51 31... Notes on window bonding

WARNING: This page is about a different car, the 2010 BMW 550i, 2009 BMW 550i, and 2008 BMW 550i. However, it is still accessible from the selected car via links, so may be relevant.

IMPORTANT: Version with head-up display (HUD):
When replacing windscreen, replace rain/light solar sensor.

These instructions are not applicable to door window cementing (door "center") on the E38/L7:

Work steps for removing and installing window glass:

See REMOVING AND INSTALLING/REPLACING WINDSCREEN , REMOVING AND INSTALLING/REPLACING REAR WINDOW , or REPLACING LEFT OR RIGHT FIXED DOOR WINDOW IN REAR WINDOW FRAME .

The following notes are mandatory and must be observed.

These notes are not applicable to side window bonding (door "center") on the E38/L7:

General:

The vehicle can be towed away or driven without a windscreen, rear window and side window.

The windscreen, rear window and side windows are glued to the body. This bonding will increase the torsional rigidity of the vehicle. To obtain perfect bonding, comply with the installation procedure described in the following.

The adhesive must be applied at room temperatures > 15 °C to avoid negatively affecting the bonded connection.
Adjust the component and vehicle temperature accordingly.
A relative humidity of < 30% significantly slows hardening.
The window glass must be secured against slipping with yellow plastic adhesive tape (sourcing reference: BMW Parts Department) after being installed. The paint must be completely hardened after painting work.
Always apply the adhesive in such a way as to achieve tension-free bonding!

On-the-job safety:

When working with bonding products (adhesive, cleaning agent, bonding agent, etc.):

Wear safety goggles, protective gloves and if necessary an apron.
Ensure rooms are well ventilated.
Change work clothing contaminated with adhesive immediately.
Change work clothing contaminated with solvents and swelling agents immediately (keep spare work clothing on hand).
Take skin protection measures, provide washing facilities including hot water, use silicone-free skin creams
Provide eye douche facilities, change water regularly (once a month).
Comply with the relevant safety regulations
Do not eat, drink or smoke in areas of polyurethane processing.
All use and safety information of the safety data sheet (SDB) for the applicable product apply. The safety data sheet (SDB) can be obtained from the Aftersales Assistance Portal (ASAP)

Replacement of windscreens:

Version with Head-Up Display (HUD):

Marking for HUD must be present on the windscreen.

Version with front passenger airbag:

Stick on SIGN .

Tools for cutting through adhesive bead:

Type

Order/part number

Special cutter (manufacturer: Fein) with oscillating knife

Pneumatically operated
Electrically operated

Sourcing reference: Fein company

BMW knife set

All required knives

PN 81 43 9 428 596

Knife (U-shape)

19.5 mm ⁽¹⁾
24 mm
36 mm
45 mm

Sourcing reference: Fein company

Knife (straight with stop roller)

16 to 35 mm (adjustable)
10 mm (fixed)⁽¹⁾
14 mm (fixed)

Sourcing reference: Fein company

"ROLL OUT 2000 " Window glass repair

Wire cutting system ⁽¹⁾

PN 81 62 0 301 768

Cutting wire

Wire cutting system ⁽¹⁾

PN 83 19 2 150 267

Scalpel

for heavy-duty applications ⁽¹⁾

Handles for cutting wire

Self-locking ⁽¹⁾

Special tool 51 3 270

⁽¹⁾	not included in BMW blade set

Storage temperature:

Storage temperature of all adhesive products of more than 15 °C must be observed.

Adhesive:

The BMW approved polyurethane adhesive must be used for bonding:

Window glass adhesive (Part number 83 19 0 444 144*)
Small repair kit (Part number 83 19 0 444 141*)
Large repair kit (part number 83 19 0 444 145* contains a second window glass adhesive cartridge)

* Sourcing reference: BMW Parts Department

Adhesive is applied to window glass with cartridge gun (pneumatically or electrically operated).

Expiry date of adhesive:

Repair kit (A) and glue cartridges (B) are marked with a date (best before).

Date (1) refers to the calendar week and year (KW/JJJJ).

Fig 1: Identifying Expiry Date Of Adhesive On Kit And Glue Cartridges

Courtesy of BMW OF NORTH AMERICA, INC.

The adhesive cannot be used after this date (1).

Disposal of adhesive:

Pure hardened adhesive is handled as normal waste.

