Removal and Replacement

Removing And Installing Bonded Windows

Safety measures
^ The following safety measures must always be followed to prevent personal injury: Wear protective gloves and arm protection. Wear protective goggles.
^ Wear protective gloves and arm protection.
^ Wear protective goggles.

Preparations
^ Before cutting out a bonded window, undo and remove any attached parts in the cutting area that are at risk, e.g. trim panels and decorative strips, as well as all electrical connections.
^ Mask any painted areas that are adjacent to the window.
^ Cut off any surplus adhesive, as this makes it easier to cut out the window.
^ Secure vertical windows against dropping out.

Cutting out the window
^ Cut into the adhesive bead at easily accessible points using the cutting tool.
^ Carefully guide the cutting tool around the window, cutting through the adhesive bead.
^ Avoid touching the window frame and the body flange.
^ Use cup suction tools to lift the cut-out window out of the window aperture.

General preparations for bonding
^ Follow the manufacturer's instructions.
^ Cut back the remaining adhesive bead on the metal flange to a residual height of about 1 mm. Do not touch or clean the cut surface afterwards.
^ Carefully rectify any paint damage (apply primer and top coat).
^ Renew the window stops as necessary.

Bonding the window glass
^ Apply an even bead of adhesive to the window or to the body flange.
^ Insert the window glass into the window aperture and center it (2 technicians required).
^ Check the gaps.

^ NOTE: Open the windows and doors while the window is left to dry and do not move the vehicle (slamming doors creates excess pressure which could cause the window to become loose).

Use adhesive tape to prevent the window from falling out or slipping.

Finishing operations
^ Reconnect all electrical connections and check that the components operate correctly.
^ Install the attached parts and check that the fit is accurate and secure. Carry out a visual inspection to ensure that the gaps and joints are even.
^ Carry out a visual inspection to ensure that the gaps and joints are even.
^ Thoroughly clean the window glass.