For 1990-2009 cars

#### Special Tools

• | BO-46974 Glass Removal System

• | BO-641 Suction Holder

For equivalent regional tools, refer to Special Tools.

Note: 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.

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

Tool 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.

Warning: Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury.

### Removal Procedure

1. Open the rear compartment lid.
2. Remove the rear window trim finish panel. Refer to Rear Window Trim Finish Panel Replacement.
3. Remove the body lock pillar upper trim panel. Refer to Body Lock Pillar Upper Trim Panel Replacement.
4. Cut the cutting wire to length.

Note: The circumference (2) of the roll of wire is approximately 1 m (3.28 ft ).

5. Unroll 6 m (19.68 ft ) of cutting wire from the roll of wire.

Note: The length of wire required for removing the glass is the diagonal length (1) of the rear window replacement multiplied by 4.

Note: Twisting the tip of the awl (1) when inserting it will damage the rear window replacement.

6. Insert awl through the adhesive bed.

• | Insert the awl (2) (by applying pressure and making slight movements parallel with the adhesive bed).

• | To make insertion with the awl easier, heat the tip (3) of the awl.

7. Attach cutting wire to the awl.

• | Thread the cutting wire (1) through the hole of the awl (2).

• | Bend over the cutting wire.

| Note: The cutting wire is bent at right angles to the "tip" of the awl, to minimize resistance when pulling it in.

Note: When pulling in the cutting wire do not twist the "tip" (1) of the awl (to avoid damaging the rear window replacement).

8. Pull the awl and cutting wire into the vehicle.

Pull the cutting wire (2) with awl into the position shown.

Note: When pulling through, keep the flat side of the awl "tip" (1) parallel with the edge of the rear window replacement.

9. Lay the cutting wire on the rear window replacement all the way round.

• | In the area of the four radii (2), lay the cutting wire (1) under the rear window replacement.

• | Fix the cutting wire in position with fabric tape (3).

10. Position winches on rear window replacement.

• | Position winches (I) and (II) and attach cutting wire (1) and (2) to the winding heads of winches (I) and (II).

• | Insert the transfer ratchet on winch (I) and pre-tension the cutting wire.

| Note: Check that the cutting wire has been laid correctly all round, correct if necessary.

• | Roll the cutting wire under the rubber seal of the rear window replacement all the way round.

11. Cut out the rear window.

Note: For a rational rear window replacement cutting operation, the winches (I, II) must be positioned on the rear window replacement in the order shown.

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.
12. Cut out with winch (II).
13. Cut out the rear window.

Re-position winch (II) and continue cutting with winch (I).

Note: Use hold-down positioner (1) and plastic plate (2) in the critical areas.

14. Cut out the rear window.

Re-position winch (I) and finish cutting out.

Note: Use hold-down positioner (1) and plastic plate (2) in the critical areas.

15. Remove rear window.

Remove rear window with second mechanic.

16. 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.

17. Repair any paint damage.

Using a touch-up pen to match the color of the vehicle, repair any paint damage.

18. Cut adhesive bead on the rear window.

Cut the adhesive bead all round using the knife supplied to around 1 mm (0.04 in) thickness.

### Installation Procedure

1. Apply primer.

Note: Only with new rear window pane.

2. 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.

3. Install rear window into the opening.

• | Second mechanic required.

• | Insert rear window with BO-641 suction holder .

• | Position using fibre tape.

4. Remove BO-641 suction holder .
5. Install the rear window trim finish panel. Refer to Rear Window Trim Finish Panel Replacement.
6. Install the body lock pillar upper trim panel. Refer to Body Lock Pillar Upper Trim Panel Replacement.
7. Remove the double layer of masking tape around the perimeter of the painted surfaces.
8. Close the rear compartment lid.