Cruze

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 the level ground and move the front wheels to the straight-ahead position.
2. Remove the rear window wiper motor. Refer to Rear Window Wiper Motor Replacement .
3. Remove the tailgate upper trim finish panel. Refer to Tailgate Upper Trim Finish Panel Replacement .
4. Disconnect the tailgate window radio aerial connector.
5. Disconnect the electrical connectors from the tailgate window demister bus bars.
6. Cover the following parts to protect from the broken glass:

•	Upper dash pad.

•	Seats and carpeting.




7. Use the BO-46974 system to remove the tailgate window.
8. Take the diagonal measurement (1) of the tailgate window.
9. Cut the cutting wire into four lengths.

Approximately 5200 mm (204.724 in), the circumference of the corresponding roll of wire is approximately 1000 mm (39.370 in).




10. 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).

11. Stick the awl through the adhesive bed in the area of the lower C-pillar.
12. 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.




13. 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.

14. Pull the remaining wire into the interior.



15. Place the winch with two winding heads on the tailgate window inside.

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

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

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

•	Insert the transfer ratchet and the pre-tension cutting wire.

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

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



17. Place the winch with two winding heads in the vehicle.

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

•	Position the winch (2) in the area of the roof frame.

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

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

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

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





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

19. Place the winch with two winding heads in the vehicle.

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

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

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

20. 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.

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

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

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

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

•	Insert the transfer ratchet and the pre-tension cutting wire.

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

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

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





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

23. Position the winch with one winding head in the vehicle.

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

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

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

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

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




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

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

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

•	Insert the transfer ratchet and the pre-tension cutting wire.

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

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

Note: A second mechanic is required.

29. Remove the liftgate window.



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

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

32. If the tailgate window rubber is damaged, replace with a new one.
33. 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 the adhesive bead.

Cut into the tip of the cartridge in such a way that a bead of adhesive approx. 13 mm (0.512 in) thick is produced.

5. Insert the tailgate window.

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

Note: A second mechanic is required.

•	Insert the tailgate window with the BO-641 holder.

6. Secure the tailgate window in position with the 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 build-ups when closing the 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. Connect the electrical connectors from the tailgate window demister bus bars.
14. Connect the tailgate window radio aerial connector.
15. Install the tailgate upper trim finish panel. Refer to Tailgate Upper Trim Finish Panel Replacement .
16. Install the rear window wiper motor. Refer to Rear Window Wiper Motor Replacement .
17. Connect the battery.