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Home/Opel/Agila/Opel Agila B (2008-2011)/Repair manual/Fixed and Moveable Window Systems/Windshield Remove and Install or Replacement
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Windshield Remove and Install or Replacement Opel Agila B

Fixed and Moveable Window Systems 3 illustrations ~1440 words

Note. This document describes the procedure for removing the front windshield 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. Open and support bonnet
  2. 2. Remove 2x wiper arm (2) from vehicle • Remove 2x cap • Remove 2x nut
  3. 3. Remove cowl panel grille (1) • Remove 5x clip, then release 14x clip, 3x locator
  4. 4. Remove 2x top trim cover (3) from front wing • Release 8x clip, then slide out of front wing
  1. 5. Partially release 2x weatherstrip from door aperture
  2. 6. Remove 2x lower inner trim panel (2) from A pillar • Release 3x clip, 6x locator
  3. 7. Remove 2x upper inner trim panel (1) from A pillar • Remove bolt • Release 6x clip, 6x locator
  1. 8. Remove 2x windshield height restrictor (1) from windshield aperture • Prise off
  1. 9. Remove support and close bonnet
  2. 10. Remove 3x weatherstrip (1) from windshield • Pull off

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

  1. 11. Cut cutting wire from Glass Removal Tool Kit BO-46974 to suitable length • Measure diagonal length of windshield 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.

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

  1. 12. Mask off awl insertion point with fabric tape (1) at top right of windshield

Important. The awl must be inserted through the adhesive bead at top right of the windshield in line with A pillar cut out, otherwise the awl will damage the windshield. Twisting the tip of the awl during insertion can also damage the windshield.

  1. 13. Insert awl from Glass Removal Tool Kit BO-46974 through adhesive bead at top right of windshield • Heat awl with suitable tool • Insert awl by applying pressure and making slight movements parallel with adhesive bead
  2. 14. Attach cutting wire to awl • Thread both ends of cutting wire through hole in awl • Bend cutting wire over

Note. Cutting wire is bent at right angles to tip of the awl, to minimise the resistance when pulling it into vehicle.

Important. Twisting the tip of the awl when pulling in cutting wire can damage windshield.

  1. 15. Pull awl and cutting wire into vehicle • Pull in awl and cutting wire to left A pillar • Remove awl – Cut wire from awl

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

  1. 16. Lay cutting wire around underside of windshield • Pull excess wire into vehicle • Apply soapy solution to aperture between windshield and vehicle body • Install fabric tape around windshield
  1. 17. Install winch No. 1 from Glass Removal Tool Kit BO-46974 horizontally to top left of windshield • Degrease relevant areas of windshield • Install ratchet and extension

Note. Winch No. 1 has two winding heads.

  1. 18. 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
  1. 19. Release first section of windshield • Apply soapy solution to windshield aperture as necessary • Cut adhesive bead until cutting wire is vertical with winch No. 1 • Use wire hold tool; position as necessary • Remove ratchet and extension from winch
  1. 20. Install winch No. 2 from Glass Removal Tool Kit BO-46974 horizontally to bottom right of windshield • Degrease relevant areas of windshield • Install ratchet

Note. Winch No. 2 has one winding head.

  1. 21. 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
  1. 22. Release second section of windshield • Apply soapy solution to windshield aperture as necessary • Cut adhesive bead until cutting wire is level with lower right side corner • Use wire hold tool; position as necessary
  1. 23. Reposition winch No. 2 horizontally under winch No. 1 • Release pre-tension on cutting wire to allow repositioning of winch No. 2 • Remove ratchet • Degrease relevant areas of windshield • Install ratchet
  2. 24. Release third section of windshield • Apply soapy solution to windshield aperture as necessary • Cut adhesive bead until cutting wire is at centre of windshield • Use plastic cover from Glass Removal Tool Kit BO-46974 ; position as necessary to protect instrument panel
  1. 25. Reposition winch No. 2 vertically with left A pillar • Release pre-tension on cutting wire to allow repositioning of winch • Remove ratchet • Degrease relevant areas of windshield • Install ratchet
  2. 26. Release fourth section of windshield • Apply soapy solution to windshield aperture as necessary • Cut adhesive bead until cutting wire is horizontal with winch No. 2 • Use plastic cover and wire hold tool; position as necessary • Remove ratchet
  1. 27. Reposition winch No. 1 horizontally to bottom of windshield • Install ratchet • Release pre-tension on cutting wire to allow repositioning of winch • Remove ratchet • Degrease relevant areas of windshield
  2. 28. Reposition winch No. 2 diagonally to upper centre of windshield • Install ratchet • Release pre-tension on cutting wire to allow repositioning of winch • Remove ratchet • Degrease relevant areas of windshield

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

  1. 29. Release fifth section of windshield • Apply soapy solution to windshield aperture as necessary • Install ratchet and extension • Use wire hold tool; position as necessary
  2. 30. Remove 2x winch from windshield • Remove ratchet and extension • Remove cutting wire from 2x winch
  3. 31. Remove windshield from vehicle, then transfer to suitable work stand • Install 2x Suction Lifter MKM-641 to windshield – Degrease relevant areas of windshield • Remove fabric tape

Note. 2x technician required.

  1. 32. Remove 2x Suction Lifter MKM-641 from windshield

Install

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

Note. 2x technician required.

  1. 34. Degrease sealing surface on windshield (if replacing windshield) • Use glass cleaner from windshield kit

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

  1. 35. Apply primer to sealing surface of windshield (if replacing windshield) • Use primer from windshield kit
  1. 36. Cut residual adhesive bead from windshield aperture to approximately 1 mm thickness • Use knife from Glass Removal Tool Kit BO-46974
  1. 37. Remove any glass splinters from vehicle

Note. If installing original windshield

  1. 38. Degrease sealing surface of windshield aperture • Use glass cleaner from windshield kit
  2. 39. Cut residual adhesive bead from windshield aperture to approximately 1 mm thickness • Use knife from Glass Removal Tool Kit BO-46974

Important. Do not use primer provided with windshield 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 windshield (if replacing windshield).

  1. 40. Apply touch up paint to any damaged bodywork after windshield is removed
  2. 41. Degrease sealing surface on windshield (if installing original windshield) • Use glass cleaner from windshield kit
  3. 42. Install 3x new weatherstrip (1) to windshield • Push on
  1. 43. Install 2x new windshield height restrictor (1) to windshield aperture • Push fit
  1. 44. Assemble suitable application tool for applying adhesive bead • Use adhesive from windshield kit

Important. Cut the tip of cartridge dispenser to enable an adhesive bead of approximately 13 mm thick to be produced.

  1. 45. Apply adhesive bead to windshield aperture • Use suitable application tool

Important. Do not use Tensioning Belt MKM-591 to secure windshield to vehicle during lay-over time.

  1. 46. Install windshield to windshield aperture • Centralise windshield, then apply gentle pressure to ensure correct sealing to windshield aperture • Remove 2x Suction Lifter MKM-641

Note. 2x technician required.

  1. 47. Install 2x upper inner trim panel (1) to A pillar • Secure 3x locator, 3x clip • Install bolt
  2. 48. Install 2x lower inner trim panel (2) to A pillar • Secure 6x locator, 3x clip
  1. 49. Secure 2x weatherstrip to door aperture
  2. 50. Install top trim cover (3) to front wing • Slide on to secure 4x clip
  3. 51. Install cowl panel grille (1) to vehicle • Secure 3x locator, 14x clip, then install 5x clip
  4. 52. Install 2x wiper arm (2) to vehicle • Adjust and align wiper arm • Install 2x nut 18 Nm • Install 2x cap

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