51 31 200 Removing and Installing/Replacing Rear Window

51 31 200 Removing And Installing/Replacing Rear Window

Special tools required:







IMPORTANT:
- The "Instructions on cementing windscreen" serve as the basis for this repair instruction and must be observed without fail.
- Cover rear side panels with protective covers.
- When reusing the rear window:
- Do not damage wires for rear window heater/aerial.

NOTE:
- Removal is performed with Roll Out 2000.
- Only use an oscillating blade when replacing the windscreen.







Necessary preliminary tasks:
- Remove panels for roof pillar at rear left/right
- Remove additional brake light
- Partially lower headlining at rear
- Remove roof frame trim strip on left and right







Disconnect plug connections (1) on left and right.







Tape off edges of rear lid and body all round with fabric adhesive tape (e.g. Tesa).
1. Rear window
2. Adhesive bead
3. Body opening
4. Fabric adhesive tape







IMPORTANT: Tape off body in area of piercing point with fabric adhesive tape (risk of damage).

Push wire starter from Roll Out 2000 at line (1) through adhesive bead.

Only replace:







Have U-shape knife with 24 mm and 36 mm blade lengths (sourcing reference: BMW Parts Department) ready.

Fit respective knife with required blade length:
24 mm = All round on rear window
36 mm = Recut window edges at bottom left and right
Regrind blade with a grinding stone while machine is running (new blades also). Insert blade carefully between rear lid and rear window.
Guide web of knife parallel to rear window.
Cut through adhesive bead as closely as possible to rear window.
Lift out rear window with special tools 51 3 010.
Pull off adhesive tapes all round.

Fitting flexible buffers:







IMPORTANT: To avoid rear window breakage and wind noises:
- Completely remove remnants of removed flexible buffers and maintain installation location exactly.

The following flexible buffers are fitted.
6x flexible buffer (5x5x20)
Installation position of flexible buffers (1) is specified on body side with markings (2).

Installation:
If necessary, replace faulty upper rear window cover.
If necessary, replace faulty lower rubber frame for rear window.

Replacement:
Replace upper rear window cover.
If necessary, replace faulty lower rubber frame for rear window.

Overview of rear window cementing:







Attach special tool 51 3 010 twice to tool trolley. Moisten suction surfaces and secure rear window from outside.
If reusing removed rear window, remove residual adhesive down to 0.5 mm.
Secure cables of heated rear window/antenna(s) with adhesive tape.
Fit rubber frames (6 and 7) in middle.
Virtually vertical part (B) of adhesive bead (1) must point to window edge or rubber frame.
Spread bead joint (4) with special tool 00 9 322.

IMPORTANT: Observe cover pressure. The cover pressure represents the outer edge of the non-squashed adhesive bead. Lay adhesive bead within the cover pressure.







NOTE: Adhesive area for plastic adhesive tapes (1) must be free from grease and dust.

Stick two yellow plastic adhesive tapes (1) to roof at distance (A) from outside corners.

Length: 400 mm
A = 250 mm







Carefully install rear window with special tools 51 3 010 as follows:
- Fix rear lid at 45°
- Feed in rear window between rear lid and body
- Position at top on roof edge
- Align sides evenly
- Insert at bottom and press down
- Press upwards until seal is uniformly contacting roof
- Press down at bottom until rubber frame is uniformly in place
- Secure rear window in this position with the two yellow plastic adhesive tapes







Installation:
The required gap dimension from the window edge to the body aperture all round is:
- 5.5 mm

Adjusting pre-tension on rear window:







In order to avoid wind noises, rear window (1) must be lower than roof outer skin (2).
Position special tool 51 0 010 in middle of vehicle depending on measurement (A) and check underprotrusion of rear window (1).

A = 3.5 mm
X = measurement stages 1 ... 4 mm