Vauxhall Workshop Service and Repair Manuals

Rear window, remove, install or replace - L69

Note:   This document describes the procedure for removing the glass from the rear window 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 window glass without destroying it.

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

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.

  Remove

3.	Remove auxiliary brake light

5.   Measure out rear window Note:   Measure the diagonal length of the rear window and cut the cutting wire to four times this length (approx. 5560 mm). The circumference of the wire roll is approximately 1 metre.

6.   Heat the awl with a suitable tool 7.   Stick the awl through the adhesive bed in the area of the lower C-pillar (1) Note:   Ensure that the rear window is not damaged in the process. Otherwise, stress cracks could form in the rear window. Mask off the area with fabric tape (1) 8.   Pull the wire through •   Thread both ends of the cutting wire (3) in the bores of the piercing awl (2) and bend them. •   Use the piercing awl to pull the cutting wire to the centre of the rear window

9.   Lay the wire under the rear window all the way round Note:   The cutting wire (1) should be rolled in beneath the rubber window seal (2) at the rear window •   Pull the remaining wire into the interior

10.   Place the winch with 2 winding heads in the vehicle •   Position the winch vertically at the same height as the C-pillar (2) •   Attach the cutting wire to the winch (1) Note:   Check that the cutting wire is laid correctly at the winch deflection roller – Insert transfer ratchet and pre-tension cutting wire 11.   Cut out rear window •   Cut out the rear window until the cutting wire is level with the winch – Arrow shows the path taken by the cutting wire

12.   Place the winch with 2 winding heads in the vehicle •   Position the winch (2) in the area of the roof frame •   Insert transfer ratchet and pre-tension cutting wire (1) Note:   Check that the cutting wire is laid correctly at the winch deflection roller 13.   Cut out rear window Note:   Increased cutting effort is required in the area of the rear window radius. •   Cut out the rear window until the cutting wire is level with the winch – Arrow shows the path taken by the cutting wire

14.   Place the winch with 2 winding heads in the vehicle •   Position winch in the middle area of rear window (2) Note:   Check that the cutting wire is laid correctly at the winch deflection roller – Insert transfer ratchet and pre-tension cutting wire (1) 15.   Cut out rear window •   Cut out the rear window until the cutting wire is level with the winch – Arrow shows the path taken by the cutting wire

16.   Position the winch with one winding head in the vehicle •   The winch with 2 winding heads (1) stays in the position •   Position winch with one winding head (2) in the area of the lower C-pillar •   Thread the second end of the wire (3) •   Insert transfer ratchet and pre-tension cutting wire Note:   Check that the cutting wire is laid correctly at the winch deflection roller 17.   Cut out rear window Note:   Increased cutting effort is required in the area of the rear window radius. •   Cut out the rear window until the cutting wire is level with the winch – Arrow shows the path taken by the cutting wire

18.   Position the winch with one winding head in the vehicle •   Position the winch with one winding head (1) in the upper area of the rear window •   Insert transfer ratchet and pre-tension cutting wire (2) Note:   Check that the cutting wire is laid correctly at the winch deflection roller 19.   Cut out rear window Note:   Increased cutting effort is required in the area of the rear window radius. •   Cut out the rear window until the cutting wire is level with the winch – Arrow shows the path taken by the cutting wire

20.   Position the winch with one winding head in the vehicle •   Position winch with one winding head (1) next to winch with two winding heads so that the cutting wire crosses (2) Note:   Check that the cutting wire is laid correctly at the winch deflection roller – Insert transfer ratchet and pre-tension cutting wire 21.   Cut out rear window •   Cut out the rear window until the cutting wire (2) has cut through the adhesive bed completely – Arrow shows the path taken by the cutting wire

25.   Remove adhesive bead from vehicle •   Using the tool supplied, remove the adhesive bead down to a thickness of approx. 1 mm

  Install

29.   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

32.	Install auxiliary brake light