LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Chevrolet >> 2016 >> Spark LS, Standard Trans >> Repair and Diagnosis >> Body & Frame >> Windows >> Fixed And MOVEABLE Window System >> Repair Instructions >> Liftgate Window Replacement >> Removal Procedure
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Removal Procedure

WARNING:

Refer to Cracked Window Warning .

WARNING:

Refer to Glass and Sheet Metal Handling Warning .

  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 .
  3. Remove liftgate window wiper motor. Refer to Rear Window Wiper Motor Replacement .
  4. Remove rear end spoiler. Refer to Rear End Spoiler Replacement
  5. Disconnect the electrical connectors from the liftgate window defogger bus bars.
  6. Cover the following parts to protect from the broken glass:
    • Upper dash pad
    • Seats and carpeting
    7. Fig 1: Liftgate Window Diagonal Measurement
    GM3212174Courtesy of GENERAL MOTORS COMPANY
  7. Use BO-46974  system to remove the liftgate window.
  8. Take the diagonal measurement (1) of the liftgate window.
  9. Cut cutting wire into four times lengths.

    Approximately. 440 cm (173.5 in), 4 the circumference of the corresponding roll of wire is approximately 100 cm (39.4 in).

    10. Fig 2: Positioning Awl With Cutting Wire Attached
    GM3212175Courtesy of GENERAL MOTORS COMPANY
  10. Heat the awl with a suitable tool.
    11. NOTE:

    Ensure that the liftgate window is not damaged in the process. Otherwise, stress cracks could form in the liftgate 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 center of the liftgate window.
    13. Fig 3: Laying Wire Under Liftgate Window
    GM2027847Courtesy of GENERAL MOTORS COMPANY
    NOTE:

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

  13. Lay the wire under the liftgate window all the way round.
  14. Pull the remaining wire into the interior.
    15. Fig 4: Liftgate Window And Retainers
    GM2787477Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Cutting the retainer could lead into increased cutting effort.

  15. On each side of the liftgate window (2) are two retainers (1) factory - installed.
    16. Fig 5: Positioning Winch With Two Winding Heads Inside Liftgate Window With Cutting Wire Attached
    GM2027971Courtesy of GENERAL MOTORS COMPANY
    NOTE:

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

  16. Place the winch with two winding heads on liftgate window inside.
    • Position the winch vertically at the same height as the C - pillar.
    • Attach the cutting wire to the winch (1).
    • Insert transfer ratchet and pre-tension cutting wire.
    17. NOTE:

    Arrow shows the path taken by the cutting wire.

  17. Cut out the liftgate window until the cutting wire is level with the winch.
    18. Fig 6: Positioning Winch In Area Of Roof Frame With Cutting Wire Attached
    GM2027972Courtesy of GENERAL MOTORS COMPANY
    NOTE:

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

  18. Place the winch 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).
    19. NOTE:

    Arrow shows the path taken by the cutting wire.

    NOTE:

    Increased cutting effort is required in the area of the liftgate window radius.

  19. Cut out the liftgate window until the cutting wire is level with the winch.
    20. Fig 7: Positioning Winch In Middle Of Liftgate Window With Cutting Wire Attached
    GM2027974Courtesy of GENERAL MOTORS COMPANY
    NOTE:

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

  20. Place the winch with two winding heads in the vehicle.
    • Position winch in the middle area of liftgate window (2).
    • Insert transfer ratchet and pre-tension cutting wire (1).
    21. NOTE:

    Arrow shows the path taken by the cutting wire.

  21. Cut out the liftgate window until the cutting wire is level with the winch.
    22. Fig 8: Positioning Both Cutting Tools With Cutting Wires Attached
    GM2027975Courtesy of GENERAL MOTORS COMPANY
    NOTE:

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

  22. Position the winch with one winding head on liftgate window inside.
    • The winch with 2 winding heads (1) stays in the position.
    • Position winch with one winding head (2) in the area of the lower C-pillar.
    • Thread the second end of the wire (3).
    • Insert transfer ratchet and pre-tension cutting wire.
    23. NOTE:

    Arrow shows the path taken by the cutting wire.

    NOTE:

    Increased cutting effort is required in the area of the liftgate window radius.

  23. Cut out the liftgate window until the cutting wire is level with the winch.
    24. Fig 9: Positioning Winch With One Winding Head In Upper Area Of Liftgate Window
    GM2027977Courtesy of GENERAL MOTORS COMPANY
    NOTE:

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

  24. Position the winch with one winding head in the vehicle.
    • Position the winch with one winding head (1) in the upper area of the liftgate window.
    • Insert transfer ratchet and pre-tension cutting wire (2).
    25. NOTE:

    Arrow shows the path taken by the cutting wire.

    NOTE:

    Increased cutting effort is required in the area of the liftgate window radius.

  25. Cut out the liftgate window until the cutting wire is level with the winch.
    26. Fig 10: Positioning Both Cutting Tools With Cutting Wires Attached
    GM2027981Courtesy of GENERAL MOTORS COMPANY
    NOTE:

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

  26. Position the winch with one winding head on liftgate window inside.
    • Position winch with one winding head (1) next to winch with two winding heads so that the cutting wire crosses (2).
    • Insert transfer ratchet and pre-tension cutting wire.
    27. NOTE:

    Arrow shows the path taken by the cutting wire.

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

    Second mechanic required.

  30. Remove liftgate window.
    31. Fig 11: Cutting Out Adhesive Tape
    GM2027901Courtesy of GENERAL MOTORS COMPANY
  31. Cut out the adhesive tape with the knife provided (1) to within 1 mm (0.039 in).
  32. Repair any paint damage.

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

  33. If the liftgate window rubber is damaged, replace with a new one.
  34. 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).

scientia non olet · About LEMON Manuals