Vauxhall Workshop Service and Repair Manuals

Replace rear quarter window (fixed) L08

Note:   This documentation describes how to remove glass from the rear quarter window (fixed) using glass removal system BO-46974 . To supplement the existing Video VT 54, the individual working steps for non-destructive removal of the rear quarter window (fixed) are shown.

Warning:   Before starting work, put on the gloves and protective goggles contained in tool kit BO-46974 to prevent injuries to the eyes and hands.

Tool BO-46974 is recommended for removing glass without destroying it. Further information can be found in video VT 54.

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

  Remove

1.   Detach additional weatherstrip on roof frame in rear area (1) •   Unclip additional weatherstrip at B-pillar (2) •   Remove additional weatherstrip from guide

3.   Measure diagonal of window •   Cut off cutting wire to four times the required length, approx. 3800 mm Note:   The circumference of the roll of wire is approx. 1 metre.

5.   Push an awl through the adhesive bed from the inside towards the outside Note:   Ensure that the PU coating is not damaged Note:   Ensure that the rear quarter window is not damaged, otherwise stress cracks may appear in the rear quarter window 6.   Pull in cutting wire •   Thread the cutting wire into the hole of the awl and bend up •   Pull cutting wire through adhesive bed •   Pull cutting wire to the middle of the pane

8.   Pull second end of wire through the adhesive bed with an awl 9.   Fix the rear quarter window in place

10.   Position the cutter •   Position the winch with two winding heads (1) in the front upper area of the rear quarter window Note:   Check that the cutting wire (2) is laid correctly at the winch deflection roller – Insert transfer ratchet and pre-tension cutting wire 11.   Cut out the rear quarter window Note:   Greater tension is required to cut in the area of the glass radius. Use lubricant on the deflector roller. •   Cut out glass until the cutting wire is level with the winch. Note:   Protect moulded headlining against damage. – Arrow shows the path taken by the cutting wire

12.   Position the cutter •   Position the winch with two winding heads (1) in the upper rear of the rear quarter window Note:   Check that the cutting wire (2) is laid correctly at the winch deflection roller – Insert transfer ratchet and pre-tension cutting wire 13.   Cut out the rear quarter window •   Cut out glass until the cutting wire is level with the winch. Note:   Protect moulded headlining against damage. – Arrow shows the path taken by the cutting wire

14.   Position the cutter •   Position the winch with the two winding heads (1) in the lower area of the rear quarter window •   Tension the second end of the wire in the free winding head Note:   Check that the cutting wire (2) is laid correctly at the winch deflection roller – Insert transfer ratchet and pre-tension cutting wire 15.   Cut out the rear quarter window Note:   Greater tension is required to cut in the area of the glass radius. Use lubricant on the deflector roller. •   Continue cutting until the cutting wire has cut through all the adhesive bed Note:   Protect front rear quarter panel from damage. – Arrow shows the path taken by the cutting wire

19.   Cut the adhesive bead off the rear quarter panel •   Using the tool supplied (1), remove the adhesive bead down to a thickness of approx. 1 mm

  Install

23.   Apply adhesive bead •   Cut into the tip of the cartridge in such a way that a bead of adhesive approx. 13 mm thick is produced