Quarter Window Replacement (5-Door Wagon 35)
Special Tools
| • |
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. |
| 3. |
Disconnect the electrical
connectors from quarter window. |
| 4. |
Install the BO-641
suction holder . |
|
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. |
|
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. |
| 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. |
| 17. |
Reposition the cutting tool
with 1 winch (1) on the right area of the quarter window.
|
| 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. |
| 21. |
Change the cutting wire ends
(2) and (3) in the winches (1). |
| 22. |
Cut out the quarter
window. |
| 23. |
Remove the quarter
window. |
| 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.
|
| 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. |
| 9. |
Remove the double layer of
masking tape around the perimeter of the painted surfaces.
|
|
