Instructions On Gluing Windshield
Instructions On Gluing Windshield
These instructions are not applicable to the door window bonding (door "center") on the E38/L7:
General:
The windshield and rear window (also the side windows of the Touring) are glued to the body. This gluing will increase the torsional strength of the vehicle. In order to obtain a perfect bond, you must follow the installation procedure described below.
It is possible to tow or drive the vehicle without a front or rear window.
The cars must stand in a room of at least 15 °C in winter.
On-the-job safety:
When working with adhesive products (glue, cleaning agent, glass primer 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 with hot water, use skin ointments that do not contain silicone products.
- Provide eye bath facilities, change water regularly (once a month).
- Observe relevant safety regulations.
- Do not eat, drink or smoke in areas of PUR processing.
Adhesive:
For gluing work, only use BMW-approved 1-component polyurethane adhesives.
- Original BMW* for cold processing
- SikaTack - Ultrafast* for hot processing
- Sikaflex 255 FC for cold processing
* Sourcing reference: BMW Parts Service
To apply a uniform glue bead to window, use a cartridge pistol operated with compressed air or electric power (refer to BMW Parts Service).
When using SikaTack - Ultrafast (hot process):
- If necessary, open aluminum membrane at rear end of cartridge.
- Heat adhesive for one hour in cartridge oven (sourcing reference: BMW Parts Service) to 80 °C.
- Remove hardened adhesive compound before further processing.
Sealed adhesive:
- can be heated up several times,
- may only be stored for max. 10 hours at 80 °C heating,
- will be damaged if this time period is exceeded,
- may not be reused and must be correctly disposed of if damaged.
Adhesive expiry date:
The repair set and glue cartridges are marked with an expiry date.
The glue 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.
Removal of window glass:
Cover side walls and if necessary interior equipment with protective covers.
When removing the windshield:
- Wear protective goggles and gloves.
Cut through adhesive bead of window using an electric cutting tool with an oscillating blade (sourcing reference: BMW Parts Service).
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.
Carefully insert knife between body and windshield.
Run blade of knife parallel to glass.
Cut through adhesive bead all around as close as possible to glass.
To remove residual cement bead in body cutout and on windshield (if windshield is to be reused):
- Using a heavy-duty scalpel,
- remove residual adhesive to a thickness of approx. 0.5 mm.
Damage to paintwork in body aperture:
To ensure long-term corrosion protection, it is absolutely essential to touch up any damage to paintwork!
Touch up damage to paintwork on body cutout with BMW MS-AK multibase filler (gray or red/brown).
Grind out scratches in non-visible areas and touch up with BMW MS-AK multibase filler.
Grind large areas of damage right down to polished metal and coat with BMW MS-AK multibase filler (coat thickness 30... 40 micro m).
Hardening time:
- With infrared, at least 10 minutes,
- without infrared, at least 4... 6 hours at mm. 18 °C.
If a complete build-up of paint is necessary in the visible area:
- Tape off primed adhesive flange before applying top coat.
CAUTION!
Observe hardening time of BMW MS-AK multibase filler, otherwise a perfect bond is not guaranteed!
Treatment of glued area in body:
Glue Treatment
Original BMW a) Clean with spirit (available in pharmacies).
SikaTack - Ultrafast or b) Air drying time at least 1 minute
Sikaflex 255 FC (at least 15 minutes when applying to the residual cement bead).
CAUTION!
Do not use Sika remover 208 for cleaning on adhesive area.
Preparation for assembly:
Prepare plastic nozzle for shaping adhesive bead; it can be cut during the air drying times.
If necessary, lay a sample bead.
Cartridge must be positioned vertically to glass.
To protect the adhesive bead, the inside edge of the window is coated with (black) UV-impermeable glass ceramic material and must be handled as follows.
Treatment of glass ceramic surface (inside of window):
Glue Treatment
Genuine BMW repair kit: a) Clean with spirit (available in pharmacies).
Part Number 81 22 9 407 497 b) Air drying time at least 1 minute.
Adhesive cartridge: c) Apply a thin coat of genuine BMW glass
Part number 81 22 9 407 526 primer 205/5
d) Air drying time at least 10 minutes.
SikaTack - Ultrafast a) Clean with spirit (available in pharmacies).
or Sikaflex 255 FC b) Air drying time at least 1 minute.
c) Apply a thin coat of Sika bonding agent 205/5.
d) Air drying time at least 10 minutes.
Version with viewing panel for vehicle number (VIN) in windshield (all except US):
- Seal sight glass (bottom left) with Sika bonding agent 206 G+P.
Assembly:
To prevent a build-up of pressure in the vehicle interior when closing a door:
- Open a door window.
CAUTION!
Assembly must be completed within 10 minutes, otherwise the cement bead will form a skin which will not be able to stick properly.
To secure window glass in position, use only yellow plastic adhesive tape (sourcing reference: BMW Parts Service, Part No.83 19 9 410 979).
The glass will slip down if other adhesive tapes are used.
Window glass slippage causes leaks and wind noises.
Remove contamination by residual adhesive immediately with adhesive cleaner (Sika remover 208, sourcing reference: BMW Parts Service). Do not press out the window glass again.
Hardened glue can only be removed by machine.
Hardening:
The glue hardens through reaction with air moisture at room temperature.
Minimum hardening time is achieved at 22 °C and 38% relative air humidity.
Adhesive hardening process is interrupted absolutely at ambient temperatures below 5 °C. In this event, there will be no increase in the strength of the adhesive bond.
The vehicle must not be subject to load on one side during the minimum hardening period, e.g.:
- one wheel on curb
- lifting platform
- etc.
Moving around inside the workshop on a flat surface is permitted but do not under any circumstances drive over approach ramps for example in multi-story car parks.
After the hardening time, remove adhesive tapes.
If the minimum hardening times are not adhered to
- the glass will be displaced and leaks and wind noises will occur.
Minimum hardening times:
Glues and their minimum hardening times:
Glues And Their Minimum Hardening Times:
CAUTION!
If the minimum hardening time is not adhered to:
- In the event of an accident, when the passenger airbag is triggered, the passenger and the windshield can be thrown out of the car.
Locate leakage
- by spraying water underneath sealing lips with an ultrasonic leak detector (sourcing reference: BMW Parts Service)
Seal off leaks if necessary with corresponding nozzle.
Version with GPS navigation system 1 up to 9/97:
After installation of the rear window:
- Recalibrate magnetic field sensor,
- refer to function description in DIS (Diagnosis and Information System).
Repair instructions for removing and installing window glass,
refer to MG 51.