Tailgate Window Remove and Install or Replacement Opel Agila B

Note. This document describes the procedure for removing the tailgate window using Glass Removal Tool Kit BO-46974 . As a supplement to the existing video VT 54, the following steps describe how to remove the glass without damaging it.

Remove

1. 1. Remove wiper arm from tailgate • Release cover (1) • Remove nut (2)
2. 2. Release wiper motor from tailgate window • Remove cap (3) – Slide off • Remove nut (4), seal (5)

3. 3. Open tailgate
4. 4. Remove inner trim panel (1) from tailgate • Remove clip (2) • Release 11x clip (3), 2x locator

5. 5. Remove wiper motor (1) from tailgate • Disconnect harness connector (2) • Release bolt (4) • Remove 2x bolt (3)

6. 6. Disconnect 2x harness connector (1) from heated tailgate window
7. 7. Remove 2x rubber trim (2) from tailgate • Release 4x clip • Pull off to release double sided tape
8. 8. Close tailgate

Important. The cutting wire (1) can only be used once.

9. 9. Cut cutting wire from Glass Removal Tool Kit BO-46974 to suitable length • Measure diagonal length of tailgate window and cut off a length of cutting wire that is four times length of diagonal

Note. The roll of cutting wire is approximately 1 metre in circumference.

10. 10. Open tailgate

Important. Fabric tape prevents damage to bodywork when inserting the wire.

11. 11. Mask off wire insertion point with fabric tape (1) at bottom right of tailgate window (when viewed from inside of vehicle)

12. 12. Insert cutting wire (1) through adhesive bead at middle left of tailgate (when viewed from inside of vehicle) • Use suitable pliers – Insert cutting wire by applying pressure and making slight movements parallel with adhesive bead

Note. Cutting wire is inserted through adhesive bead from outside vehicle.

13. 13. Pull cutting wire into vehicle • Pull in cutting wire to right side of tailgate window (when viewed from inside of vehicle) – Use suitable pliers
14. 14. Close tailgate

Important. Fabric tape prevents damage to bodywork and prevents tailgate window falling from vehicle.

15. 15. Lay cutting wire around underside of tailgate window • Install fabric tape around tailgate window
16. 16. Open tailgate
17. 17. Pull excess cutting wire into vehicle • Use suitable pliers

18. 18. Install winch No. 1 from Glass Removal Tool Kit BO-46974 horizontally to bottom left corner of tailgate window (when viewed from outside of vehicle looking up) • Degrease relevant areas of tailgate window • Install ratchet and extension

Note. Winch No. 1 has two winding heads.

19. 19. Install cutting wire to winch • Attach cutting wire to winding head • Ensure cutting wire is correctly located in guide roller • Pre-tension cutting wire using ratchet and extension

20. 20. Release first section of tailgate window • Cut adhesive bead until cutting wire is vertical with winch No. 1 • Use 2x plastic cover from Glass Removal Tool Kit BO-46974 ; position as necessary to protect terminals for heated tailgate window • Remove ratchet and extension from winch

Important. Both plastic covers must be used to prevent the cutting wire damaging the terminals for the heated tailgate window.

21. 21. Install winch No. 2 from Glass Removal Tool Kit BO-46974 horizontally to top right corner of tailgate window (when viewed from outside of vehicle looking up) • Degrease relevant areas of tailgate window • Install ratchet and extension

Note. Winch No. 2 has one winding head.

22. 22. Install cutting wire to winch • Attach cutting wire to winding head • Ensure cutting wire is correctly located in guide roller • Pre-tension cutting wire using ratchet

23. 23. Release second section of tailgate window • Cut adhesive bead until cutting wire is level with top right side corner • Use wire hold tool; position as necessary

24. 24. Reposition winch No. 2 to left side, parallel with winch No. 1 (when viewed from outside of vehicle looking up) • Release pre-tension on cutting wire to allow repositioning of winch No. 2 • Remove ratchet and extension • Degrease relevant areas of tailgate window • Install ratchet and extension
25. 25. Release third section of tailgate window • Cut adhesive bead until cutting wire is at top centre of tailgate window • Use wire hold tool; position as necessary

26. 26. Reposition winch No. 1 horizontally to bottom right corner of tailgate • Install ratchet and extension • Release pre-tension on cutting wire to allow repositioning of winch No. 1 • Remove ratchet and extension • Degrease relevant areas of tailgate window
27. 27. Reposition winch No. 2 diagonally to top left side corner (when viewed from outside of vehicle looking up) • Release pre-tension on cutting wire to allow repositioning of winch No. 2 • Degrease relevant areas of tailgate window • Install ratchet and extension
28. 28. Release fourth section of tailgate window • Cut adhesive bead until cutting wire is level with top left corner • Use wire hold tool; position as necessary • Remove ratchet and extension