The adhesive is disposed of in paper sacks so that it can react with moisture.

Non-hardened adhesive, cartridges and mixtures of adhesive and solvents and the like must be disposed of as hazardous waste.

Note national regulations.

Bonding agent (glass activator):

The BMW-approved bonding agents must be used to treat adhesive areas:

Glass activator (on ceramic glass), yellow stick, BMW part number: 83 19 0 444 142
Paint activator (on sheet metal flange or residual adhesive bead) blue stick, BMW part number: 83 19 2 154 458

WARNING: Wear cut resistant gloves when breaking the glass ampule

Prepare glass activator and paint activator for application by shaking and snapping (breaking glass ampule).

Apply glass activator by pressing gently. There is no need for final wiping. Air drying time approx. 2 minutes.

Apply paint activator by pressingly gently. Then wipe dry with a paper towel (included in the set).

Bonding agent expiry date:

Repair kit and bonding agent are marked with a date (Best Before).

The bonding agent may only be used up to this date (if not already opened previously).
After opening, keep only for one week even if the expiry date has not yet been reached.

Application of bonding agent:

The bonding agent is used for adhesion between glass or ceramic glass and the adhesive. Therefore, a thin, homogeneous and continuous line of bonding agent must be applied.

After compressing the adhesive bead, make sure that there is 1 to 2 mm wide bonding agent trace is on the ceramic glass next to the adhesive bead (serves visual inspection).

The adhesive bead may become up to 15 mm wide in compressed condition. The width of the adhesion agent is therefore at least 17 mm with windscreens and rear windows and at least 9 mm with side window.

The bonding agent may not be applied in the field of view or the point grid. Fresh bonding agent in the field of view must immediately be wiped off with solvent because hardened bonding agent will leave a haze behind.

Fig 2: Identifying Adhesive Bead And Bonding Agent On Window Glass (With And Without Cover)

Courtesy of BMW OF NORTH AMERICA, INC.

Graphic A	Graphic B
Window glass with cover If the adhesive bead (1) cannot expand further (a = 0 mm) into one direction when pressing down, the outer edge of the bonding agent bead (3) will run through Point a.	Window glass without cover. If the adhesive bead (1) can expand into both directions while pressing down, the bonding agent (3) and adhesive bead (2) will run toward each other in the center (m).

Removal of window glass:

IMPORTANT: As of E63 and E87 it will only be possible to remove the rear window with the "ROLL OUT 2000 ".

Cover side walls, roof-mounted aerial and if necessary interior equipment with protective covers.

Tape off body with fabric adhesive tape (e.g. Tesa) in areas where the oscillating knife could damage the window glass or the paint.

When using cutting wire, pull cutting wire ends through special tool 51 3 270 , bend and tape over with fabric adhesive tape (e.g. Tesa) (risk of injury and damage).

When removing the window glass:

Wear safety goggles and protective gloves.

Cut through adhesive bead of window glass:

With "ROLL OUT 2000 " (wire cutting system); no paint is damaged here in the case of narrow gaps
With special CUTTER and OSCILLATING KNIFE

Prior to each use, regrind the knife with a grindstone while the machine is running (new knives also).

Avoid damage to paint on body cutout.

Guide knife carefully between body and window glass.

Run blade of knife parallel to glass.

Cut through adhesive bead as closely as possible to window glass.

To remove residual adhesive bead in body aperture (and on window glass if reusing):

Use a scalpel for heavy-duty applications
Cut off adhesive residue to a thickness of approx. 0.5 mm
Remove residual adhesive bead only briefly before bonding

Damage to paintwork in body aperture:

To ensure long-term corrosion protection, it is absolutely essential to touch up damage to paintwork!

The "BMW Color System" painting handbook forms the basis of these repair instructions and must be observed without fail.

Touch up damage to paintwork on body aperture with BMW multibase filler.

Grind out scratches in non-visible areas and touch up with BMW multibase filler.

Grind extensive areas of damage down to the bare metal and coat with BMW multibase filler (layer thickness 30... 40 μm).

Hardening time:

With infrared, at least 10 minutes
Without infrared for at least 60 °C, at least 30 minutes
Without infrared for at least 20 °C, at least 24 hours

If a complete build-up of paint is required in the visible area:

Tape off primed adhesive flange before applying top coat

IMPORTANT: Observe hardening time of BMW multibase filler otherwise a perfect bond cannot be guaranteed!

