Orlando

Liftgate Window Replacement

Special Tools

For equivalent regional tools, refer to Special Tools .

Warning: Refer to Cracked Window Warning in the Preface section.

Warning: Refer to Glass and Sheet Metal Handling Warning in the Preface section.

1. Position the vehicle on level ground and move the front wheels to the straight-ahead position.
2. Disconnect battery. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
3. Remove tailgate upper trim finish panel. Refer to Tailgate Upper Trim Finish Panel Replacement .
4. Remove tailgate trim finish panel. Refer to Liftgate Trim Finish Panel Replacement .
5. Remove tailgate lower trim finish panel. Refer to Tailgate Lower Trim Finish Panel Replacement .
6. Remove high mount brake light. Refer to High Mount Brake lamp Replacement .
7. Remove rear window wiper motor. Refer to Rear Window Wiper Motor Replacement .
8. Disconnect the electrical connectors from the tailgate window demister bus bars.
9. Cover the following parts to protect from the broken glass:

•	Upper dash pad

•	Seats and carpeting




10. Use BO-46974 system to remove the tailgate window.
11. Take the diagonal measurement (1) of the tailgate window.
12. Cut cutting wire to needed lengths.



13. Heat the awl with a suitable tool.

Note: Ensure that the tailgate window is not damaged in the process. Otherwise, stress cracks could form in the tailgate window. Mask off the area with fabric tape (1).

14. Stick the awl through the adhesive bead in the area of the lower C-pillar.
15. 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 centre of the tailgate window.




16. Lay the wire under the tailgate window all the way round.

Note: The cutting wire (1) should be rolled in beneath the rubber window seal (2) at the tailgate window.

17. Pull the remaining wire into the interior.




Note: Ensure that the cutting wire is fitted correctly to the winch deflection roller.

18. Place the winch (2) with two winding heads on tailgate window inside.

•	Position the winch vertically at the same height as the C-pillar.

•	Attach the cutting wire (1) to the winch (2).

•	Insert transfer ratchet and pre-tension cutting wire.

Note: Arrow shows the path taken by the cutting wire.

19. Cut out the tailgate window until the cutting wire is level with the winch.




Note: Ensure that the cutting wire is fitted correctly to the winch deflection roller.

20. Place the winch (2) 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).

Note: Arrow shows the path taken by the cutting wire.

Note: Increased cutting effort is required in the area of the tailgate window radius.

21. Cut out the tailgate window until the cutting wire levels with the winch.




Note: Ensure Check that the cutting wire is laid correctly to the winch deflection roller.

22. Place the winch (2) with two winding heads in the vehicle.

•	Position winch (2) in the middle area of tailgate window.

•	Insert transfer ratchet and pre-tension cutting wire (1).

Note: Arrow shows the path taken by the cutting wire.

23. Cut out the tailgate window until the cutting wire levels with the winch.




Note: Ensure that the cutting wire (3) is fitted correctly to the winch deflection roller.

24. Position the winch with one winding head on tailgate window inside.

•	The winch (1) with 2 winding heads stays in the position.

•	Position winch (2) with one winding head in the area of the lower C-pillar.

•	Thread the second end of the wire (3).

•	Insert transfer ratchet and apply tension to the cutting wire.

Note: Arrow shows the path taken by the cutting wire.

Note: Increased cutting effort is required in the area of the tailgate window radius.

25. Cut out the tailgate window until the cutting wire levels with the winch.




Note: Check that the cutting wire is laid correctly at the winch deflection roller.

26. Position the winch (1) with one winding head in the vehicle.

•	Position the winch (1) with one winding head in the upper area of the tailgate window.

•	Insert transfer ratchet and pre-tension cutting wire (2).

Note: Arrow shows the path taken by the cutting wire.

Note: Increased cutting effort is required in the area of the tailgate window radius.

27. Cut out the tailgate window until the cutting wire levels with the winch.




Note: Check that the cutting wire (2) is laid correctly to the winch deflection roller.

28. Position the winch (1) with one winding head on tailgate window inside.

•	Position winch (1) with one winding head next to winch with two winding heads so that the cutting wire (2) crosses.

•	Insert transfer ratchet and pre-tension cutting wire.

Note: Arrow shows the path taken by the cutting wire.

29. Cut out the tailgate window until the cutting wire (2) has cut through the adhesive bead completely.
30. Remove glass removal system.
31. Fit and lock BO-641 holder onto tailgate window.

Note: Second mechanic required.

32. Remove the rear window.



33. Cut out the adhesive tape with the knife provided (1) to within 1 mm (0.039 in).
34. Repair any paint damage.

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

35. If the tailgate window rubber is damaged, replace with a new one.
36. 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).

1. Remove all mounds or loose pieces of urethane adhesive from the pinch-weld area.
2. Inspect for any of the following problems in order to help prevent future breakage of the window:

•

High weld

•	Solder spots

•	Hardened sealer

•	Any other obstruction or irregularity in the pinch-weld flange.

3. After repairing the opening as indicated, perform the following steps:

Remove all traces of broken glass from the outer cowl panel, seats and floor.




4. Apply adhesive bead.

Cut into the tip of the cartridge in such a way that a bead of adhesive approx. 13 mm (0.511 in) thick is produced.

5. Insert tailgate window.

•	Place the tailgate window at the upper area and lower down.

Note: Second mechanic required.

•	Insert liftgate window with BO-641 holder.

6. Secure tailgate window in position with fabric tape.
7. Clean any excess urethane adhesive from the body.
8. Use a soft spray of warm water in order to immediately water test the window.
9. Inspect the window for leaks.
10. If any leaks are found, use a plastic paddle in order to apply extra urethane adhesive at the leak point.
11. Retest the window for leaks.
12. Maintain the following conditions in order to properly cure the urethane adhesive:

•	Partially lower a door window in order to prevent pressure buildups when closing doors before the urethane adhesive cures.

•	Do not drive the vehicle until the urethane adhesive is cured. Refer to the above curing times.

•	Do not use compressed air in order to dry the urethane adhesive.

13. Install rear window wiper motor. Refer to Rear Window Wiper Motor Replacement .
14. Install high mount brake light. Refer to High Mount Brake lamp Replacement .
15. Install tailgate lower trim finish panel. Refer to Tailgate Lower Trim Finish Panel Replacement .
16. Install tailgate trim finish panel. Refer to Liftgate Trim Finish Panel Replacement .
17. Install tailgate upper trim finish panel. Refer to Tailgate Upper Trim Finish Panel Replacement .
18. Connect the electrical connectors from the tailgate window demister bus bars.
19. Connect battery. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .