Removal Procedure
Refer to Cracked Window Warning .
Refer to Glass and Sheet Metal Handling Warning .
- Position the vehicle on level ground and move the front wheels to the straight-ahead position.
- Disconnect battery. Refer to Battery Negative Cable Disconnection and Connection .
- Remove liftgate window wiper motor. Refer to Rear Window Wiper Motor Replacement .
- Remove rear end spoiler. Refer to Rear End Spoiler Replacement
- Disconnect the electrical connectors from the liftgate window defogger bus bars.
- Cover the following parts to protect from the broken glass:
- Upper dash pad
- Seats and carpeting
Use BO-46974 system to remove the liftgate window.
- Take the diagonal measurement (1) of the liftgate window.
- Cut cutting wire into four times lengths.
Approximately, 440 cm (173.5 in), 4 the circumference of the corresponding roll of wire is approximately 100 cm (39.4 in).
Heat the awl with a suitable tool.
- Stick the awl through the adhesive bed in the area of the lower C-pillar.
- Pull the wire through.
- Thread both ends of the cutting wire (3) in the bores of the piercing awl (2) and bend them.
- Use the piercing awl (2) to pull the cutting wire to the center of the liftgate window.
- NOTE:
The cutting wire (1) should be rolled in beneath the rubber window seal (2) at the liftgate window.
Lay the wire under the liftgate window all the way round.
- Pull the remaining wire into the interior.
- NOTE:
Cutting the retainer could lead into increased cutting effort.
On each side of the liftgate window (2) are two retainers (1) factory - installed.
- NOTE:
Ensure that the cutting wire is fitted correctly to the winch deflection roller.
Place the winch with two winding heads on liftgate window inside.
- Position the winch vertically at the same height as the C-pillar.
- Attach the cutting wire to the winch (1).
- Insert transfer ratchet and pre-tension cutting wire.
- Cut out the liftgate window until the cutting wire is level with the winch.
- NOTE:
Ensure that the cutting wire is fitted correctly to the winch deflection roller.
Place the winch with two winding heads in the vehicle.
- Position the winch (2) in the area of the roof frame.
- Insert transfer ratchet and pre-tension cutting wire (1).
- Cut out the liftgate window until the cutting wire is level with the winch.
- NOTE:
Ensure that the cutting wire is laid correctly to the winch deflection roller.
Place the winch with two winding heads in the vehicle.
- Position winch in the middle area of liftgate window (2).
- Insert transfer ratchet and pre-tension cutting wire (1).
- Cut out the liftgate window until the cutting wire is level with the winch.
- NOTE:
Ensure that the cutting wire is fitted correctly to the winch deflection roller.
Position the winch with one winding head on liftgate window inside.
- The winch with 2 winding heads (1) stays in the position.
- Position winch with one winding head (2) in the area of the lower C-pillar.
- Thread the second end of the wire (3).
- Insert transfer ratchet and pre-tension cutting wire.
- Cut out the liftgate window until the cutting wire is level with the winch.
- NOTE:
Check that the cutting wire is laid correctly at the winch deflection roller.
Position the winch with one winding head in the vehicle.
- Position the winch with one winding head (1) in the upper area of the liftgate window.
- Insert transfer ratchet and pre-tension cutting wire (2).
- Cut out the liftgate window until the cutting wire is level with the winch.
- NOTE:
Check that the cutting wire is laid correctly to the winch deflection roller.
Position the winch with one winding head on liftgate window inside.
- Position winch with one winding head (1) next to winch with two winding heads so that the cutting wire crosses (2).
- Insert transfer ratchet and pre-tension cutting wire.
- Cut out the liftgate window until the cutting wire (2) has cut through the adhesive bead completely.
- Remove glass removal system.
- Fit and lock BO-641 holder onto liftgate window.
- Remove liftgate window.
Cut out the adhesive tape with the knife provided (1) to within 1 mm (0.039 in).
- Repair any paint damage.
Using a touch-up pen to match the color of the vehicle, repair any paint damage.
- If the liftgate window rubber is damaged, replace with a new one.
- Cut off the adhesive bead on the glass pane.
Cut out the adhesive tape with the knife provided to within 1 mm (0.039 in).
Ensure that the liftgate window is not damaged in the process. Otherwise, stress cracks could form in the liftgate window. Mask off the area with fabric tape (1).
Arrow shows the path taken by the cutting wire.
Arrow shows the path taken by the cutting wire.
Increased cutting effort is required in the area of the liftgate window radius.
Arrow shows the path taken by the cutting wire.
Arrow shows the path taken by the cutting wire.
Increased cutting effort is required in the area of the liftgate window radius.
Arrow shows the path taken by the cutting wire.
Increased cutting effort is required in the area of the liftgate window radius.
Arrow shows the path taken by the cutting wire.
Second mechanic required.