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Technical Note 560A

All types

Other sub-sections concerned: 54A

General procedure for bonding windows and sunroof assembly

General information, equipment, tools and products, operating procedures for removal, preparation and fitting bonded windows and sunroof assembly.

77 11 295 462

"The repair procedures given by the manufacturer in this document are based on the technical specifications current when it was prepared.

The procedures may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed."

Edition 3 - NOVEMBER 2005

All rights reserved by RENAULT s.a.s.

EDITION ANGLAISE

Copying or translating, in part or in full, of this document or use of the service part reference numbering system is prohibited without the prior written authority of RENAULT s.a.s.

© Renault s.a.s. 2005

Contents

Page

54A WINDOWS

General information: – Basic rules 54A-1– Diagrams of operating principles 54A-3Equipment and tools:– Protection, cutting, gripping,

application 54A-4Products:– Composition of bonding kits 54A-7– Product information 54A-10Operating procedures:– Removal 54A-15– Fitting 54A-17– Special notes about the cement bead 54A-27

WINDOWSGeneral information: Basic rules 54A

154AWINDOWSGeneral information: Basic rules

I. INTRODUCTION

Bonded windows form an integral part of the vehicle structure.

The adhesives recommended for repair operations have been tested in RENAULT laboratories according to precise specifications.

To ensure optimum safety and product quality, carefully observe:● the safety instructions,● the recommended instructions for use,● the repair procedures.

This note may change depending on the product, equipment and tools.

II. INDIVIDUAL PROTECTION:

III. REPAIR TIME

All of the times indicated are the minimum vehicle repair times for a temperature of 20 °°°°C with 50 % relative humidity.

Do not use single component products at temperatures below 10 °°°°C.

IMPORTANTAlways wear protective gear (gloves, goggles and breathing masks).

Vehicle which isequipped with:

No airbagOne airbag

Two airbags

Bonding kit used

Bipac + 2 30 minutes 1 hour

Monopac + 2 1 hour 2 hours

Monopac 1 hour 30 minutes 3 hours

IMPORTANTIt is essential that these repair times are observed in order to guarantee optimal safety.

IMPORTANTNever mix the products when carrying out any adhesive bonding process.Only products contained in the selected bonding kit must be used. Shake the primers for at least 1 minute before use.

54A-1

WINDOWSGeneral information: Basic rules 54A

54A-2

IV. PROHIBITED PRODUCTS

Contact between the adhesive product and any of the following products is prohibited:

– THINNERS– GREASES– OILS– ALCOHOLS– PRE-TREATMENT PRIMER (before drying)– SILICONE PRODUCTS– SOAP AND SOAPY WATER

In the event of serious contamination (with silicone type products), clean with distilled water or acetone before carrying out any preparation work.

WINDOWS 54A

54A-3

General information: Diagrams of operating principles

Replacing a window or sunroof assembly:

1 Glass + screen printing or sunroof assembly (Parts Department)

2 Glass cleaner (yellow mark)3 Primer (green mark) for the glass4 Cement bead5 Primer (red mark) for the residual bead6 Residual bead7 Bodywork mounting

Removing - refitting a window or sunroof assembly:

1 Glass + screen printing or sunroof assembly removed

2 Residual bead on window or sunroof assembly3 Cement bead4 Primer (red mark) for the residual bead5 Residual bead6 Bodywork mounting

Note:Most cases where water is entering the vehicle result from the bonding procedures not being observed. Lay down the cement bead so that it is perpendicular to the mounting to be bonded.

WINDOWSEquipment and tools: Protection, cutting, gripping,

application54A

54A-4

Equipment and tools: Protection, cutting, gripping, application

Examples of equipment and tools:

PROTECTION

Dashboard protector

CUTTING OPERATION

Cutting wire insertion tool

Wire insertion tool

Cutting wire

Part no.: 77 11 210 485


application54A

54A-5

Pulling handle

Support tool

Pneumatic or electric cutting tool


application54A

54A-6

GRIPPING

Supporting suction cups

PARV 202 + APARV 200 ESP (for sunroof assembly)

andPARV 200 (for windscreen)

APPLICATION

Nozzle for dual component adhesive

Part no.: 77 01 408 909

Nozzle for single component adhesive

Part no.: 77 11 171 310Note:When removing - refitting the sunroof assembly, use two PARV 202 and two APARV 200 ESP.

