51 31... Notes on window bonding

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

Work steps for removing and installing window glass 

• Is located at the end of the document under the cross reference "Refer to repair instructions"

General 

• It is possible to tow or drive without windscreen or rear 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 interior temperature accordingly.

• An air 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 LABEL

Tools for cutting through adhesive bead:

Type	Type	Order/part number
Special cutter (manufacturer: Fein) with oscillating knife	Compressed air operated Electrically operated	7 23 63 100 23 8 7 53 60 200 00 4
BMW knife set	All required knives	PN 81 43 9 428 596 or 6 39 03 167 05 4
Knife (U-shape)	19.5 mm (1) 24 mm 36 mm 45 mm	6 39 03 118 01 3 6 39 03 076 01 6 6 39 03 079 01 2 6 39 03 154 01 0
Knife (straight with stop roller)	16 to 35 mm (adjustable) 10 mm (fixed)(1) 14 mm (fixed)	6 39 03 143 01 3 6 39 03 189 01 0 6 39 03 082 01 6
" ROLL OUT 2000	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 13270
(1) not included in BMW blade set

Storage temperature 

1-day system:  Storage temperature of all adhesive products of 5°C to 25°C must be observed.

1-hour system:  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:

• 1-day system:  Window glass adhesive (Part number 83 19 0 444 144*)

1-hour system:  Repair kit, small (part number 83 19 0 444 141) or large (part number 83 19 0 444 145)

The repair kit, large contains a second window glass glue cartridge.

Adhesive is applied to window glass with cartridge gun (compressed airy or electrically operated, sourcing reference: BMW Workshop Equipment and Planning Documentation).

When using accelerator (hot working, 3-hour system) 

• Temperature (min. 80 ± 5°C) of cartridge oven must be checked every morning. Connect temperature sensor to diagnosis system
• Heat adhesive for one hour in cartridge oven (sourcing reference: BMW Parts Department) to 80 ±5°C
  • Write date and time on cartridge when inserting into cartridge oven
  • Insufficient heating (< 1 hour) results in the formation of bubbles/blisters (bonding not permitted)
  • Temperature < 80 ± 5°C results in the formation of bubbles/blisters (bonding not permitted)
• Remove hardened adhesive prior to further processing.
• Mistake in mixing in event of an interruption in application > 1 minute (bonding not permitted)
  • A sample bead of 50...70 mm must be rejected after an interruption in application
• Expiration dates of accelerator and adhesive must not be more than 3 months apart
  • Expiration date >3 months results in the formation of bubbles/blisters (bonding 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 (bonding not permitted)
• Damaged adhesive must not be used and must be disposed of in compliance with national regulations
• The glue 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 expiration date.

Adhesive expiration date 

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).

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

Adhesive disposal 

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.

Accelerator (3-hour system) 

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

Bonding agent (activator) 

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

1-day system: 

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

1-hour system: 

• "Glass Activator (2)" (on ceramic glass), yellow stick, BMW part number: 83 19 0 444 142
• "Paint Activator (B)" (on sheet metal flange), blue stick, BMW part number: 83 19 2 154 458

Prepare Glass Activator (2) and Paint Activator (B) for application by shaking and kinking (breaking glass ampoule).

Apply Glass Activator (2) by pressing gently. There is no need for final wiping. Air drying time approx. 2 minutes.

Apply Paint Activator (B) by pressingly gently. Then wipe dry with a paper towel (included in the set).

Bonding agent expiration 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 (circlip broken), use for 1 week only even if the expiration date has not 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 17mm with windscreens and rear windows and at least 9 mm with door window glass.

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

Graphic A	Graphic B
Window glass with cover	Window glass without 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.	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 

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 those areas where the oscillating blade could damage the window glass or the paint.

When using the cutting wire, pull the cutting wire ends through special tool 513270, bend and tape off 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 paintwork damage on body aperture.

Guide knife carefully between body and window glass.

Run blade of knife parallel to window 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

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) 1-day system:  Apply "Paint Activator A" to paint and residual adhesive bead 1-hour system:  Apply "Paint Activator B" (blue stick) to paint Observe an air drying time of at least 1 minute (at least 10 minutes when applied to residual adhesive bead)

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 - watch out for formation of bubbles/blisters when hot bonding; 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.

1-day system: Treatment of ceramic glass surface (inside of window):

Adhesive (with part numbers)	Treatment
Repair kit Cold/Hot Bonding: 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 minute Apply a thin coating of "Glass Activator (2)" Observe an air drying time of at least 2 minutes

1-hour system: 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 (2)" 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 Department)

Except for: 

All US/GB models. In addition, all models or models on which the black I-panel cover means that the body color can not 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

In the case of hot bonding (with accelerator), the missing residual adhesive bead is applied from a second glue cartridge but while cold and without accelerator (formation of bubbles/blisters).

Minimum hardening time is thus not increased.

• First apply cold adhesive to cowl panel at bottom (skin formation time)
• Accelerator from repair kit must not be used with the second glue cartridge (formation of bubbles/blisters)

Formation of bubbles/blisters results in leakage and insufficient bonding strength (torsional rigidity, front passenger airbag).

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 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

Installation 

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

• Open a side window

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 510010 or 513210.

Assemble vehicle.

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 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 table, without front passenger airbag):

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

1-day system: Adhesives and their minimum hardening times:

Adhesive	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)
Hot working with accelerator	2 hours	3 hours(1)
Cold processing	9 hours	20 hours(1)
(1) Note Vehicles with front passenger airbag:  The vehicle can be handed over to the customer after the hardening time (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 time" table for countries where seatbelt use is not required by law.

1-hour system: Adhesives and their minimum hardening times:

Adhesive	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)
Cold processing	1 hour	2 hours(1)
(1) Note Vehicles with front passenger airbag:  The vehicle can be handed over to the customer after the hardening time (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 time" table for countries where seatbelt use is not required by law.

• 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 (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/Diagnosis and Information System)

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

Remove complete rain sensor, rain/light sensor or rain/light solar sensor, see repair instructions.

After replacing windscreen:

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

Version with automatic air conditioning 

After replacing windscreen:

If condensation sensor is not mounted on new windscreen:

Replace condensation sensor, REFER TO 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.

Work steps for removing and installing window glass 

See Recommended Engine Oils For BMW Group Engines  See 5134191 REPLACING LEFT OR RIGHT FIXED DOOR WINDOW IN REAR WINDOW FRAME ; or .