Pella 80YV0102 Guide

These instructions were tested and developed for replacing windows in wood-frame wall
construction systems designed to manage moisture. This method of installation involves removing
the sash, frame stops and frame hardware from the existing window. The original window frame
will remain in place. If the existing window frame shows signs of water infiltration or is damaged
beyond repair, this method should not be followed and the entire existing window should
be removed. Installation recommendations for other types of wall construction, wall systems,
conditions, multiple windows or bow/bay windows, may be obtained from Pella Corporation or a
local Pella retailer. Building designs, construction methods, building materials, and site conditions
unique to your project may require an installation method different from these instructions and
additional care on your part. Determining the appropriate installation method is the responsibility
of you, your architect, or other construction professional.
CAUTION: Many windows in older homes are painted with lead-based paint. Removal of old
windows may disturb this paint. Proper precautions must be taken to minimize exposure to dust
and debris. Consult state or local authorities for more information.
EXTERIOR
REPLACEMENT WINDOW
INSTALLED
EXTERIOR
INSERT REPLACEMENT
WINDOW
EXISTING WINDOW
EXTERIOR
REMOVE EXISTING
SASH and STOPS
EXTERIOR
Always read the Vinyl Window and Door Limited Warranty before purchasing or installing
Vinyl Windows and Doors manufactured by Pella Corporation. By installing this product,
you are acknowledging that this Limited Warranty is part of the terms of the sale. Failure to comply with all
Pella installation and maintenance instructions may void your Pella product warranty. See Limited Warranty for
complete details at http://warranty.pella.com.
Part Number: 80YV0102© 2009 Pella Corporation
WINDOW REPLACEMENT INSTRUCTIONS FOR
SINGLE-HUNG, DOUBLE-HUNG, CASEMENT, AWNING
INTO EXISTING CASEMENT FRAME USING FRAME SCREWS
YOU WILL NEED TO SUPPLY:
•CedarorImperviousshims/spacers(12to20)
•Closedcellfoambackerrod/sealantbacker
 (12to30ft.)
•Pella®SmartFlash™foil backed butyl window
and door flashing tape or equivalent
•PellaWindowandDoorInstallationSealantor
equivalent high quality, multi-purpose sealant
 (1tubeperwindow)
•Lowexpansion,lowpressurepolyurethane
insulating window and door foam sealant.
DO NOT use high pressure or latex foams
•#8x2-1/2"Woodscrews
(6to10perwindow)
TOOLS REQUIRED:
•Tapemeasure
•Level
•Sealantgun
•Prybar
•Utilityknife
•Puttyknife
•Hammer
•Screwdrivers(Flat&Phillips)
•Adjustablepliers
•Sidecutter
•Roto-tool,reciprocatingsaw
•Woodchisel
•1/8"drillbit
•Drill
Installation will require two or more persons
for safety reasons.
SEALANT
SEALANT

1REMOVE THE EXISTING SASH
Note: Remove the new window from its packaging.
Inspect and measure the new window to confirm it will fit
into the opening prior to removing the existing window.
The window needs to be 3/8" smaller in both width and
height than the pocket frame, i.e. existing sash opening.
A. Remove the existing sash. This will vary per manufacturer
oftheexistingwindow.Removingthehingeandoperator
fasteners will generally allow the sash to be removed from
the existing frame.
Note: Two or more people may be required when
handling existing sash.
B. Remove operator hardware and all head, jamb, and sill
stops. This can usually be accomplished with a prybar.
SILL STOP
HEAD STOP
JAMB STOPS
1B
2OPENING PREPARATION
A. Inspect the existing window frame and repair or replace
anydefectiveorrottedwoodparts.Removeorseatany
nails.
B. Clean the opening of any dirt, debris, or excess
old paint before proceeding. Chisel off any high
spots.
C. Apply one piece of sill flashing tape to the sill of the
existing window frame.Cutthetape12"longerthan
the existing window sill width. Apply the tape on the
existingsill6"upeachjambandpressdownrmly.The
tape will not cover the sill depth completely under the
new window.
D. Install and level sill shims.Place1”wideby1/4”thick
shimsonthebottomofthewindowopening1/2”from
eachside.Keepshimsback1/2"frominteriorfaceof
window. Shims are required at points where windows
are joined in multiple window applications. Add shims
as necessary to ensure the sill is level. Once level,
attach spacers to prevent movement.
Note: Improper placement of shims may result in
bowing the bottom of the window.
2B
2C 6“

