Land Rover Discovery: Bonded Glazing
Adhesive bonding of bonded windows
![Adhesive bonding of bonded windows](images/books/227/index(5).62.jpg)
- Rubber strip
- Window frame
- Adhesive
- Window glass
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.
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 1mm. 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.
Thoroughly clean the window glass.
PROTECTIVE EQUIPMENT AND SAFETY AT WORK
- Various safety measures and legal requirements must be met when
carrying out repairs. All regulations relating to health and safety at work
must be followed.
Welding safety precautions
The following safety precautions must be observed to prevent the risk of
personal injury:
- Safety hood (face protection).
- Welding shield.
- Safety gloves.
- Safety shoes.
- Extraction unit for welding smoke.
Welding should always be carried out in well ventilated areas. A fire
extinguisher must also always be within reach.
General body repair safety measures
Extraction unit
![Extraction unit](images/books/227/index(5).63.jpg)
- Sealing compound, underbody protection etc. must not be burned off
with a naked flame. This would produce toxic gases. If for instance PVC is
burned, then gases containing hydrochloric acid are produced. For this
reason a suitable extraction unit should always be used when performing
grinding, welding or soldering work.
- Always ensure good ventilation when working with materials that contain
solvents, wear breathing equipment and use an extraction unit.
- Ear defenders should always be worn when cutting, grinding or
straightening metal, as the noise levels can reach or even exceed 85 - 90
dB(A).
- Take care not to look directly into any laser measuring systems, for
instance used to measure the under body.
- When removing components from a vehicle mounted on a lifting ramp,
watch out for a shift in its center-of-gravity. When first placing the
vehicle
on the ramp, take into account that it may need to be secured against
tipping over.
- Chains and chain clamps must be secured with safety ropes during
straightening work.
Safety rope
![Safety rope](images/books/227/index(5).64.jpg)
READ NEXT:
Galvanic corrosion is the cross-contamination of dissimilar metals, in this
case aluminium and steel. Avoidance of galvanic corrosion is an important
issue to be considered in the repair of aluminium
The procedure to follow when partially renewing components is the same as
described in the section "Welded Components".
The main difference when components are partially, rather than completely
renew
SEE MORE:
PRINCIPLES OF OPERATION
For a detailed description of the Accessory Drive Belt, refer to the relevant
Description and Operation section in the workshop manual. REFER to:
Accessory Drive (303-05B Accessory Drive - INGENIUM I4 2.0L Diesel,
Description and Operation).
INSPECTION AND VERIFICATION
WARNIN
Before exiting the vehicle, always
make sure that the correct gear
for parking is selected, the engine
is switched off, the Electric
Parking Brake (EPB) is applied,
and the Smart key is removed
from the vehicle.
Press the lock button on the Smart key
briefly to lock the vehicle and activate the
Peri