WINDOWSProducts: Composition of bonding kits 54A

54A-7

Products: Composition of bonding kits

MONOPAC bonding kit (conductive adhesive) Part no.: 77 11 222 570– Additional cartridge + nozzle (Part no.: 77 11 222 571)

– One 310 ml cartridge– One packet of glass cleaner or activator including two wipes: one wet and one dry– One 15 ml bottle of primer (green mark)– One 15 ml bottle of primer (red mark)– Two primer applicators– One pair of gloves– One preparation nozzle for the cartridge– One application nozzle for the cement bead

IMPORTANTNever mix the products when carrying out any adhesive bonding process.Only products contained in the selected bonding kit must be used.The expiry date on the packaging of the bonding kit must be respected.


54A-8

MONOPAC + 2 bonding kit (high modulus, non conductive adhesive)Part no.: 77 11 218 570– Additional cartridge + nozzle (Part no.: 77 11 218 571)

– One 310 ml cartridge– One packet of glass cleaner or activator including two wipes: one wet and one dry– One 10 ml tube of primer (green mark)– One 10 ml tube of primer (red mark)– One pair of gloves– One preparation nozzle for the cartridge– One application nozzle for the cement bead


54A-9

BIPAC + 2 bonding kit (high modulus, non conductive adhesive)Part no.: 77 11 219 552

– Two 225 ml cartridges: adhesive and accelerator– One mixer– One packet of glass cleaner or activator including two wipes: one wet and one dry– One 10 ml tube of primer (green mark)– One 10 ml tube of primer (red mark)– One pair of gloves– One application nozzle for the cement bead

WINDOWSProducts: Product information 54A

54A-10

Products: Product information

CLEANING PRODUCTS

Heptane

Part no.: 77 11 170 064

Heptane is a highly volatile solvent and allows optimal cleaning of the area surrounding the bond.It evaporates quickly.

Glass cleaner or activator

Most of the new windows from the Parts Department are already primed when they are supplied. This primed area shows the bonding path.The glass cleaner or activator reactivates this primer and promotes adhesion.

IMPORTANTThis product containing active agents must be cleaned with the dry wipe before applying the primer (green mark) supplied in the bonding kit.


54A-11

PRIMERS

Primers ensure that cement beads adhere to different mountings.They also protect the cement bead from ultraviolet rays which can damage the molecular structure of the cement bead and lower its resistance.

Primer (green mark)

This is only applied to a new window after the glass cleaner or activator has been applied and is dry.

Primer (red mark)

This is applied to lacquer, cataphoresis, primed mountings, composite materials and residual beads.

IMPORTANTWipe away any product outside the bonding area immediately (as it may mark the window).

NOTEWipe away any product visible outside the bonding area immediately.


54A-12

Additional primer

Part no.: 77 11 219 620

This provides anti-corrosion protection.

It is applied to uncoated sheet metal on damaged areas greater than 2 mm.


54A-13

USE OF PRIMER TUBES

Shake the tubes for approximately 1 minute so that the product has an even consistency.

Hold the neck of the tube, ensuring that the applicator pad is pointing upwards.

Screw the applicator pad on properly so that the tube is well sealed.

Soak the applicator pad.

Apply a uniform layer of primer to the bonding area in a single stroke.

Leave to dry for a minimum of 10 minutes.Never apply the cement bead onto wet primer.

Note:Ensure that all damaged areas are covered with primer.

IMPORTANTWipe away any primer visible outside the bonding area immediately.


54A-14

USE OF ADDITIONAL PRIMER

Shake the bottle for approximately 1 minute so that the product has an even consistency.

It is applied to uncoated sheet metal on damaged areas greater than 2 mm.

