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 Edition 3 - NOVEMBER 2005 EDITION ANGLAISE

"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."
All rights reserved by RENAULT s.a.s.
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-3
Equipment and tools:
– Protection, cutting, gripping,
application 54A-4
Products:
– Composition of bonding kits 54A-7
– Product information 54A-10
Operating procedures:
– Removal 54A-15
– Fitting 54A-17
– Special notes about the cement bead 54A-27
 154A
WINDOWS
General information: Basic rules 54A
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:

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

III. REPAIR TIME

Vehicle which is No airbag Two airbags

equipped with: One airbag

Bonding kit
used

Bipac + 2 30 minutes 1 hour

Monopac + 2 1 hour 2 hours

Monopac 1 hour 30 minutes 3 hours

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.

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

IMPORTANT
Never 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
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General information: Basic rules 54A
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.

54A-2
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General information: Diagrams of operating principles 54A
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.
Removing - refitting a window or sunroof
Replacing a window or sunroof assembly: assembly:

1 Glass + screen printing or sunroof assembly (Parts 1 Glass + screen printing or sunroof assembly
Department) removed
2 Glass cleaner (yellow mark) 2 Residual bead on window or sunroof assembly
3 Primer (green mark) for the glass 3 Cement bead
4 Cement bead 4 Primer (red mark) for the residual bead
5 Primer (red mark) for the residual bead 5 Residual bead
6 Residual bead 6 Bodywork mounting
7 Bodywork mounting

54A-3
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Equipment and tools: Protection, cutting, gripping,
application
54A
Examples of equipment and tools: Wire insertion tool

PROTECTION

Dashboard protector

CUTTING OPERATION

Cutting wire insertion tool Cutting wire

Part no.: 77 11 210 485

54A-4
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Equipment and tools: Protection, cutting, gripping,
application
54A
Pulling handle Pneumatic or electric cutting tool

Support tool

54A-5
 WINDOWS
Equipment and tools: Protection, cutting, gripping,
application
54A
GRIPPING APPLICATION

Supporting suction cups Nozzle for dual component adhesive

Part no.: 77 01 408 909

PARV 202 + APARV 200 ESP

(for sunroof assembly)
and
PARV 200 (for windscreen) Nozzle for single component adhesive

Part no.: 77 11 171 310

Note:
When removing - refitting the sunroof assembly, use
two PARV 202 and two APARV 200 ESP.

54A-6
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Products: Composition of bonding kits 54A
IMPORTANT
Never 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.

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

54A-7
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Products: Composition of bonding kits 54A
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-8
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Products: Composition of bonding kits 54A
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

54A-9
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Products: Product information 54A
CLEANING PRODUCTS

Heptane Glass cleaner or activator

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.
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.

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

54A-10
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Products: Product information 54A
PRIMERS Primer (red mark)

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 applied to lacquer, cataphoresis, primed

mountings, composite materials and residual beads.

NOTE
Wipe away any product visible outside the bonding
area immediately.

This is only applied to a new window after the glass

cleaner or activator has been applied and is dry.

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

54A-11
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Products: Product information 54A
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-12
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Products: Product information 54A
USE OF PRIMER TUBES

Screw the applicator pad on properly so that the tube

is well sealed.
Shake the tubes for approximately 1 minute so that
the product has an even consistency. Soak the applicator pad.

Apply a uniform layer of primer to the bonding area in a

single stroke.

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

IMPORTANT
Wipe away any primer visible outside the bonding
area immediately.

Leave to dry for a minimum of 10 minutes.

Never apply the cement bead onto wet primer.

Hold the neck of the tube, ensuring that the applicator

pad is pointing upwards.

54A-13
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Products: Product information 54A
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).

54A-14
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Operating procedures: Removal 54A
PREPARATION CUTTING OPERATION

Make a hole in the cement bead using a wire insertion

IMPORTANT
tool.
Gloves and protective goggles must be worn when
removing a window or sunroof assembly.
Note:
Place the wire insertion tool into the most accessible
IMPORTANT part of the window or sunroof assembly.
A suitable work station must be used when replacing
a window or sunroof assembly.

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).

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.

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

54A-15
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Operating procedures: Removal 54A

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.

54A-16
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Operating procedures: Fitting 54A
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:

Procedure 1
Examples: Removal - Refitting and/or replacing a window or sunroof assembly.

Bodywork component repaired and/or replaced:

Procedure 2
Examples: replacing the roof or windscreen frame.

New bodywork component (Parts Department):

Examples: Uncoated bodywork supplied painted, cataphoretic steel tailgate, Procedure 3
primed plastic tailgate.

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-17
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Operating procedures: Fitting 54A
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-18
 WINDOWS
Operating procedures: Fitting 54A
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.

Level down the residual bead (leave a 1 to 2 mm

layer of beading).

54A-19
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Operating procedures: Fitting 54A
ON REPAIRED AND/OR REPLACED BODYWORK COMPONENT
PROCEDURE 2
(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).

Apply the cement bead (preferably on the

window) and bond immediately.

54A-20
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Operating procedures: Fitting 54A
ON NEW BODYWORK COMPONENT
PROCEDURE 3
(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.

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

54A-21
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Operating procedures: Fitting 54A
ON NEW BODYWORK COMPONENT
PROCEDURE 3
(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).

Apply the cement bead (preferably on the

window) and bond immediately.

54A-22
 WINDOWS
Operating procedures: Fitting 54A
PROCEDURE 4 ON NEW WINDOWS (Parts Department)

Check that it is the correct window, and check for

the absence of faults or cracks.

Carefully clean the bonding area with heptane

and wipe with a lint-free cloth.

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.
Leave to dry for a minimum of 10 minutes.

Apply the cement bead

and
bond immediately.

54A-23
 WINDOWS
Operating procedures: Fitting 54A
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.

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

Fit the trims (according to the vehicle).

Perform a test installation for the vehicle window.

Area without residual bead

Area with residual bead.
Example: 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).

Leave to dry for a minimum of 10 minutes.

Apply the cement bead and bond immediately.

54A-24
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Operating procedures: Fitting 54A
PROCEDURE 6 ON NEW SUNROOF ASSEMBLY (Parts Department)

Carefully clean the bonding area with heptane

and wipe with a lint-free cloth.

Fit the indexing guides and positioning shims

onto the sunroof assembly.

Apply the primer (red mark) to the entire bonding

area.
Leave to dry for a minimum of 10 minutes.

Apply the cement bead and bond immediately.

54A-25
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Operating procedures: Fitting 54A
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.

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

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

Area without residual bead

Area with residual bead.
Example: 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.

Apply the cement bead and bond immediately.

54A-26
 WINDOWS
Operating procedures: Special notes about the cement bead 54A
Apply adhesive to the windows (rather than the
IMPORTANT
mounting) for the following reasons:
If using a Bipac + 2 bonding kit, squeeze out 100 to
150 mm of beading so that the product has an even
Application on windows
consistency before it is applied.

IMPORTANT
Non 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).

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

– the working position is ideal,
adhesive application nozzle is supplied in each
– the trim (1) can be used as a guide,
bonding kit).
– 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

If you do not have a special nozzle, respect the size of

bead (in millimetres).

– 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.

54A-27
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Operating procedures: Special notes about the cement bead 54A
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.

54A-28