Vauxhall Workshop Service and Repair Manuals

Windscreen, remove and install or replace

Note:   This document describes the procedure for removing the glass from the windscreen using the glass removal system BO-46974 . As a supplement to the existing video VT 54, individual steps will be shown for removing the windscreen glass without destroying it.

Remove glass from windscreen

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

4.   Remove wind protection panel (1) seal 5.   Remove wiper arms (2) •   Remove 2x cover caps •   Unscrew 2x nut •   Remove 2x washers •   Pull 2x wiper arms off shaft with KM-6626-20 6.   Remove wind protection panel •   Unscrew 2x bolt (arrows) •   Remove wind protection panel from windscreen guide •   Separate washer system hose

8.   Detach roof trim strip (1) in front area on both sides •   Use plastic wedge

9.   Remove lower windscreen trim strip (1) •   Remove from guide

10.   Detach inside rear view mirror •   Manual interior rear view mirror •   Electric interior rear view mirror

11.   Remove A-pillar panelling (2) - both sides •   Unclip 2x clips (1) •   Remove A-pillar panelling from guide

12.   Measure diagonals of front screen •   Cut off cutting wire to four times the required length, 6000 mm Note:   The circumference of the roll of wire is approx. 1 metre.

13.   Heat the awl using a suitable tool 14.   Push awl (1) out through adhesive bed in bulkhead area Note:   To protect the instrument panel padding, place suitable material between windscreen and instrument panel padding. Ensure that the windscreen is not damaged else stress cracks can occur in the windscreen.

15.   Lay wire below windscreen all round. Note:   At the windscreen, the cutting wire (1) must be rolled under the rubber seal (2) all round. Use soap as an aid.

18.   Position winches in the vehicle •   Position the winch with one winding head (1) on the right-hand side of the windscreen •   Position the winch with two winding heads (2) in the lower left-hand area of the windscreen •   Attach 2x cutting wire to winch Note:   Check that the cutting wire is laid correctly at the winch deflection roller – Insert transfer ratchet and pre-tension cutting wire 19.   Cut out windscreen •   Use plastic plate to protect instrument panel padding – Cut out the windscreen using the winch and two winding heads until the cutting wire is level with the winding head – Arrow shows the path taken by the cutting wire 20.   Cut out windscreen •   Use retainers to protect the A-pillar Note:   Increased tension is required to cut in the area of the A-pillar/bulkhead. •   Cut out the windscreen using the winch and one winding head until the cutting wire is level with the winding head •   Arrow shows the path taken by the cutting wire

21.   Position winch with one winding head (1) in the vehicle •   Attach roof frame in the top right-hand area •   Insert transfer ratchet and pre-tension cutting wire Note:   Check that the cutting wire is laid correctly at the winch deflection roller 22.   Cut out windscreen •   Cut out the windscreen using the winch and one winding head until the cutting wire is level with the winding head Note:   Use lubricant on the deflection roller; increased tension is required to cut in the area of the windscreen radius, avoid damage to moulded headlining with plastic sheets. •   Arrow shows the path taken by the cutting wire

23.   Position winch with one winding head (1) in the vehicle •   Attach roof frame in the left area •   Insert transfer ratchet and pre-tension cutting wire Note:   Check that the cutting wire is laid correctly at the winch deflection roller 24.   Cut out windscreen •   Cut out the windscreen using the winch and one winding head until the cutting wire is level with the winding head Note:   Avoid damage to moulded headlining with plastic sheet •   Arrow shows the path taken by the cutting wire

25.   Position winch with one winding head (1) in the vehicle •   Attach in the centre area of the windscreen •   Insert transfer ratchet and pre-tension cutting wire Note:   Check that the cutting wire is laid correctly at the winch deflection roller 26.   Position winch with two winding heads (2) in the vehicle •   Attach in the lower left area of the A-pillar •   Insert transfer ratchet and pre-tension cutting wire Note:   Check that the cutting wire is laid correctly at the winch deflection roller 27.   Cut out windscreen •   Cut out the windscreen using the winch and two winding heads until the cutting wire is level with the winding head Note:   Use a lubricant on the deflection roller, more pulling force is required to cut in the windscreen corner area. •   Arrow shows the path taken by the cutting wire

28.   Position winch with two winding heads (1) in the vehicle •   Attach roof frame in the left area •   Insert transfer ratchet and pre-tension cutting wire Note:   Check that the cutting wire is laid correctly at the winch deflection roller 29.   Cut out windscreen •   Cut out the windscreen until the cutting wire is level with the winch Note:   Use lubricant on the deflection roller; increased tension is required to cut in the area of the windscreen radius, avoid damage to moulded headlining with plastic sheets. •   Arrow shows the path taken by the cutting wire

30.   Position winch with two winding heads (1) in the vehicle •   Attach roof frame in the right-hand area •   Insert transfer ratchet and pre-tension cutting wire Note:   Check that the cutting wire is laid correctly at the winch deflection roller 31.   Cut out windscreen •   Cut out the windscreen until the cutting wire has cut through the adhesive bead completely Note:   Avoid damage to moulded headlining with plastic sheet •   Arrow shows the path taken by the cutting wire

35.   Cut adhesive bead on the vehicle •   Cut the adhesive bead all round using the knife supplied (1) to around 1 mm thickness

  Install

39.   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

44.	Attach interior rear view mirror •   Manual interior rear view mirror •   Electric interior rear view mirror