Rear Window Replacement (Sedan)
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Rear Window Replacement (Sedan)
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Special Tools
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BO-46974
Glass Removal System
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For equivalent regional tools, refer to
Special Tools
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Warning
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Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury.
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Note
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The following document describes the procedure for removing the rear window replacement using glass removal system BO-46974. As a supplement to the existing video VT 54, concise steps will be shown for removing the rear window replacement without destroying it. With the introduction of
BO-46974
glass removal system , the conventional glass removing methods are no longer used.
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Position the vehicle on level ground and move the front wheels to the straight-ahead position.
BO-46974
glass removal system is recommended for removing glass without destroying it. Further information can be found in video VT 54.
Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces.
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1.
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Open the rear compartment lid.
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4.
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Note
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The length of wire required for removing the glass is the diagonal length (1) of the rear window replacement multiplied by 4.
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The circumference (2) of the roll of wire is approximately
1 m (3.28 ft)
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Cut the cutting wire to length.
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5.
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Unroll
6 m (19.68 ft)
of cutting wire from the roll of wire.
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6.
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Note
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Twisting the tip of the awl (1) when inserting it will damage the rear window replacement.
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Insert awl through the adhesive bed.
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Insert the awl (2) (by applying pressure and making slight movements parallel with the adhesive bed).
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To make insertion with the awl easier, heat the tip (3) of the awl.
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7.
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Note
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The cutting wire is bent at right angles to the "tip" of the awl, to minimize resistance when pulling it in.
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Attach cutting wire to the awl.
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Thread the cutting wire (1) through the hole of the awl (2).
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Bend over the cutting wire.
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8.
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Note
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When pulling in the cutting wire do not twist the "tip" (1) of the awl (to avoid damaging the rear window replacement).
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When pulling through, keep the flat side of the awl "tip" (1) parallel with the edge of the rear window replacement.
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Pull the awl and cutting wire into the vehicle.
Pull the cutting wire (2) with awl into the position shown.
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9.
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Lay the cutting wire on the rear window replacement all the way round.
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In the area of the four radii, lay the cutting wire (1) under the rear window replacement.
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Fix the cutting wire in position with fabric tape (2).
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10.
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Note
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Check that the cutting wire has been laid correctly all round, correct if necessary.
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Position winches on rear window replacement.
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Position winches (I) and (II) and attach cutting wire (1) and (2) to the winding heads of winches (I) and (II).
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Insert the transfer ratchet on winch (I) and pre-tension the cutting wire.
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Roll the cutting wire under the rubber seal of the rear window replacement all the way round.
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11.
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Note
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For a rational rear window replacement cutting operation, the winches (I, II) must be positioned on the rear window replacement in the order shown.
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When cutting out with the winch, more pulling force is required to cut the areas around the radii. The hold-down positioner (1) and the plastic plate (2) should also be used when cutting in the critical areas.
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Cut out the rear window.
Cut out with winch (II).
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12.
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Note
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Use hold-down positioner (1) and plastic plate (2) in the critical areas.
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Cut out the rear window.
Re-position winch (II) and continue cutting with winch (I).
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13.
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Note
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Use hold-down positioner (1) and plastic plate (2) in the critical areas.
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Cut out the rear window.
Re-position winch (I) and finish cutting out.
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14.
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Remove the rear window.
Remove rear window with second mechanic.
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15.
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Cut adhesive bead on the vehicle.
Cut the adhesive bead all round using the knife supplied (1) to around
1 mm (0.04 in)
thickness.
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16.
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Repair any paint damage.
Using a touch-up pen to match the color of the vehicle, repair any paint damage.
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17.
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Cut adhesive bead on the rear windshield.
Cut the adhesive bead all round using the knife supplied to around
1 mm (0.04 in)
thickness.
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1.
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Note
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Only with new rear window pane.
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Apply primer.
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2.
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Apply adhesive bead.
Cut into the tip of the cartridge in such a way that a bead of adhesive approximately
13 mm (0.5 in)
thick is produced.
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3.
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Install rear window into the opening.
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Second mechanic required.
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Insert rear window with
BO-641
suction holder.
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Position using fibre tape.
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4.
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Remove
BO-641
suction holder.
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7.
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Remove the double layer of masking tape around the perimeter of the painted surfaces.
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8.
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Close the rear compartment lid.
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