Vauxhall Workshop Service and Repair Manuals

Tailgate Window, Remove and Install or Replace - F35 with BO-46974

Note:   This document describes the removal of the tailgate window using the Glass Removal System BO-46974 . Individual steps in the operation for non-destructive removal of the tailgate window are described as an addition to the existing video VT 54.

Warning:   To avoid injuries to the hand and eye area, always put on gloves and goggles from the Tool Kit BO-46974 before starting work.

The Tool BO-46974 is recommended for non-destructive removal of the glass. You will find further information in the video VT 54.

Note:   Park vehicle on a flat surface and move front wheels to the straight ahead position.

  Remove

1.   Detach windscreen wiper arm •   Release cap •   Unscrew nut (1) •   Remove wiper arm (2)

3.   Detach tailgate lower inner panelling •   Unscrew 10x screw (1) •   Unscrew 2x screws at the bottom (arrows) •   Unclip 2x cap for handle (2) •   Unscrew 2x screw for handle – Remove lower tailgate inner panelling

4.   Remove windscreen wiper motor of tailgate wash/wipe system •   Unscrew and remove 2x fastening screws (1) •   Unscrew nut (2) •   Disconnect wiring harness plug. •   Remove windscreen wiper motor •   Remove windscreen wiper motor panelling on the outside

5.   Unclip panelling for third brake light 6.   Remove third brake light •   Unscrew bolt (1) •   Disconnect wiring harness plug (2) •   Take out third brake light

7.   Detach tailgate upper inner panelling •   Unclip 6x cover (1) •   Unscrew 6x bolt (2) •   Remove tailgate upper inner panelling

9.   Detach rubber seal around the circumference

10.   Measure rear window diagonals •   Cut off cutting wire to four times the required length, approx 4960 mm Note:   The circumference of the roll of wire is approx. 1 metre.

12.   Push awl through bed of adhesive •   Push awl (1) through the bed of adhesive in the area of the windscreen wiper motor of the tailgate Note:   Ensure that the tailgate window is not damaged as otherwise stress cracks may occur in the tailgate window. 13.   Insert the cutting wire •   Thread cutting wire (2) into the bore in the awl and bend over •   Draw cutting wire in as far as the centre of the window

15.   Pull though end of the wire •   Push pointed awl through the bed of adhesive overlapping the first entry point by approx. 1 cm . •   Thread cutting wire (1) into the bore in the awl and bend over – Draw the rest of the wire into the interior with the pointed awl

16.   Position the winch with two reels in the vehicle •   Position winch (1) in the lower left area of the tailgate window •   Attach cutting wire (2) to winch Note:   Ensure the cutting wire is laid correctly around the pulley of the winch – Insert ratchet and apply tension to the cutting wire 17.   Cut out the tailgate window •   Cut out tailgate window until the cutting wire reaches the height of the reel – Arrow shows the direction in which the cutting wire is running

18.   Position the winch with two reels in the vehicle •   Position winch (1) in the left area of the tailgate window Note:   Ensure the cutting wire (2) is laid correctly around the pulley of the winch. – Insert ratchet and apply tension to the cutting wire 19.   Cut out the tailgate window Note:   It is necessary to apply additional tensioning force when cutting in the area of the window radius. Use lubricant on the pulley. •   Cut out tailgate window until the cutting wire reaches the height of the reel – Arrow shows the direction in which the cutting wire is running

20.   Position winch with one reel in the vehicle •   Position winch (3) in the lower right area of the tailgate window •   Attach cutting wire (2) to winch Note:   Ensure the cutting wire is laid correctly around the pulley of the winch Note:   Winch with two reels (1) retains its position. – Insert ratchet and apply tension to the cutting wire 21.   Cut out the tailgate window •   Cut out tailgate window until the cutting wire reaches the height of the reel – Arrow shows the direction in which the cutting wire is running

22.   Position winch with one reel in the vehicle •   Position winch (3) in the right area of the tailgate window Note:   Ensure the cutting wire (2) is laid correctly around the pulley of the winch. Note:   Winch with two reels (1) retains its position. – Insert ratchet and apply tension to the cutting wire 23.   Cut out the tailgate window Note:   It is necessary to apply additional tensioning force when cutting in the area of the window radius. Use lubricant on the pulley. •   Cut out tailgate window until the cutting wire reaches the height of the reel – Arrow shows the direction in which the cutting wire is running

24.   Position the winch with two reels in the vehicle •   Position winch (1) in the upper left area of the tailgate window Note:   Ensure the cutting wire (2) is laid correctly around the pulley of the winch. Note:   Winch with one reel (3) remains in position. – Insert ratchet and apply tension to the cutting wire 25.   Cut out the tailgate window Note:   It is necessary to apply additional tensioning force when cutting in the area of the window radius. Use lubricant on the pulley. •   Cut out tailgate window until the cutting wire reaches the height of the reel – Arrow shows the direction in which the cutting wire is running

26.   Position the winch with two reels in the vehicle •   Position winch (1) in the upper right area of the tailgate window Note:   Ensure the cutting wire (2) is laid correctly around the pulley of the winch. Note:   Winch with one reel (3) remains in position. – Insert ratchet and apply tension to the cutting wire 27.   Cut out the tailgate window •   Cut out tailgate window until the cutting wire reaches the height of the reel – Arrow shows the direction in which the cutting wire is running

28.   Position both winches in the vehicle •   Position winch with two reels (1) in the central area of the tailgate window •   Position winch with one reel (3) in the upper right area of the tailgate window Note:   Ensure the cutting wire (2) is laid correctly around the pulley of the winch. – Insert ratchet and apply tension to the cutting wire 29.   Cut out the tailgate window Note:   It is necessary to apply additional tensioning force when cutting in the area of the window radius. Use lubricant on the pulley. •   Cut out tailgate window until the cutting wire reaches the height of the reel – Arrow shows the direction in which the cutting wire is running

30.   Position winches with one reel in the vehicle •   Position winch (3) in the upper central area of the tailgate window Note:   Ensure the cutting wire (2) is laid correctly around the pulley of the winch. Note:   Winch with two reels (1) retains its position. – Insert ratchet and apply tension to the cutting wire 31.   Cut out the tailgate window •   Cut out tailgate window until the cutting wire has cut through the bed of adhesive completely – Arrow shows the direction in which the cutting wire is running •   Remove cutting tool completely

33.   Cut down the bead of adhesive on the vehicle •   Using the tool supplied (1), remove the adhesive bead down to a thickness of approx. 1 mm

  Install

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