Vauxhall Workshop Service and Repair Manuals

Windscreen, remove, install or replace

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

Remove glass from windscreen

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:   Position the vehicle on level ground and move the front wheels to the straight-ahead position

  Remove

4.   Take the diagonal measurement of the windscreen 5.   Cut cutting wire into four-times lengths •   L48 / L35: ca. 6500 mm •   L08: ca. 6150 mm Note:   The circumference of the corresponding roll of wire is approximately 1 metre.

6.   For vehicles with a rain sensor: •   Unclip rain sensor cover (1) •   Disconnect wiring harness plug (2) •   Release 2x clamp (3)

7.   Detach inside rear view mirror •   Disconnect wiring harness plug (1) •   Compress clamp (2) and pull mirror downwards to remove

9.   Heat the awl with a suitable tool 10.   Stick the awl (1) with adhesive bed in the area of the front wall Note:   Ensure that the windscreen is not damaged in the process, otherwise stress cracks in the windscreen may occur.

12.   Release the roof rail front right and left •   Unclip 2x clip

13.   Lay the wire under the windscreen all the way round Note:   The cutting wire (1) should be rolled in beneath the rubber window seal (2) at the windscreen

14.   Pull the second wire end through •   Stick awl approx. 1 cm overlapping the first entry place with adhesive bed •   Thread the cutting wire into the hole of the awl and bend it over – Pull the rest of the wire into the interior with the awl

17.   Cut out windscreen •   Use the plastic sheet for the protection of the armature board Note:   In the area of the A-pillar/front wall, increased cutting effort must be made. •   Arrow shows the path taken by the cutting wire (1) – Cut out the windscreen until the cutting wire is level with the winch

18.   Place the winch with 2 winding heads in the vehicle •   Position the winch near to the interior rear view mirror (2) Note:   Ensure that the cutting wire is fitted correctly to the winch deflection roller – Insert transfer ratchet and pre-tension cutting wire 19.   Cut out windscreen •   Use the hold-down positioner and the plastic sheet to protect the sunroof Note:   In the area of the A-pillar/roof frame, increased cutting effort must be made. •   Arrow shows the path taken by the cutting wire – Cut out the windscreen until the cutting wire is level with the winch

20.   Place the winch with 1 winding head in the vehicle •   Position the winch with one winding head on the A-pillar on the driver's side (2) •   Attach the cutting wire (1) to the winch 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 windscreen •   Arrow shows the path taken by the cutting wire – Cut out the windscreen until the cutting wire is level with the winch – Use the plastic sheet for the protection of the armature board Note:   Use lubricant on the winch deflection roller. More pulling force is required to cut the area around the A-pillar/bulkhead.

22.   Place the winch with 1 winding head in the vehicle •   Position the winch with one winding head in the area of the roof frame (1) Note:   Ensure that the cutting wire is fitted correctly to the winch deflection roller – Insert transfer ratchet and pre-tension cutting wire (2) 23.   Cut out windscreen •   Arrow shows the path taken by the cutting wire – Cut out the windscreen until the cutting wire is level with the winch – Use the plastic sheet for the protection of the ceiling Note:   Use lubricant on the winch deflection roller. More pulling force is required to cut the area around the A-pillar/roof frame.

24.   Position both cutting tools •   Shift winch with 2 winding heads downwards (1) •   Shift the winch with one winding head (2) in the ceiling area so that the cutting wire (3) is crossed – Insert transfer ratchet and pre-tension cutting wire 25.   Cut out windscreen •   Use the plastic sheet for the protection of the ceiling •   Cut out windscreen until the cutting wire has cut through the adhesive bed completely – Arrow shows the path taken by the cutting wire

29.   Cut off adhesive bead on vehicle •   Cut out the adhesive tape with the knife provided (1) to within 1 mm

  Install

32.   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