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Liftgate Window Replacement (5-Door Wagon 35)

Special Tools

•  BO-641   Suction Holder
•  BO-46974   Glass Removal System

For equivalent regional tools, refer to Special Tools .

For needed amount of one part adhesive, refer to Adhesives, Fluids, Lubricants, and Sealers .

Removal Procedure

Warning:  Refer to Cracked Window Warning .

Warning:  Refer to Glass and Sheet Metal Handling Warning .


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

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the liftgate trim finish panel. Refer to Liftgate Trim Finish Panel Replacement .
3. Remove the liftgate window side garnish molding. Refer to Liftgate Window Side Garnish Molding Replacement .
4. Disconnect the liftgate window radio antenna connector.
5. Disconnect the electrical connectors from the liftgate window defogger bus bars.
6. Cover the following parts to protect from the broken glass:
  •  Upper dash pad
  •  Seats and carpeting

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7. Use BO-46974   system to remove the liftgate window.
8. Take the diagonal measurement (1) of the liftgate window.
9. Cut cutting wire into four times lengths.
  Approximately 5400 mm (212.597 in), the circumference of the corresponding roll of wire is approximately 1000 mm (39.369 in).

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10. Heat the awl with a suitable tool.

Note:  Ensure that the liftgate window is not damaged in the process. Otherwise, stress cracks could form in the liftgate window. Mask off the area with fabric tape (1).
11. Stick the awl (2) through the adhesive bed in the area of the lower C-pillar.
12. 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 (2) to pull the cutting wire to the centre of the liftgate window.

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

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Note:  Ensure that the cutting wire is fitted correctly to the winch deflection roller.
15. Place the winch with two winding heads on liftgate window inside.
  •  Position the winch vertically at the same height as the C-pillar.
  •  Attach the cutting wire to the winch (1).
  •  Insert transfer ratchet and pre-tension cutting wire.

Note:  Arrow shows the path taken by the cutting wire.
16. Cut out the liftgate window until the cutting wire is level with the winch.

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Note:  Ensure that the cutting wire is fitted correctly to the winch deflection roller.
17. Place the winch with two 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:  Arrow shows the path taken by the cutting wire.

Note:  Increased cutting effort is required in the area of the liftgate window radius.
18. Cut out the liftgate window until the cutting wire is level with the winch.

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Note:  Ensure that the cutting wire is laid correctly to the winch deflection roller.
19. Place the winch with two winding heads in the vehicle.
  •  Position winch in the middle area of liftgate window (2).
  •  Insert transfer ratchet and pre-tension cutting wire (1).

Note:  Arrow shows the path taken by the cutting wire.
20. Cut out the liftgate window until the cutting wire is level with the winch.

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Note:  Ensure that the cutting wire is fitted correctly to the winch deflection roller.
21. Position the winch with one winding head on liftgate window inside.
  •  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:  Arrow shows the path taken by the cutting wire.

Note:  Increased cutting effort is required in the area of the liftgate window radius.
22. Cut out the liftgate window until the cutting wire is level with the winch.

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Note:  Check that the cutting wire is laid correctly at the winch deflection roller.
23. Position the winch with one winding head in the vehicle.
  •  Position the winch with one winding head (1) in the upper area of the liftgate window.
  •  Insert transfer ratchet and pre-tension cutting wire (2).

Note:  Arrow shows the path taken by the cutting wire.

Note:  Increased cutting effort is required in the area of the liftgate window radius.
24. Cut out the liftgate window until the cutting wire is level with the winch.

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Note:  Check that the cutting wire is laid correctly to the winch deflection roller.
25. Position the winch with one winding head on liftgate window inside.
  •  Position winch with one winding head (1) next to winch with two winding heads so that the cutting wire crosses (2).
  •  Insert transfer ratchet and pre-tension cutting wire.

Note:  Arrow shows the path taken by the cutting wire.
26. Cut out the liftgate window until the cutting wire (2) has cut through the adhesive bead completely.
27. Remove glass removal system.
28. Fit and lock BO-641   holder onto liftgate window.

Note:  Second technician required.
29. Remove liftgate window.

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30. Cut out the adhesive tape with the knife provided (1) to within 1 mm (0.039 in).
31. Repair any paint damage.
  Using a touch-up pen to match the color of the vehicle, repair any paint damage.
32. If the liftgate window rubber is damaged, replace with a new one.
33. Cut off the adhesive bead on the glass pane.
  Cut out the adhesive tape with the knife provided to within 1 mm (0.039 in).

Installation Procedure

1. Remove all mounds or loose pieces of urethane adhesive from the pinch-weld area.
2. Inspect for any of the following conditions in order to help prevent future breakage of the window:
  •  High weld
  •  Solder spots
  •  Hardened sealer
  •  Any other obstruction or irregularity in the pinch-weld flange
3. After repairing the opening as indicated, perform the following steps:
  Remove all traces of broken glass from the outer cowl panel, seats and floor.

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4. Apply adhesive bead (1).
  Cut into the tip of the cartridge in such a way that a bead of adhesive approx. 13 mm (0.511 in) thick is produced.
5. Insert liftgate window.
  •  Place the liftgate window at the upper area and lower down.
Note:  Second technician required.
   
  •  Insert liftgate window with BO-641   holder .
6. Secure liftgate window in position with fabric tape.
7. Clean any excess urethane adhesive from the body.
8. Use a soft spray of warm water in order to immediately water test the window.
9. Inspect the window for leaks. Refer to Water Hose Test .
10. If any leaks are found, use a plastic paddle in order to apply extra urethane adhesive at the leak point.
11. Retest the window for leaks.
12. Maintain the following conditions in order to properly cure the urethane adhesive:
  •  Partially lower a door window in order to prevent pressure buildups when closing doors before the urethane adhesive cures.
  •  Do not drive the vehicle until the urethane adhesive is cured. Refer to the above curing times.
  •  Do not use compressed air in order to dry the urethane adhesive.
13. Connect the electrical connectors to the liftgate window defogger bus bars.
14. Connect the liftgate window radio antenna connector.
15. Install the liftgate window side garnish molding. Refer to Liftgate Window Side Garnish Molding Replacement .
16. Install the liftgate trim finish panel. Refer to Liftgate Trim Finish Panel Replacement .
17. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .

Body Systems > Fixed and Moveable Window Systems > Repair Instructions > Liftgate Window Replacement - 5-Door Estate 35

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