3WINDOW PREPARATION (AWNING and CASEMENT ONLY)
The interior frame covers must be removed to provide access to the pre-drilled frame screw
installation holes.
CAUTION: To Avoid Interior Frame Cover Breakage - Carefully read and understand
the following steps before proceeding with cover removal.
CASEMENT
COVER 3
COVER 1
COVER 2
FIXED AW/CM
COVER 3
COVER 1
COVER 2
LARGE AWNING
COVER 3
COVER 1
COVER 2
STANDARD AWNING
COVER 3
COVER 1
COVER 2
Note: The following interior frame cover removal steps are for Casement, Standard
Awning, Fixed Awning/Casement and Large Awning. The steps are similar for each, but
the order in which covers are removed will vary depending on the window type.
AWNING/
CASEMENT
A. Prepare the Window.
1. Removethescreenandsetaside.
Hook
Spline Hole
Bend in Tool
Construction Handle Tool
REFERENCE DESCRIPTION
2. Useplierstoremovetheplug(s)fromthelock
handlelocation(s).
3. Removetheconstructionhandletoolfromthe
handle package.
A2
ConstructionHandleToolmaybeusedasa
lock handle or crank handle.
Theorderofinteriorframecoverremovalisindicatedbelow.Usereverseorder
for re-installation of covers.

B1 B2
Spline
hole
B. Remove Interior Frame Cover #1. IfanInteriorFrameCoverhasa"QuickReleaseBand"
around the cover, pull the band to help remove the cover.
The cover on vent units where the lock handle slot is located and the cover on the
opposite frame side.
Note: Interior Frame Covers #1 are jamb covers on Casement, Fixed Awning/Casement
and Large Awning units. On Standard Awning units, Interior Frame Covers #1 are the
head and sill covers.
1. Approximately1"fromthe
bottom(end)ofthecover,insert
the"hooked"endofthetool
between the cover and the sash.
2. Rotatethetooltowardthesash
and continue to insert the tool
past the spline hole up to the
point where the bend in the
tool is aligned with the edge
of the cover.
Note: When the tool is inserted with the bend aligned with the cover edge there
will be a slight gap between the tool and the face of the sash.
3. Pushthetoolatagainst
thesash(notalotofforceis
needed)toreleasetheback
cover barb from the frame
kerf behind the cover. While
keeping tension on the tool,
pull the tool away from the
frame to start releasing the
cover barbs from the frame
kerfs.
B3
Cross Section of
Interior Frame Cover with
Tool Placement Detail
Barb released
from kerf
B3
Sash
Tool
Cover
AWNING/
CASEMENT
4. Rotatethecoverendslightlytowardtheinterior;whenthe
cover begins to pull away from the frame, relocate the tool
under the cover towards the interior as shown, then pull
the tool away from the frame to continue the release of the
cover barbs from the frame.
5. Repositionthetoolwiththehookunderthefrontedge
of the cover. Slide the tool over while pulling the cover
away from the frame. This will release the flexible barbs
on the interior side of the cover, which will aid in cover
removal. Continue sliding along the length of the cover
while pulling it away from the frame until it is removed.
6. RepeatStepsB1thruB5to
remove the other Interior
FrameCover#1.
If installing a single Casement,
Large Awning or Fixed unit less
than 42" in width, go to Step E.
B4
Flexible barbs
B5
Lock handle slot
B5
If installing a Standard Awning, multiple window combinations, or units greater than 42"
in width, go to Step C.

C2
C3
C. Remove Interior Frame Cover #2.
The cover on vent units where the crank handle and roto-cover will be located.
ForStandardAwning,singleunitsgreaterthan42"inheightandmultiplewindow
combinations.
1. Startingatthecoverend
closest to where the crank
handle will be located, insert
the tool between the sash and
cover(usingthesamemethod
of insertion used for Interior
FrameCover#1).
Note: Insert the tool under
Interior Frame Cover #2 next
to the FRAME CORNER (C2).
2. Pullthetoolawayfromtheframetostartreleasingthecoverbarbsfromtheframekerfs.
3. Whenthecoverbeginstopullawayfromtheframe,relocatethetoolneartheendof
the cover as shown and continue to pull up to release the barbs from the kerfs.
4. Whenthecoverhasbeenreleasednearthecrankhandlecut-out,repositionthetool
with the hook under the front edge of the cover. Slide the tool over while pulling up on
the cover. Continue along the length of the cover until it is removed.
C4
C4 NOTE
Cover support bracket
AWNING/
CASEMENT
D. Remove Interior Frame Cover #3.
The cover on vent units on the opposite frame side from where the crank handle is located.
ForStandardAwninggreaterthan42"inwidth,singleunitsgreaterthan42"inheightand
multiple window combinations.
1. Startatoneendofthecoverandinsertthetool
between the frame and cover as shown.
2. Pullthetoolawayfromtheframetostartreleasingthe
cover barbs from the frame kerfs.
3. Whenthecoverbeginstopullawayfromtheframe,grasp
the cover and continue to pull to release the barbs from
the kerfs, removing the cover.
D1
TWO OR MORE PEOPLE ARE REQUIRED FOR THE FOLLOWING STEPS
Note: Take note of the cover
support bracket around the
roto operator hardware, (on
the sill of casement and
large awning units and on
the jamb of standard awning
units) as the cover support
bracket will be referenced
when re-installing Interior
Frame Cover #2.