After applying the product, leave it to dry for a minimum of 30 minutes.

Note:If applying primer to an aluminium mounting (see Technical Note 573A).

WINDOWSOperating procedures: Removal 54A

54A-15

Operating procedures: Removal

PREPARATION

Protect the vehicle interior.

Remove the various interior and exterior trims and accessories (see MR for the relevant vehicle).

Protect the bodywork around the window or sunroof assembly using masking tape.

Fit the dashboard protector specific to the vehicle (see MR for the relevant vehicle) or remove the top of the dashboard (according to the vehicle).

CUTTING OPERATION

Make a hole in the cement bead using a wire insertion tool.

The first operator threads support tool (1) through the cement bead into the vehicle interior, passing through approximately 300 mm of wire.

The second operator pulls the pulling handle on the vehicle exterior (2) in the same direction as the first operator's tool.

Repeat this operation until the cement bead is completely cut.

IMPORTANTGloves and protective goggles must be worn when removing a window or sunroof assembly.

IMPORTANTA suitable work station must be used when replacing a window or sunroof assembly.

Note:Place the wire insertion tool into the most accessible part of the window or sunroof assembly.

IMPORTANTEnsure that the cutting wire does not cut the:– trim mounting,– bodywork,– window or sunroof assembly.

WINDOWSOperating procedures: Removal 54A

54A-16

The cement bead can be cut using a pneumatic cutting tool (see Technical Note 414A, Pneumatic tool for removing bonded windows) or an electric cutting tool.

WINDOWSOperating procedures: Fitting 54A

54A-17

Operating procedures: Fitting

PREPARATION AND BONDING PROCEDURES

Special notes for preparation and bonding operations.For cutting operations, see 54A, Windows, Operating procedures: Removal.

On bodywork components

Original bodywork component:Examples: Removal - Refitting and/or replacing a window or sunroof assembly.

Procedure 1

Bodywork component repaired and/or replaced:Examples: replacing the roof or windscreen frame.

Procedure 2

New bodywork component (Parts Department):Examples: Uncoated bodywork supplied painted, cataphoretic steel tailgate, primed plastic tailgate.

Procedure 3

On windows

New windows (Parts Department) Procedure 4

Removed window (with residual bead) Procedure 5

On sunroof assembly

New sunroof assembly (Parts Department) Procedure 6

Removed sunroof assembly (with residual bead) Procedure 7


54A-18

PROCEDURE 1 ON ORIGINAL BODYWORK COMPONENT

Carefully clean the bonding area with heptane and wipe with a lint-free cloth (avoiding the cement bead).

Level down the residual bead (leave a 1 to 2 mm layer of beading).

Apply the primer (red mark) to the entire bonding area (residual/lacquered bead).Leave to dry for a minimum of 10 minutes.

Note:For aluminium bodywork: see Technical Note 573A.

Prepare the window or the sunroof assembly (procedures 4, 5, 6 or 7).

Apply the cement bead (preferably on the window) and bond immediately.


54A-19

PROCEDURE 2 ON REPAIRED AND/OR REPLACED BODYWORK COMPONENT

Carefully clean the bonding area with heptane and wipe with a lint-free cloth (avoiding the cement bead).

Apply the additional primer to the uncoated sheet metal (damaged area greater than 2 mm)

Part no.: 77 11 219 620.

Leave to dry for a minimum of 30 minutes.

Protect the bonding area with masking tape before painting.

After painting:– remove the masking tape,

– carefully clean the bonding area with heptane and wipe with a lint-free cloth.



54A-20

PROCEDURE 2ON REPAIRED AND/OR REPLACED BODYWORK COMPONENT

(continued)

Apply the primer (red mark) to the entire bonding area (residual/lacquered bead).Leave to dry for a minimum of 10 minutes.

Note:Apply the primer one hour after the component has been completely dried and cooled.

Note:For aluminium bodywork:see Technical Note 573A.

Prepare the window or sunroof assembly (procedure 4, 5, 6 or 7).



