Vauxhall Workshop Service and Repair Manuals

Tailgate window, remove, install or replace - L48

Note:   This document describes the procedure for removing the glass from the tailgate 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 glass from the tailgate 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.   Detach lock covering •   Unclip clip •   Unscrew bolt

2.   Detach upper inner panelling (2) - left side •   Unscrew parcel shelf bracket (3) •   Unclip 4x clips 3.   Detach upper inner panelling (2) - right side •   Unscrew parcel shelf bracket (3) •   Unclip 4x clips 4.   Detach inner panelling of lower rear end panel (1) •   Unclip 8x clip

5.   Detach wiper arm •   Unscrew nut (1) and detach wiper arm Note:   Prepare KM-6166 (2) and remove the tailgate arm by tightening the removal screw (3) (arrow)

6.   Unclip windscreen washer motor wiring harness plug (1) and remove 7.   Detach windscreen washer motor •   Unscrew 3x screws (2)

9.   Measure tailgate window •   Measure glass pane •   Cut off cutting wire to four times the required length, 5600 mm

10.   Insert the cutting wire Note:   Cover the puncture on tailgate with fabric tape to avoid damage •   Pierce the cutting wire (1) through with a suitable tool (2) from the outside inward (arrow) at height of the wiring harness plug heatable rear tailgate glass pane •   Pull in the cutting wire to approx. the middle of the glass pane

13.   Insert the second end of the wire •   Stick the cutting wire through the adhesive bed approx. 1 cm overlapping the first puncture •   Pull in the rest of the wire

14.   Position winch in the vehicle •   Position winch with 2 reels (2) in lower area of tailgate window •   Attach cutting wire (1) to winch Note:   Check that the cutting wire is laid correctly at the winch deflection roller •   Insert transfer ratchet and pre-tension cutting wire 15.   Cut out the tailgate window Note:   Use a lubricant on the deflection roller, more pulling force is required to cut in the area of the tailgate window corners •   Cut out tailgate window with winch and 2 reels until the cutting wire is level with the winch – Arrow shows the path taken by the cutting wire

16.   Relocate the winch in the vehicle •   Position winch with 2 reels (2) in lower right area of tailgate window •   Insert transfer ratchet and pre-tension cutting wire (1) Note:   Check that the cutting wire is laid correctly at the winch deflection roller 17.   Cut out the tailgate window •   Cut out tailgate window with winch and 2 reels until the cutting wire is level with the winch – Arrow shows the path taken by the cutting wire

18.   Relocate the winch in the vehicle •   Position the winch with the 2 reels (2) on the right-hand side of the tailgate window •   Insert transfer ratchet and pre-tension cutting wire (1) Note:   Check that the cutting wire is laid correctly at the winch deflection roller 19.   Cut out the tailgate window Note:   Use a lubricant on the deflection roller, more pulling force is required to cut in the area of the tailgate window corners •   Cut out tailgate window with winch and 2 reels until the cutting wire is level with the winch – Arrow shows the path taken by the cutting wire

20.   Relocate the winch in the vehicle •   Position the winch with the 2 winding heads (1) on the upper right-hand side of the tailgate window •   Insert transfer ratchet and pre-tension cutting wire (2) Note:   Check that the cutting wire is laid correctly at the winch deflection roller 21.   Cut out the tailgate window Note:   Use a lubricant on the deflection roller, more pulling force is required to cut in the area of the tailgate window corners •   Cut out tailgate window with winch and 2 reels until the cutting wire is level with the winch – Arrow shows the path taken by the cutting wire

22.   Relocate the winch in the vehicle •   Position the winch with the 2 winding heads (1) on the upper left-hand side of the tailgate window •   Insert transfer ratchet and pre-tension cutting wire (2) Note:   Check that the cutting wire is laid correctly at the winch deflection roller 23.   Cut out the tailgate window •   Cut out tailgate window with winch and 2 reels until the cutting wire is level with the winch – Arrow shows the path taken by the cutting wire

24.   Insert the second end of the wire into the 2nd winding head •   attach cutting wire (2) on empty reel (1) of the winch •   Insert transfer ratchet and pre-tension cutting wire Note:   Check that the cutting wire is laid correctly at the winch deflection roller 25.   Cut out the tailgate window Note:   Use a lubricant on the deflection roller, more pulling force is required to cut in the area of the tailgate window corners •   Cut out tailgate window with winch and 2 reels until the cutting wire is level with the winch – Arrow shows the path taken by the cutting wire

26.   Relocate the winch in the vehicle •   Position winch with 2 reels (1) 180° in the upper left area of the tailgate window so that the reels are pointed towards to middle of the window •   Insert transfer ratchet and pre-tension cutting wire (2) Note:   Cutting wire must cross over itself 27.   Cut out the tailgate window •   Cut out the tailgate window until the cutting wire (2) has cut through the adhesive bed completely •   Remove cutting tools

30.   Cut adhesive bead off the tailgate •   Using the tool supplied (1), remove the adhesive bead down to a thickness of approx. 1 mm

  Install

33.   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