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Body Side Front Window Replacement > < Quarterlight Replacement - 5-Door Hatchback 68

Astra J

Windshield Replacement (Regular Windshield)

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 .

Removal Procedure

Warning:  Refer to Cracked Window Warning .

Warning:  Refer to Glass and Sheet Metal Handling Warning .

1. Position the vehicle on level ground and move the front wheels to the straight-ahead position.
2. Disconnect battery. Refer to Battery Negative Cable Disconnection and Connection .
3. Remove plenum water deflector - center. Refer to Plenum Water Deflector Replacement - Center .
4. Remove plenum water deflector - left side. Refer to Plenum Water Deflector Replacement - Left Side .
5. Remove windshield side garnish molding. Refer to Windshield Garnish Molding Replacement .
6. Remove windshield side reveal molding. Refer to Windshield Side Reveal Molding Replacement .
7. Remove inside rearview mirror. Refer to Inside Rearview Mirror Replacement .

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8. Use BO-46974   removal system .
Warning:  Refer to Defroster Outlet Warning .
9. Take the diagonal measurement of the windshield.
10. Cut cutting wire into four times lengths.
  Approx. 6200 mm (244.093 in), the circumference of the corresponding roll of wire is approximately 1000 mm (39.369 in).

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11. Heat the awl with a suitable tool.

Note:  Ensure that the windshield is not damaged in the process, otherwise stress cracks in the windshield may occur.
12. Stick the awl (1) with adhesive bed in the area of the front wall.
13. Pull the wire through.
  •  Thread the cutting wire into the hole of the awl and bend it over.
  •  Pull the cutting wire with the awl to the middle of the steering wheel in the interior.

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14. Release the roof rail front right and left in direction of arrow.

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

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16. Pull the second wire end through.
  •  Stick awl approx. 1 cm (0.393 in) 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.

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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 (2) on windshield inside.
  •  Position winch in right-hand area of the windshield.
  •  Attach the cutting wire to the winch.

Note:  In the area of the A-pillar/front wall, increased cutting effort must be made.
18. Cut out windshield.
  •  Use the plastic sheet for the protection of the armature board.
  •  Arrow shows the path taken by the cutting wire (1).
  •  Insert transfer ratchet and pre-tension cutting wire.
  •  Cut out the windshield 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.
19. Place the winch with two winding heads (2) in the vehicle.
  •  Position the winch near to the interior rear view mirror.
  •  Insert transfer ratchet and pre-tension cutting wire.

Note:  In the area of the A-pillar/roof frame, increased cutting effort must be made.
20. Cut out windshield.
  •  Use the hold-down positioner and the plastic sheet to protect the sunroof.
  •  Arrow shows the path taken by the cutting wire (1).
  •  Cut out the windshield 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. Place the winch with one 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.
  •  Insert transfer ratchet and pre-tension cutting wire.

Note:  Use lubricant on the winch deflection roller. More pulling force is required to cut the area around the A-pillar/bulkhead.
 Arrow shows the path taken by the cutting wire.
22. Cut out windshield.
  •  Cut out the windshield until the cutting wire is level with the winch.
  •  Use the plastic sheet for the protection of the armature board.

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Note:  Ensure that the cutting wire is fitted correctly to the winch deflection roller.
23. Place the winch with one winding head in the vehicle.
  •  Position the winch with one winding head in the area of the roof frame (1).
  •  Insert transfer ratchet and pre-tension cutting wire (2).

Note:  Use lubricant on the winch deflection roller. More pulling force is required to cut the area around the A-pillar/roof frame.
 Arrow shows the path taken by the cutting wire.
24. Cut out windshield.
  •  Cut out the windshield until the cutting wire is level with the winch.
  •  Use the plastic sheet for the protection of the ceiling.

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25. Position both cutting tools.
  •  Shift winch with two 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.

Note:  Arrow shows the path taken by the cutting wire.
26. Cut out windshield.
  •  Cut out windscreen until the cutting wire has cut through the adhesive bed completely.
  •  Use the plastic sheet for the protection of the ceiling.
27. Remove glass removal system.
28. Fit and lock BO-641   holder to windshield.

Note:  Second mechanic required.
29. Remove windshield.

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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. Cut off the adhesive bead on the glass pane
  Cut out the adhesive tape with the knife provided (1) 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 problems 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, floor, and defroster ducts.

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4. Apply adhesive bead.
  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 windshield.
  •  Place the windshield on the roof frames and lower down.
  •  Insert windshield with BO-641   holder. .
6. Secure windshield in position with fabric tape.
7. Second mechanic required.
8. Clean any excess urethane adhesive from the body.
9. Use a soft spray of warm water in order to immediately water test the window.
10. Inspect the window for leaks.
11. If any leaks are found, use a plastic paddle in order to apply extra urethane adhesive at the leak point.
12. Retest the window for leaks.
13. 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.
14. Install the roof rail front right and left.
15. Install inside rearview mirror. Refer to Inside Rearview Mirror Replacement .
16. Install windshield side reveal molding. Refer to Windshield Side Reveal Molding Replacement .
17. Install windshield side garnish molding. Refer to Windshield Garnish Molding Replacement .
18. Install plenum water deflector - left side. Refer to Plenum Water Deflector Replacement - Left Side .
19. Install plenum water deflector - center. Refer to Plenum Water Deflector Replacement - Center .

Body Side Front Window Replacement > < Quarterlight Replacement - 5-Door Hatchback 68