Vauxhall Workshop Service and Repair Manuals

Tailgate Window, Remove and Install

Note:   The removal and installation of the tailgate window is identical on model F 08, F 08 & W5L and F 68.

  Remove

1.   Detach wiper arm (1) KM-6626-20 2.   Detach centre brake light (4) 3.   Remove tailgate inner panelling (2) 4.   For vehicles with tailgate spoiler, detach spoiler 5.   Remove rear window wiper motor 6.   Disconnect wiring harness plug for heated tailgate window 7.   Detach inner gasket (3) – tailgate window.

Important:   To avoid damaging paintwork, protect all adjoining paint surfaces (1, 2) in cutting area of tailgate window with masking tape. Self-adhesive rubber spacers are located in the area of the radii (3) between tailgate and tailgate window. The position of the rubber spacers is indicated on the outer panel of the tailgate by embossed marks. 8.   Remove pane of tailgate window using the following methods: 9.   Method I Note:   The glass is removed from the tailgate window with cutting blades. •   MKM-846-1E Cutting Tool (electric) •   MKM-846-P (pneumatic) 10.   Method II Note:   The glass of the tailgate window is removed with a wire cutting tool. •   MKM-589-B Wire Cutting Tool

11.   Remove glass from tailgate window Note:   Method I •   with Cutting Tool MKM-846 12.   The following cutting blades are used to remove the pane of the tailgate window: 13.   Cutting from inside •   Areas (2) with MKM-846-1 1 from Blade Set MKM-846-90 Note:   Cutting from inside •   Areas (1) with MKM-846-23 from Blade Set MKM-846-110 Note:   14.   Cutting from outside •   Areas (4) with MKM-846-15 from Blade Set MKM-846-100 Note:   If necessary, re-cut in the areas of the radii.

16.   Cutting out the tailgate window Note:   Start at position (1). 17.   I Insert cutting wire through adhesive bead at the side from the outside inwards with pliers. Note:   Cutting wire length approx. 400 mm . 18.   II Cut out tailgate window all around the edge. 19.   Lift tailgate window from tailgate using suction lifter and lay aside on holding device.

  Install

20.   For re-used tailgate windows: 21.   Immediately before installing the tailgate window, cut back adhesive bead on tailgate and tailgate window using a commercially available scraper or using Scraper MKM-846-70 to a depth of 1 mm 22.   Remove masking tape (1) on tailgate without leaving residue. Clean and activate residual bead on tailgate window and window frame. Position rubber spacer (2) in radii of tailgate (see embossed marks on outer panel) and glue in. 23.   Attach inner seal of tailgate window onto welding flange of tailgate. 24.   Apply glass adhesive

25.   For new tailgate windows: 26.   Clean area to be bonded, apply black glass primer – allow to dry for 15 minutes. Apply glass adhesive to primer area of tailgate window all around edge. Use precut applicator nozzle from adhesive set. Areas I and II     1 Primer area 2 Adhesive bead in centre 3 Glass edge 27.   The primer area of the radii (1) is correspondingly transferred from the tailgate to the new tailgate window.

28.   Fit Fixing Aids (3) KM-6187-2 to tailgate window and secure in place with adhesive tape. Insert tailgate window (1) with Suction Lifter MKM-641 into tailgate and gently press into adhesive bed. Align tailgate window uniformly with rear lights (2). 29.   Apply only slight tension to tailgate window using Tensioning Belt MKM-591 . Important:   Comply with lay-over times for freshly bonded panes of glass in conjunction with glass adhesive and airbag equipment 30.   Follow the instructions on processing from the manufacturer of the adhesive and on the packaging

32.	Install rear window wiper motor

34.	Install tailgate inner panelling