Treatment of adhesive area in body aperture:

Adhesive	Treatment
Bonding and sealant for car window glass	Clean with cleaning agent R2 (sourcing reference: BMW Parts Department, part number 83 19 0 417 324) Observe an air drying time of at least 5 minutes (at least 15 minutes when applied to residual adhesive bead) Apply paint activator (blue stick) to paint Observe an air drying time of at least 1 minute (at least 10 minutes when applied to residual adhesive bead)

IMPORTANT: Do not use Sika remover 208 for cleaning in the adhesive area.

Preparation for installation:

Prepare plastic nozzle(s) for shaping adhesive bead (when not using the standard nozzle C), can be cut to size during the air drying time.

Lay a sample bead of approx. 50 mm; if OK, apply immediately to window glass.

Interruption must be < 5 seconds (incorrect mixture ratio).

Glue cartridge must be vertical to window glass.

Black ceramic glass impermeable to UV light is located on the peripheral zone of the inside edge of the window to protect the adhesive bead.

Ceramic glass must not be damaged and must be treated as follows.

Treatment of ceramic glass surface (inside of window):

Adhesive (with part numbers)	Treatment
Repair kit: 83 19 0 444 141/145 Glue cartridge: 83 19 0 444 144	Clean with cleaning agent R2 (sourcing reference: BMW Parts Department, part number 83 19 0 417 324) Observe an air drying time of at least 5 minutes Apply a thin coating of glass activator Observe an air drying time of at least 2 minutes

Adhesive (with part numbers)

Treatment

Repair kit:

83 19 0 444 141/145

Glue cartridge:

83 19 0 444 144

Clean with cleaning agent R2 (sourcing reference: BMW Parts Department, part number 83 19 0 417 324)
Observe an air drying time of at least 5 minutes
Apply a thin coating of glass activator
Observe an air drying time of at least 2 minutes

Version with inspection glass for vehicle identification number in windscreen only:

Close inspection glass (left bottom) with Sika bonding base VP 206 (part number 83 19 9 407 777*)
(*sourcing reference: BMW Parts Service)

Except for:

All US/GB models. In addition, all models or models on which the black dashboard cover means that the body color cannot be seen through the inspection glass.

Adhesive quantities:

Approx. 1 1/4 glue cartridges are required to bond the windscreen on the following vehicles:

7 Series
5 Series from E60
X5
X3

Effect of differing adhesive quantities:

Too little adhesive:	Too much adhesive:
Window glass rests too low in body aperture Strains/tensions may occur (window glass breakage) Insufficient squeezing of adhesive bead (leaking)	Window glass rests too high in body aperture Wind noise may occur Strains/tensions may occur (window glass breakage) Dirt contamination of add-on parts by emerging adhesive Adhesive on un-insulated strainer pressure lines of aerial(s) (interference of reception)

Spacer buffer (spacer):

Before sticking on new spacer buffers, remove all remaining traces of existing spacer buffers completely.

Position of spacer buffers must be observed exactly.

Incorrectly fitted spacer buffers will result in:

Windscreen glass breakage
Leakage (if the spacer buffer is in the adhesive area)
Wind noises

Assembly:

To prevent a pressure build-up in the passenger compartment when the doors are closed:

Open a side window

IMPORTANT: Once the adhesive bead has been applied, the window glass must be installed within 7 minutes (depending on air humidity, temperature).
After 7 minutes the adhesive bead forms a skin which can no longer guarantee a perfect bond.
The general rule is:
To secure the window glass, use only the yellow plastic adhesive tape (sourcing reference: BMW Parts Department, part number 83 19 9 410 979).
The glass will slip down if other adhesive tapes are used.
Window glass slippage will result in leaks and wind noises.

Remove adhesive residue immediately with adhesive remover (Sika remover 208, sourcing reference: BMW Parts Department). Do not press out the window glass again.

Hardened adhesive can only be removed mechanically.

Check height of windscreen/rear window with special tool 51 0 010 or 51 3 210 .

Assemble vehicle.

Hardening:

The adhesive hardens by reacting with air humidity at room temperature.

Minimum hardening time (table) is obtained from 22 °C and 38 % relative air humidity.

A relative humidity of < 30% significantly slows hardening.

