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Quarter 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 the needed amount of one part adhesive, refer to Adhesives, Fluids, Lubricants, and Sealers

Tool BO-46974   glass removal system is recommended for removing glass without destroying it.

Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces.

Removal Procedure

Warning: Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury.
1. Open the rear door.
2. Remove the quarter inner trim finish panel. Refer to Quarter Inner Trim Finish Panel Replacement - Right Side .
3. Disconnect the electrical connectors from quarter window.
4. Install the BO-641   suction holder .

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Note:  The circumference (2) of the roll of wire is approximately 1 m (3.28 ft) .
The length of wire required for removing the glass is the diagonal length (1) of the rear window multiplied by 4.

Note:  The cutting wire is bent at right angles to the "tip" of the awl, to minimize resistance when pulling it in.
5. Unroll 3 m (9.8 ft ) of cutting wire from the roll of wire and cut it to this length.

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Note:  To make insertion with the awl easier, heat the tip (2) of the awl.

Note:  Twisting the tip of the awl (1) when inserting it will damage the quarter window.
6. Insert the awl through the adhesive bead from inner to outer (by applying pressure and making slight movements parallel with the adhesive bead).
7. Thread the end of the cutting wire through the hole of the awl.
8. Pull in the cutting wire with the awl.
9. Lay the cutting wire all round the quarter window under the rubber seal - outside.
10. Insert the awl through the adhesive bead from inner to outer so that after pull in the cutting wire, the wire crosses.
11. Thread the end of the cutting wire through the hole of the awl.
12. Pull in the cutting wire with the awl so that the wire crosses.

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13. Position the cutting tool with 1 winch (2) in the upper left and the cutting tool with 2 winches (3) lower left on the quarter window.
14. Attach the cutting wire (1) and (4) to the winding heads of the winches.
15. Insert the transfer ratchet on the winch and pre-tension the cutting wire.
16. Do the first cut.

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17. Reposition the cutting tool with 1 winch (1) on the right area of the quarter window.
18. Do the second cut.

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19. Reposition the cutting tool with 1 winch (1) to the left area of the quarter window and the cutting tool with 2 winches (2) to the right area of the quarter window.
20. Do the third cut.

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21. Change the cutting wire ends (2) and (3) in the winches (1).
22. Cut out the quarter window.
23. Remove the quarter window.

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24. Cut the adhesive bead all round, using the BO-46974   knife (1) to around 1 mm (0.04 in) thickness.
25. Using a touch-up pen to match the color of the vehicle, repair any paint damage.

Installation Procedure


Note:  Only with new quarter window.
1. Apply primer.

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2. Apply one-part urethane adhesive bead to quarter window.
3. Cut into the tip of the cartridge in such a way that a bead of adhesive approximately 13 mm (0.5 in) thick is produced.
4. Insert quarter window with BO-641   suction holder into the opening.
5. Fix the quarter window using fibre tape.
6. Remove BO-641   suction holder .
7. Connect the electrical connectors to the quarter window.
8. Install the quarter inner trim finish panel. Refer to Quarter Inner Trim Finish Panel Replacement - Right Side .
9. Remove the double layer of masking tape around the perimeter of the painted surfaces.
10. Close the rear door.

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

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