Trim, Glass, Accessories and Final Assembly
Removal and refitting
Use proper trim tools, not a screwdriver. Warm adhesive-backed mouldings before lifting. Label clips and screws. Replace single-use clips, weatherstrip retainers and adhesive tapes; old clips cause rattles and water leaks. Torque fixings to specification, and route wiring and washer tubes exactly as before.
Glass
Windscreen and backlight bonding uses urethane adhesive. Cut out the old bead, clean and prime the body flange and glass according to the adhesive system, apply a continuous bead, set the glass and check the gap. Respect the safe drive-away time, which depends on the adhesive.
Systems and final assembly
Bumper-mounted sensors, cameras and radar need calibration after removal, replacement or a change in ride height. Airbags and pretensioners need care: disconnect the battery and follow the wait time. Check lamps, horn, washers, locks, windows and wipers before handover.
Worked example
A front bumper with a radar unit is replaced. Refitting and painting is not the end of the job: the radar needs aiming and calibration with the specified target and conditions, or adaptive cruise and emergency braking may not work. Record the calibration on the job card. Reasoning: the repair is complete only when safety systems function within specification.
Traps
- Reusing clips and tapes.
- Pulling trim with a metal tool and scratching paint.
- No water test after glass or lamp work.
- Skipping ADAS calibration.
- Damaging airbag wiring during trim removal.