At ambient temperatures above 23 °C and 50 % relative air humidity (hot countries), the adhesive open time is shortened to approx. 5 minutes (skin formation time).

The adhesive hardening process is interrupted completely at ambient temperatures below 5 °C. In this event, there will be no increase in the strength of the bonded connection.

Do not subject the vehicle to load on one side during the minimum hardening time (see table, without front passenger airbag), such as e.g.:

one wheel on curb
vehicle hoist
etc.

Maneuvering inside garage/workshop:

only permitted on level ground
do not under any circumstances drive over approach ramps, e.g. into multi-story parking structures

Remove adhesive tapes after hardening time.

If you fail to adhere to the minimum hardening times (see "without front passenger airbag" in MINIMUM HARDENING TIME ):

Leaks and/or wind noises may occur at the window glass

MINIMUM HARDENING TIME

Minimum hardening time "without front passenger airbag" (after which vehicle can be moved)

Minimum hardening time "with front passenger airbag" (countries where seatbelt use is not required by law)

1 hour

2 hours ⁽¹⁾

NOTE:

⁽¹⁾	Vehicles with front passenger airbag:

The vehicle can be transferred to the customer after a 1-hour hardening time with the following warning:
Once the windscreen glass has been bonded, all occupants must travel with their seat belts attached for 1 hour .

IMPORTANT: If the minimum hardening time is not adhered to, an accident can cause the passenger together with the windscreen to fall out of the vehicle after the front passenger airbag deploys.

Locate leaks:

by spraying water underneath sealing lips
with ultrasonic leak detector (sourcing reference: BMW Parts Department)

If necessary, seal leakage with appropriate nozzle.

Version with GPS navigation system 1 (up to 9/97):

After installation of rear window:

Recalibrate magnetic field probe
Refer to functional description in ISID (Integrated Service Information Display)

Version with rain sensor, rain/light sensor or rain/light solar sensor:

Remove complete RAIN/LIGHT SENSOR or RAIN/LIGHT SOLAR SENSOR .

After replacing windscreen:

Initialize rain sensor, rain/light sensor or rain/light solar sensor
Refer to functional description in ISID (Integrated Service Information Display)

Version with automatic air conditioning:

After replacing windscreen:

If condensation sensor is not mounted on new windscreen:

Replace condensation sensor, see REPAIR INSTRUCTIONS .

Version with Head-Up Display (HUD):

When replacing windscreen in vehicles with rain/light solar sensor , replace this completely: see REPAIR INSTRUCTIONS .

Before bonding, install windscreen with seal(s) and check HUD ; if necessary, press expanding foam tape down with hand roller.

After bonding windscreen, check and if necessary adjust HUD .

General:

The windscreen and rear window (also the rear side windows if necessary) are bonded to the body. This gluing will increase the torsional strength of the vehicle. To obtain perfect bonding, comply with the installation procedure described in the following.

It is possible to tow or drive without windscreen or rear window.

The windscreen must be secured with yellow plastic adhesive tape after being installed. The paint must be completely hardened after painting work.

Set down window glass and process on BMW-approved X-universal stand.
In winter, the vehicles must stand in a room with a temperature of at least 15°C.

On-the-job safety:

When working with adhesive products (adhesive, cleaning agent, bonding agent etc.):

Wear protective goggles, protective gloves and if necessary an apron.
Ensure rooms are well ventilated.
Change work clothing contaminated with adhesive immediately.
Change work clothing contaminated with solvents and swelling agents immediately (keep spare work clothing on hand).
Take skin protection measures, provide washing facilities including hot water, use silicone-free skin creams
Provide eye bath facilities, change water regularly (once a month).
Comply with the relevant safety regulations
Do not eat, drink or smoke in areas of PUR processing.