29. 29. Reposition winch No. 1 horizontally to top right of tailgate window (when viewed from outside of vehicle looking up) • Install rachet and extension • Release pre-tension on cutting wire to allow repositioning of winch • Remove ratchet and extension • Degrease relevant areas of tailgate window
30. 30. Reposition winch No. 2 diagonally to bottom right corner of tailgate window (when viewed from outside of vehicle looking up) • Install ratchet and extension • Release pre-tension on cutting wire to allow repositioning of winch No. 2 • Remove ratchet and extension • Degrease relevant areas of tailgate window

Note. Cutting wire must cross over itself to complete the cutting operation.

31. 31. Release fifth section of tailgate window • Install ratchet and extension • Use wire hold tool; position as necessary
32. 32. Remove 2x winch from tailgate window • Remove ratchet and extension • Remove wire from 2x winch
33. 33. Close tailgate
34. 34. Remove tailgate window (1) from vehicle, then transfer to suitable work stand • Install 2x Suction Lifter MKM-641 to tailgate window – Degrease relevant areas of tailgate window • Remove fabric tape

Note. 2x technician are required.

35. 35. Remove 2x Suction Lifter MKM-641 from tailgate window

Install

36. 36. Install new tailgate window to suitable work stand (if replacing tailgate window) • Install 2x Suction Lifter MKM-641 to tailgate window – Degrease relevant areas of tailgate window

Note. 2x technician are required.

Important. Allow 10 minutes for the primer to set before installing tailgate window to vehicle.

37. 37. Apply primer to sealing surface of tailgate window (if replacing tailgate window) • Use primer from tailgate window kit

38. 38. Remove 4x height restrictor (1) from tailgate window aperture • Pull off
39. 39. Remove 4x height restrictor (2) from tailgate window • Pull off

40. 40. Cut residual adhesive bead (1) from tailgate window aperture to approximately 1 mm thickness • Use knife from Glass Removal Tool Kit BO-46974

41. 41. Remove any glass splinters from vehicle
42. 42. Degrease sealing surface of tailgate window aperture • Use glass cleaner from tailgate window kit
43. 43. Cut residual adhesive bead from tailgate window to approximately 1 mm thickness • Use knife from Glass Removal Tool Kit BO-46974

44. 44. Install 2x seal (1) to tailgate window (If replacing tailgate window) • Push on to secure double sided tape

Important. Do not use primer provided with tailgate window kit to touch up any damage to bodywork as this is corrosive. Primer is used solely to provide protection against UV light and must only be used on the sealing surface of tailgate window (if replacing tailgate window).

45. 45. Apply touch up paint to any damaged bodywork after tailgate window is removed
46. 46. Degrease sealing surface on tailgate window (if installing original tailgate window) • Use glass cleaner from tailgate window kit
47. 47. Install 4x new height restrictor (2) to tailgate window • Clean mating surfaces of tailgate window • Push on to secure double sided tape
48. 48. Install 4x new height restrictor (1) to tailgate window aperture • Push in
49. 49. Assemble suitable application tool for applying adhesive bead • Use adhesive from tailgate window kit

Important. Cut the tip of cartridge dispenser to enable an adhesive bead of 4 mm to 20 mm thick to be produced.

50. 50. Apply adhesive bead (1) to tailgate window aperture – see “Technical Data” • Use suitable application tool

51. 51. Install tailgate window to tailgate window aperture • Centralise tailgate window, then apply gentle pressure to ensure correct sealing to tailgate window aperture • Install fabric tape to secure tailgate window to vehicle • Remove 2x Suction Lifter MKM-641

Note. 2x technician are required.

52. 52. Install 2x new rubber trim (2) to tailgate • Push on to secure double sided tape • Secure 4x clip
53. 53. Connect 2x harness connector (1) to heated tailgate window

54. 54. Install wiper motor (1) to tailgate • Install 2x bolt (3) 8 Nm • Secure bolt (4) 8 Nm • Connect harness connector (2)

55. 55. Install inner trim panel (1) to tailgate • Secure 2x locator, 11x clip (3) • Install clip (2)
56. 56. Close tailgate

57. 57. Secure wiper motor to tailgate window • Install seal (5), nut (4) 5 Nm • Install cap (3) – Slide on
58. 58. Install wiper arm to wiper motor • Align wiper arm – see operation “Tailgate Window Wiper Arm Position” • Install nut (2) 8 Nm • Secure cover (1)

59. 59. Remove fabric tape from tailgate window