) using the glass removal system BO-46974 . As a supplement to the existing video VT 54, individual steps will be shown for removing the rear quarter window without destroying it.

Warning:   Before beginning any work, put on work gloves and protective goggles from tool set BO-46974 in order to prevent injuries to the eyes and hands.

To remove the glass without destroying it, tool BO-46974 is recommended. For further information, see the video VT 54.

Note:   Park the vehicle on level ground and move the front wheels to the straight-ahead position.

  Remove

1.   Remove roof frame cover •   Prise off with plastic wedge •   Unclip 3x clips (middle arrows) •   Unclip 4x guides (left and right arrows) from D-pillar inner panelling

2.   Remove D-pillar inner panelling •   Unclip D-pillar inner panelling (arrows) – Lift off the moulding from the seat with a plastic wedge – Unclip 5x clip

4.   Detach load compartment cover, side •   Unscrew 4x bolt (1) •   Unclip rear clip

5.   Remove upper inner panelling B-pillar •   Unclip panel (arrow) •   Unclip C-pillar inner panelling

6.   Loosen roof frame additional weatherstrip •   Detach in the area of glass pane

7.   Measure glass pane diagonal •   Cut cutting wire to four times the required length, approx. 3000 mm Note:   The circumference of the roll of wire is approximately 1 metre.

9.   Push the awl (1) through the adhesive bed from the inside to the outside Note:   Ensure that the PU-coating is not damaged in the process. Note:   Ensure that the rear quarter window is not damaged in the process, as otherwise stress cracks may occur in the rear quarter window 10.   Pull in cutting wire •   Thread the cutting wire (2) into the hole of the awl and bend it over •   Pull in the cutting wire through the adhesive bed •   Pull in the cutting wire to the middle of the glass pane

13.   Pull the second wire end through •   Pierce the awl from the inside through the adhesive bed approx.. 1 cm overlapping the first parting place outwards Note:   Ensure that the PU-coating is not damaged in the process. 14.   Pull the second wire end (1) with the awl through the adhesive bed 15.   Fix the rear quarter window in place

16.   Position the cutter •   Position winch with two reels (1) in lower front area of rear quarter window Note:   Ensure that the cutting wire is fitted correctly to the winch deflection sheave (2) – Insert transfer ratchet and pre-tension cutting wire 17.   Cut out the rear quarter window Note:   Increased traction power must be used when cutting within the area of the glass pane radius •   Cut out the screen until the cutting wire is level with the spool Note:   Protect moulded headlining from damage. – Arrow shows path taken by the cutting wire

18.   Position the cutter •   Position winch with two reels (1) in lower rear upper area of rear quarter window Note:   Ensure that the cutting wire is fitted correctly to the winch deflection sheave (2) – Insert transfer ratchet and pre-tension cutting wire 19.   Cut out the rear quarter window •   Cut out the screen until the cutting wire is level with the spool Note:   Protect moulded headlining from damage. – Arrow shows path taken by the cutting wire

20.   Position the cutter •   Position the winch with two winding heads (1) in the direction of travel •   Clamp second end of wire (2) in free reel Note:   Ensure that the cutting wire is fitted correctly to the winch deflection roller – Insert transfer ratchet and pre-tension cutting wire 21.   Cut out the rear quarter window Note:   Increased traction power must be used when cutting within the area of the glass pane radius •   Continue cutting until the cutting wire has cut through all the adhesive bed Note:   Protect front rear quarter panel from damage. – Arrow shows path taken by the cutting wire •   Remove cutting tools

25.   Cut the adhesive bead off the rear quarter panel •   Using the tool supplied, remove the adhesive bead down to a thickness of approx. 1 mm

  Install

28.   Apply adhesive bead •   Cut into the tip of the cartridge in such a way that a bead of adhesive approx. 13 mm thick is produced