Replacement of windscreens:

Version with head-up display (HUD):

Marking for HUD must be present on the windscreen

Version with front passenger airbag:

Stick on reminder label

Tools for cutting through adhesive bead:

TOOLS FOR CUTTING THROUGH ADHESIVE BEAD

Type	Type	Order/part number
Special cutter (manufacturer: Fein) with oscillating blade	Pneumatically operated	81 43 9 429 183
Special cutter (manufacturer: Fein) with oscillating blade	Electrically operated	81 43 9 427 786
BMW blade set	All required blades	81 43 9 428 596
Blade (U-shape)	19.5 mm	6 39 03 118 01 3
	24 mm	6 39 03 076 01 6
	36 mm	6 39 03 079 01 2
	45 mm	6 39 03 154 01 0
Blade (straight with stop roller)	16 to 35 mm (adjustable)	6 39 03 143 01 3
	10 mm (fixed)	6 39 03 189 01 0
	14 mm (fixed)	6 39 03 082 01 6
"Roll Out 2000"	Wire cutting system	81 62 0 301 76 8
Scalpel	for heavy-duty applications
Handles for cutting wire	Self-locking	special tool 51 3 270

Storage temperature:

Storage temperature of all adhesive products of 5°C to 25°C must be observed.

Adhesive:

The BMW-approved 1-component polyurethane adhesive must be used for bonding.

Adhesive is applied to window glass with cartridge gun (pneumatically or electrically operated

When using accelerator (hot processing):

Temperature (min. 80 ± 5°C) of cartridge oven must be checked every morning. Connect temperature sensor to DIS (Diagnosis and Information System), if necessary in conjunction with MIB (Measurement Interface Box)
Heat adhesive for at least 1 hour in cartridge oven to 80 ± 5°C
- Write date and time on adhesive when inserting into cartridge oven
- Insufficient heating (< 1 hour) results in the formation of bubbles/blisters (gluing/cementing not permitted)
- Temperature < 80 ± 5°C results in the formation of bubbles/blisters (gluing/cementing not permitted)
Remove cured adhesive prior to further processing.
Mistake in mixing in event of an interruption in application >1 minute (gluing/cementing not permitted)
- A test bead of 50...70 mm must be rejected after an interruption in application
Best before dates of accelerator and adhesive must not be more than 3 months apart
- Best before date >3 months results in the formation of bubbles/blisters (gluing/cementing not permitted)

Sealed adhesive:

May only be stored for a maximum of 8 hours once it has been heated up to 80 ± 5°C.
The adhesive will be damaged if this time is exceeded (gluing/cementing not permitted)
Damaged adhesive must not be used and must be disposed of in compliance with national regulations
Cartridge may only be heated up once
- If the lower label is black, this adhesive may only still be used cold without accelerator while adhering to the Best before date.

IMPORTANT: Not all window glass may be bonded with accelerator (hot processing).
If hot processing is not permitted, this is described in the relevant service information.

Adhesive Best before date:

Repair kit and adhesive cartridges are marked with a date (Best before).

The adhesive cannot be used after this date.

Adhesive disposal:

Pure hardened adhesive is handled as normal waste.

The adhesive is disposed of in paper bags so that it can react with moisture.

Non-hardened adhesive, cartridges and mixtures of adhesive and solvents and the like must be disposed of as special waste.

Accelerator:

Accelerator is screwed onto the adhesive cartridge and contains a reaction paste which is mixed with the heated adhesive.

IMPORTANT: The accelerator may only be paired with the adhesive cartridge of an unopened package (bubbling).
Adhesive and accelerator must be paired while taking into account the Best before dates.
The accelerator may no longer be used if the Best before dates are more than 3 months apart.

Bonding agent (activator):

The BMW-approved bonding agents must be used to treat bonding areas:

"Glass Activator 1" (on glass ceramic material)
"Paint Activator A" (on sheet metal flange or residual adhesive bead)

Bonding agent Best before date:

Repair kit and bonding agent are marked with a date (Best before).

The bonding agent may only be used up to this date (if not already opened previously).
Once it has been opened (locking ring broken), use for 1 week only even if the Best before date has not been reached.

NOTE: Write the date on the bottle when opening the bonding agent for the first time.
Close the bottle immediately after extracting the bonding agent (reaction with air).

Removal of window glass:

IMPORTANT: As of E63 and E87 it will only be possible to remove the rear window with the "Roll Out 2000".

Cover side panels, roof aerial and if necessary interior trim with protective covers.

Tape off body with fabric adhesive tape (e.g. Tesa) in areas where the oscillating blade could damage the window glass or the paint.

When using cutting wire, pull cutting wire ends through special tool 51 3 270 , bend and tape off with fabric adhesive tape (e.g. Tesa) (risk of injury and damage).

When removing the windscreen:

Wear protective goggles and gloves.

