Vauxhall Workshop Service and Repair Manuals

Windscreen, Remove and Install or Replace - F69, F35 with BO-46974

Note:   This document describes the removal of the windscreen glass using the Glass Removal System BO-46974 . Individual steps in the operation for non-destructive removal of the windscreen 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 arms (1) •   Detach 2x cap •   Unscrew 2x nut •   Pull off wiper arms 2.   Detach rubber seal (2), water deflector

3.   Detach lower windscreen trim strip •   Detach windscreen trim strip with a suitable tool

4.   Detach water deflector (right side) •   Unscrew and remove 3x quick-release fitting 5.   Detach water deflector (left side) •   Unscrew and remove 5x quick-release fitting •   Unscrew bolt

6.   Detach windscreen trim strip around the circumference •   Remove with plastic wedge

7.   For model year 2000, the windscreen trim strip was installed with retaining clamps on the lower left and right-hand sides. Note:   Mask off the wing to prevent damage (1). •   Carefully prise 2x clamps (3) out of the bed of adhesive using a suitable tool (2)

10.   Detach both inner panelling sections, upper A-pillar •   Prise out 4x covering panels (1), handle •   Unscrew 4x bolt •   Remove 2x handle •   Detach 2x A-pillar upper inner panelling – Unclip 6x clip

11.   Measure windscreen diagonals •   Cut off the cutting wire to four times the length, approx 5900 mm Note:   The circumference of the relevant roll of wire is approx. 1 metre.

13.   Push awl through bed of adhesive in the area of the front bulkhead Note:   Ensure that the windscreen is not damaged as otherwise stress cracks may occur in the windscreen.

14.   Insert wire •   Thread cutting wire into the bore in the awl and bend over •   Draw cutting wire into the interior of the vehicle as far as the centre of the steering wheel with the pointed awl

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

19.   Position the winch with two reels in the vehicle •   Position winch (1) in the upper left area of the A-pillar •   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 20.   Cut out windscreen •   Cut out windscreen until the cutting wire reaches the height of the reel – Arrow shows the direction in which the cutting wire is running

21.   Position the winch with two reels in the vehicle •   Position winch (1) in the upper left area of the A-pillar •   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 22.   Cut out windscreen Note:   It is necessary to apply additional tensioning force when cutting in the area of the windscreen radius. •   Cut out windscreen until the cutting wire reaches the height of the reel Note:   Ensure that the moulded headlining is not damaged. Apply lubricant to the pulley – Arrow shows the direction in which the cutting wire is running

23.   Position winch with one reel in the vehicle •   Position winch (3) horizontally in the lower centre area of the windscreen 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 24.   Cut out windscreen •   Cut out windscreen until the cutting wire reaches the height of the reel Note:   Protect instrument panel from damage. – Arrow shows the direction in which the cutting wire is running

25.   Position winch with one reel in the vehicle •   Position winch (3) in the right lower area of the A-pillar 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 26.   Cut out windscreen Note:   It is necessary to apply additional tensioning force when cutting in the area of the windscreen radius. •   Cut out windscreen until the cutting wire reaches the height of the reel Note:   Protect instrument panel from damage. Use lubricant on the pulley – Arrow shows the direction in which the cutting wire is running

27.   Position winch with one reel in the vehicle •   Position winch (3) in the right upper area of the roof frame 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 28.   Cut out windscreen Note:   It is necessary to apply additional tensioning force when cutting in the area of the windscreen radius. •   Cut out windscreen until the cutting wire reaches the height of the reel Note:   Protect moulded headlining from damage. Use lubricant on the pulley. – Arrow shows the direction in which the cutting wire is running

29.   Position winch with one reel in the vehicle •   Position winch (3) in the centre area of the the windscreen 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 30.   Cut out windscreen •   Cut out windscreen until the cutting wire reaches the height of the reel Note:   Protect moulded headlining from damage. – Arrow shows the direction in which the cutting wire is running

31.   Position the winch with two reels in the vehicle •   Position winch (1) in the right upper area of the roof frame 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 32.   Cut out windscreen •   Cut out windscreen until the cutting wire has cut through the adhesive bed completely – Arrow shows the direction in which the cutting wire is running •   Remove cutting tool completely

35.   Cut down the bead of adhesive on the vehicle •   Cut the bead of adhesive down to a thickness of approx. 1 mm with the enclosed tool

  Install

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