54A-21

PROCEDURE 3ON NEW BODYWORK COMPONENT

(Parts Department)

Before painting, roughen the bonding area with a grey roughening pad.

Carefully clean the bonding area with heptane and wipe with a lint-free cloth.

Protect the bonding area with masking tape.

After painting, remove the masking tape.



54A-22

PROCEDURE 3ON NEW BODYWORK COMPONENT

(Parts Department) (continued)

Apply the primer (red mark) to the entire bonding area.Leave to dry for a minimum of 10 minutes.

Note:Apply the primer one hour after the component has been completely dried and cooled.

Note:For aluminium bodywork: see Technical Note 573A.

Prepare the window or sunroof assembly (procedure 4, 5, 6 or 7).



54A-23

PROCEDURE 4 ON NEW WINDOWS (Parts Department)

Check that it is the correct window, and check for the absence of faults or cracks.


Fit the trims (according to the vehicle).

Perform a test installation for the vehicle window.

Apply the glass cleaner/activator (yellow mark) or wet wipe

(According to the composition of the bonding kit).

Clean immediately with the dry wipe.

Apply the primer (green mark) around the window following the bonding path.


Apply the cement bead and

bond immediately.


54A-24

PROCEDURE 5 ON REMOVED WINDOW (with residual bead)

Check for the absence of faults or cracks.

Carefully clean the bonding area with heptane and wipe with a lint-free cloth, avoiding the cement bead.


Fit the trims (according to the vehicle).

Perform a test installation for the vehicle window.

Area without residual beadExample: if there is an adhesion fault.

Apply the glass cleaner/activator (yellow mark) or wet wipe (according to the composition of the

bonding kit).

Clean immediately with the dry wipe.

Apply the primer (green mark).


Apply the cement bead and bond immediately.

Area with residual bead.


54A-25

PROCEDURE 6 ON NEW SUNROOF ASSEMBLY (Parts Department)


Fit the indexing guides and positioning shims onto the sunroof assembly.

Apply the primer (red mark) to the entire bonding area.




54A-26

PROCEDURE 7 ON REMOVED SUNROOF ASSEMBLY (with residual bead)

Carefully clean the bonding area with heptane and wipe with a lint-free cloth, avoiding the cement bead.


Fit the indexing guides and positioning shims onto the sunroof assembly.

Area without residual beadExample: if there is an adhesion fault.

Apply the primer (red mark) to the entire bonding area.Leave to dry for a minimum of 10 minutes.


Area with residual bead.

WINDOWSOperating procedures: Special notes about the cement bead 54A

54A-27

Operating procedures: Special notes about the cement bead

APPLICATION

Level down the residual bead as late as possible to maximise cleanliness (reduced risk of contamination).

The cement bead must be triangular in shape (an adhesive application nozzle is supplied in each bonding kit).

If you do not have a special nozzle, respect the size of bead (in millimetres).

Apply adhesive to the windows (rather than the mounting) for the following reasons:

Application on windows

– the working position is ideal,– the trim (1) can be used as a guide,– the cement bead (2) is removed in the correct way; it

acts as a link between the window (3) and the mounting (4).

Application on mounting

– the working position is poor,– there are no marks to aid the application of the

cement bead,– laying down the cement bead without a guide may

prevent it from making contact with the window (5) in places and may result in a sealing fault.

IMPORTANTIf using a Bipac + 2 bonding kit, squeeze out 100 to 150 mm of beading so that the product has an even consistency before it is applied.

IMPORTANTNon conductive adhesive must be used (See Products, Composition of bonding kits) for the following cases:– vehicle aerial integrated into the window (may

disrupt radio reception),– aluminium structures (may lead to corrosion).

WINDOWSOperating procedures: Special notes about the cement bead 54A

54A-28

The bead must be even and applied perpendicular to the bonding area (starting with the bottom and centre of the mounting when bonding a window).

The join is made at the end of the application by overlapping the beads by approximately 50 mm.

Application on window or mounting

Application on sunroof assembly or mounting

Note:After laying down the cement bead, fit the window or sunroof assembly onto the vehicle immediately.

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