Cut through adhesive bead of window glass:

with "Roll Out 2000" (wire cutting system); no paint is damaged here in the case of narrow gaps
with special cutter and oscillating blade

Prior to each use, regrind the blade with a grinding stone while the machine is running (new blades also).

Avoid damage to paintwork on body cutout.

Guide blade carefully between body and window glass.

Run blade of knife parallel to glass.

Cut through adhesive bead as closely as possible to window glass.

To remove adhesive bead in body cutout (and on window glass if reusing):

Use a scalpel for heavy-duty applications
Cut off residual adhesive to a thickness of approx. 0.5 mm
Remove residual bead only briefly before bonding

Damage to paintwork in body aperture:

To ensure long-term corrosion protection, it is absolutely essential to touch up damage to paintwork!

The "BMW Color System" painting handbook forms the basis of these repair instructions and must be observed without fail.

Touch up damage to paintwork on body cutout with BMW multibase filler.

Grind out scratches in non-visible areas and touch up with BMW multibase filler.

Grind extensive areas of damage down to the bare metal and coat with BMW multibase filler (coating thickness 30... 40 μm).

Hardening time:

With infrared, at least 10 minutes
Without infrared for at least 60°C, at least 30 minutes
Without infrared for at least 20°C, at least 24 hours

If a complete build-up of paint is required in the visible area:

Tape off primed bonding flange before applying top coat

IMPORTANT: Observe hardening time of BMW multibase filler otherwise a perfect bond cannot be guaranteed!

Treatment of glued area in body:

GLUED TREATMENT

Glue	Treatment
Bonding and sealing compound for car window glass	Clean with spirit (available in pharmacies). Observe an air drying time of at least 1 minute (at least 15 minutes when applied to residual bead) Apply "Paint Activator A" to paint and residual bead Observe an air drying time of at least 1 minute (at least 10 minutes when applied to residual bead)

IMPORTANT: Do not use Sika remover 208 for cleaning in the bonding area.

Preparation for assembly:

Prepare plastic nozzle(s) for shaping adhesive bead (when not using the standard nozzle), can be cut to size during the air drying time.

Lay a test bead of approx. 50 mm - watch out for formation of bubbles/blisters when hot cementing; if OK, apply immediately to window glass.

Interruption must be < 5 second (incorrect mixture ratio).

Cartridge must be vertical to window glass.

Black ceramic material impermeable to UV light is located on the peripheral zone of the inside edge of the window to protect the adhesive bead.

Glass ceramic material must not be damaged and must be treated as follows.

Treatment of glass ceramic surface (inside of window):

TREATMENT OF GLASS CERAMIC SURFACE

Adhesive (with part numbers)	Treatment
Hot cementing: 83 19 0 147 370 Cold cementing: 83 19 0 147 369 Adhesive cartridge: 83 19 0 152 031	Clean with spirit (available in pharmacies). Observe an air drying time of at least 1 minute Apply a thin coating of "Glass Activator 1" Observe an air drying time of at least 10 minutes

Adhesive (with part numbers)

Treatment

Hot cementing:

83 19 0 147 370

Cold cementing:

83 19 0 147 369

Adhesive cartridge:

83 19 0 152 031

Clean with spirit (available in pharmacies).
Observe an air drying time of at least 1 minute
Apply a thin coating of "Glass Activator 1"
Observe an air drying time of at least 10 minutes

Version with inspection window for vehicle identification number in windscreen only (all except US/GB):

Seal inspection window (bottom left) with Sika primer 206 G+P

Adhesive quantities:

Approx. 1 1/4 adhesive cartridges are required to cement the windscreen on the following vehicles:

7 Series
5 Series from E60
X5
X3

In the case of hot cementing (with accelerator), the missing residual bead is applied from a second adhesive cartridge (not contained in the repair kit) but while cold and without accelerator (bubbling).

Minimum hardening period is thus not increased.

IMPORTANT: If a second cartridge is required for cementing:

First apply cold adhesive to cowl panel at bottom (skin formation time)
Accelerator from repair kit must not be used with the second cartridge (bubbling)

Bubbling results in leakage and insufficient bonding strength (torsional rigidity, passenger airbag).

