Chevrolet Cruze Repair Manual: Removal Procedure

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

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

Note: Position the vehicle on level ground and move the front wheels to the straight-ahead position.

1. Disconnect battery.
2. Remove air inlet grille panel. Refer to Air Inlet Grille Panel Replacement.
3. Remove windshield garnish molding. Refer to Windshield Garnish Molding Replacement.
4. Remove inside rearview mirror. Refer to Inside Rearview Mirror Replacement.

5. Use BO-46974 system to remove the windshield.

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

6. Take the diagonal measurement of the windshield.
7. Cut cutting wire into four times lengths.

Ca. 6200 mm (244.093 in), the circumference of the corresponding roll of wire is approximately 1000 mm (39.369 in).

8. Heat the awl with a suitable tool.
9. Stick the awl (1) with adhesive bed in the area of the front wall.

Ensure that the windshield is not damaged in the process, otherwise stress cracks in the windshield may occur.

10. Pull the wire through.

• Thread the cutting wire into the hole of the awl and bend it over.
• Pull the cutting wire with the awl to the middle of the steering wheel in the interior.

11. Release the roof   rail front right and left.

12. Lay the wire under the windshield all the way round.

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

13. Pull the second wire end through.

• Stick awl approx. 10 mm (0.393 in) overlapping the first entry place with adhesive bed.
• Thread the cutting wire into the hole of the awl and bend it over.
• Pull the rest of the wire into the interior with the awl.

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

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

• Position winch in right-hand area of the windshield.
• Attach the cutting wire to the winch.
• Insert transfer ratchet and pre-tension cutting wire.

Note: In the area of the A-pillar/front wall, increased cutting effort must be made.

15. Cut out windshield.

• Use the plastic sheet for the protection of the armature board.
• Arrow shows the path taken by the cutting wire (1).
• Cut out the windshield until the cutting wire is level with the winch.

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

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

• Position the winch near to the interior rear view mirror.
• Insert transfer ratchet and pre-tension cutting wire.

Note: In the area of the A-pillar/roof frame, increased cutting effort must be made.

17. Cut out windshield.

• Use the hold-down positioner and the plastic sheet to protect the sunroof.
• Arrow shows the path taken by the cutting wire (1).
• Cut out the windshield until the cutting wire is level with the winch.

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

18. Place the winch with one winding head in the vehicle.

• Position the winch with one winding head on the A-pillar on the driver's side (2).
• Attach the cutting wire (1) to the winch.
• Insert transfer ratchet and pre-tension cutting wire.

Note: Use lubricant on the winch deflection roller. More pulling force is required to cut the area around the A-pillar/bulkhead.

19. Cut out windshield.

• Arrow shows the path taken by the cutting wire.
• Cut out the windshield until the cutting wire is level with the winch.
• Use the plastic sheet for the protection of the armature board.

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

20. Place the winch with one winding head in the vehicle.

• Position the winch with one winding head in the area of the roof frame (1).
• Insert transfer ratchet and pre-tension cutting wire (2).

Note: Use lubricant on the winch deflection roller. More pulling force is required to cut the area around the A-pillar/roof frame.

21. Cut out windshield.

• Arrow shows the path taken by the cutting wire.
• Cut out the windshield until the cutting wire is level with the winch.
• Use the plastic sheet for the protection of the ceiling.

22. Position both cutting tools.

• Shift winch with two winding heads downwards (1).
• Shift the winch with one winding head (2) in the ceiling area so that the cutting wire (3) is crossed.
• Insert transfer ratchet and pre-tension cutting wire.

23. Cut out windshield.

• Use the plastic sheet for the protection of the ceiling.
• Cut out windscreen until the cutting wire has cut through the adhesive bed completely.
• Arrow shows the path taken by the cutting wire.

24. Remove glass removal system.
25. Fit BO-641 holder .

Note: Second mechanic required.

26. Remove windshield.

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

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

29. Cut off the adhesive bead on the glass pane.

Cut out the adhesive tape with the knife provided (1) to within 1 mm (0.039 in).