Land Rover Discovery Owners & Service Manuals

Land Rover Discovery: Bonded Glazing

  • The windscreen, side and rear windows are bonded directly onto the window frames on the body and liftgate.
  • The windows are bonded primarily for reasons of adhesive strength.

    Bonded glazing provides additional torsional stiffness to the body.

Adhesive bonding of bonded windows

Adhesive bonding of bonded windows

  1. Rubber strip
  2. Window frame
  3. Adhesive
  4. Window glass


Safety measures

The following safety measures must always be followed to prevent personal injury:

  • Wear protective gloves and arm protection.
  • Wear protective goggles.


  • 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.


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.


  • 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

  • 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


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