Effect of differing adhesive quantities:

EFFECT OF DIFFERING ADHESIVE QUANTITIES

Too little adhesive:	Too much adhesive:
Windscreen rests too low in body cutout Strains/tensions may occur (windscreen breakage) Insufficient squeezing of adhesive bead (leaking)	Windscreen rests too high in body cutout Wind noise may occur Strains/tensions may occur (windscreen breakage) Fouling of add-on parts by emerging adhesive Adhesive on uninsulated strainer pressure lines of aerial(s) (interference of reception)

Spacer buffers:

Before sticking on new spacer buffers, remove all remaining traces of old spacer buffers completely.

Position of spacer buffers must be observed exactly.

Incorrectly fitted spacer buffers will result in:

Windscreen glass breakage
Leakage (if the spacer buffer is in the adhesive area)
Wind noises

Assembly:

To prevent a pressure increase in the vehicle interior when the doors are closed:

Open a window

IMPORTANT: After the adhesive bead has been applied, the window glass must be fitted within 5 to 10 minutes (depending on air humidity, temperature and use of accelerator).
After 5 to 10 minutes the adhesive bead forms a skin which can no longer guarantee a perfect bond.
To secure the windscreen, use only the yellow plastic adhesive tape.
The glass will slip down if other adhesive tapes are used.
Windscreen slippage will result in leaks and wind noises.

Remove adhesive residue immediately with adhesive remover. Do not press out the window glass again.

Hardened adhesive can only be removed by machine.

Check height of windscreen/rear window with special tool 51 0 010 or 51 3 210 .

Assemble car.

Hardening:

The adhesive hardens as it reacts with air humidity (with accelerator also due to mixed-in reaction paste) at room temperature.

Minimum hardening time (table) is obtained from 22°C and 38 % relative air humidity.

At ambient temperatures above 23°C and 50 % relative air humidity (hot countries), the adhesive open time is shortened to approx. 5 minutes (skin formation time).

The adhesive hardening process is interrupted completely at ambient temperatures below 5°C. In this event, there will be no increase in the strength of the adhesive bond.

Do not subject the vehicle to load on one side during the minimum hardening time (see "without passenger airbag" in GLUES HARDENING TIMES ), such as e.g.:

one wheel on curb
lifting platform
etc.

Maneuvering inside garage/workshop:

only permitted on level ground
do not under any circumstance driver over access ramps, e.g. into multi-store car parks

Remove adhesive tapes after hardening time.

If you fail to adhere to the minimum hardening times (see "without passenger airbag" in GLUES HARDENING TIMES ):

leaks and wind noises will occur when the windscreen is moved

Glues and their minimum hardening times:

GLUES HARDENING TIMES

Glue

Minimum hardening time "without passenger airbag" (after which vehicle can be moved)

Minimum hardening time "with passenger airbag" (countries where seatbelt use is not required by law)

Hot processing with accelerator

2 hours

3 hours⁽¹⁾

Cold processing

9 hours

20 hours⁽¹⁾

NOTE:

⁽¹⁾

Vehicles with passenger airbag: The vehicle can be handed over to the customer after the hardening period (vehicle can be moved, adhesive-dependent) with the following warning: Once the windscreen glass has been bonded, all occupants must travel with their seatbelts attached for "... hours"! The time is taken from the "Minimum hardening period" table for countries where seatbelt use is not required by law.

IMPORTANT: If the minimum hardening time is not adhered to:

the front passenger together with the windscreen may fall out of the vehicle in the event of an accident after the front passenger airbag has been triggered

Locate leaks:

by spraying water underneath sealing lips
with ultrasonic leak detector

If necessary, seal leakage with appropriate nozzle.

Version with GPS navigation system 1 (up to 9/97):

After installation of rear window:

Recalibrate magnetic field sensor
Refer to function description in DIS (Diagnosis and Information System)

Version with rain sensor, rain/light sensor or rain/light solar sensor:

Remove complete RAIN/LIGHT SENSOR or RAIN/LIGHT SOLAR SENSOR .

After replacing windscreen:

Initialize rain sensor, rain/light sensor or rain/light solar sensor
Refer to function description in DIS (Diagnosis and Information System)

Version with automatic air conditioning:

After replacing windscreen:

If condensation sensor is not mounted on new windscreen:

Replace CONDENSATION SENSOR

Version with head-up display (HUD):

When replacing windscreen, replace rain/light solar sensor.

Before bonding, install windscreen with seal(s) and check HUD ; if necessary, press expanding foam tape down with hand roller.

After bonding windscreen, check and if necessary adjust HUD .