Volt

Tailgate Upper 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. Open the tailgate.
3. Remove the tailgate lower trim finish panel. Refer to Tailgate Lower Trim Finish Panel Replacement .
4. Disconnect the electrical connectors from the tailgate window demister bus bar.
5. Remove the rear end spoiler. Refer to Rear End Spoiler Replacement .

Warning: Refer to Defroster Outlet Warning in the Preface section.

6. Cover the following parts to protect from broken glass:

•	Upper dash pad

•	Seats and carpeting




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

Approx. 5200 mm (204.724 in), the circumference of the corresponding role of wire is approx. 1000 mm (39.369 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.

12.1.

Thread both ends of the cutting wire (3) in the bores of the piercing awl (2) and bend them over.

12.2.

Use the piercing awl (2) to pull the cutting wire to the centre of the tailgate window.





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

13. Lay the wire under the tailgate window all the way around.
14. Pull the remaining wire into the interior.




Note: Ensure that the cutting wire (1) is fitted correctly to the winch deflection roller.

15. Place the winch (2) with two winding heads on the tailgate window inside.
16. Position the winch vertically at the same height as the C-pillar.
17. Attach the cutting wire (1) to the winch (2).
18. Insert transfer ratchet and apply tension to the cutting wire.

Note: Arrow shows the path of the cutting wire (1).

19. Cut out the tailgate window until the cutting wire (1) is on the same level with the winch.




Note: Ensure that the cutting wire (1) is fitted correctly to the winch deflection roller.

20. Place the winch (2) with two winding heads on the inside of the tailgate window, in the area of the roof frame.
21. Insert transfer ratchet and apply tension to the cutting wire.

Note: In the area of the tailgate window radius, increased cutting effort is necessary. Arrow shows the path of the cutting wire (1).

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




Note: Ensure that the cutting wire (1) is fitted correctly to the winch deflection roller.

23. Place the winch (2) with two winding heads on the inside of the tailgate window, in the centre area of the tailgate window.
24. Insert transfer ratchet and apply tension to the cutting wire.

Note: Arrow shows the path of the cutting wire (1).

25. Cut out the tailgate window until the cutting wire is on the same level with the winch.




Note: Ensure that the cutting wire (1) is fitted correctly to the winch deflection roller.

26. Place the winch (2) with one winding heads on the inside of the tailgate window, in the area of the lower C-pillar.
27. The winch (1) with 2 winding heads remains in the position.
28. Insert transfer ratchet and apply tension to the cutting wire.

Note: In the area of the tailgate window radius, increased cutting effort is necessary. Arrow shows the path of the cutting wire (1).

29. Cut out the tailgate window until the cutting wire is on the same level with the winch.




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

30. Place the winch with one winding head on the inside of the tailgate window, in the area of the lower C-pillar.
31. The winch (1) with 2 winding heads remains in the position.
32. Insert transfer ratchet and apply tension to the cutting wire.

Note: In the area of the tailgate window radius, increased cutting effort is necessary. Arrow shows the path of the cutting wire (1).

33. Cut out the tailgate window until the cutting wire is on the same level with the winch.




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

34. Place the winch (1) with one winding head on the inside of the tailgate window.
35. Position winch (1) with one winding head next to winch with two winding heads so that the cutting wire (2) crosses.
36. The winch (1) with 2 winding heads remains in the position.
37. Insert transfer ratchet and apply tension to the cutting wire.

Note: Arrow shows the path of the cutting wire (1).

38. Cut out the tailgate window until the cutting wire (2) has cut through the adhesive bead completely.
39. Remove the glass removal system.
40. Install and lock the BO-641 holder onto the tailgate window.

Note: A second technician is required.

41. Remove the tailgate window from the vehicle.



42. Cut the adhesive tape with the provided knife (1) within a depth of 1 mm (0.039 in).
43. Repair any paint damage, using a touch-up pen that matches the vehicle color.
44. Replace the tailgate window rubber if damaged.
45. Cut the adhesive tape on the glass pane with the provided knife within a depth of 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 conditions 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 tailgate window opening as indicated, remove all traces of broken glass from the outer cowl panel, seats, and floor.



4. Apply an adhesive bead (1).

Cut into the tip of the cartridge so that a bead of adhesive with a thickness approx. of 13 mm (0.511 in) is produced.

Note: A second technician is required.

5. Insert the tailgate window.

5.1.	Insert tailgate window, using the BO-641 holder .

5.2.	Place the tailgate window on the roof frames and lower it down.

6. Use fabric tape to secure the tailgate window in position.
7. Remove any excessive urethane adhesive from the body, using a suitable cleaner.

Note: A second technician is required.

8. Use a soft spray of warm water in order for a immediate water leak test.
9. Inspect the tailgate window for leaks.
10. If any leaks are found, use a plastic paddle in order to apply extra urethane adhesive to the leak point.
11. Repeat the water leak test.
12. Maintain the following conditions in order to assure a proper cure of the urethane adhesive:

12.1.

Lower a door window partially in order to prevent pressure buildups when closing the doors before the adhesive is cured.

12.2.

DO NOT drive the vehicle until the adhesive is cured. Refer to the above curing times.

12.3.

DO NOT use compressed air to dry the adhesive.

13. Install the rear end spoiler. Refer to Rear End Spoiler Replacement .
14. Connect the tailgate window demister electrical connectors to the bus bar.
15. Install the rear window radio antenna connects.
16. Install the tailgate lower trim finish panel. Refer to Tailgate Lower Trim Finish Panel Replacement .
17. Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior trim.
18. Close the tailgate.