51 31 000 Removing and installing windshield (Protection)

Provision of work accessories:

Special tool 51 9 002 with accessories
Special tool 51 3 010
Special tool 51 3 130

CAUTION: Danger of injury!
The weight of the windshield is considerably greater than on the normal version. The above-mentioned special tools are therefore absolutely essential.
A second person is necessary to help remove and install the windshield.

Support pedestal for windshield
Materials for repairing paintwork damage in body area, refer to 51 31... INSTRUCTIONS ON GLUING WINDSCREEN
Materials for gluing windshield and rear window, refer to 51 31... INSTRUCTIONS ON GLUING WINDSCREEN
Electric cutting tool *
Blade for electric cutting tool (hook 24 mm and 36 mm) *
Scalpel for heavy-duty applications *
Cartridge gun * Fabric adhesive tape *
Sika remover 208 *
Spirit *
Yellow plastic adhesive tape *
Sidol *

* Sourcing reference: BMW Parts Service

Remove engine bonnet/hood, refer to 41 61 000 REMOVING AND INSTALLING ENGINE HOOD . Remove interior rearview mirror, refer to 51 16 060 Removing and installing or replacing interior rearview mirror .

If necessary, remove rain sensor.

Remove both sun visors and counter supports, refer to 51 16 080 REMOVING AND INSTALLING OR REPLACING SUN VISOR AND LEFT OR RIGHT COUNTER SUPPORT .

Remove both panels for front roof pillar (A-pillar finishers), refer to 51 43 201 REMOVING AND INSTALLING OR REPLACING TRIM FOR FRONT LEFT OR RIGHT ROOF PILLAR .

Remove cover from windshield. Refer to 61 61 270 REMOVING AND INSTALLING COMPLETE WIPER CONSOLE .

Remove both gutter strips on windshield, refer to 51 31 030 REMOVING AND INSTALLING OR REPLACING LEFT OR RIGHT GUTTER ALONG WINDSHIELD .

Remove both windshield wiper arms. Refer to 61 61 100 REMOVING AND INSTALLING/REPLACING BOTH WINDSHIELD WIPER ARMS .

Cold processing:

Comply with instructions on gluing windows, refer to 51 31... INSTRUCTIONS ON GLUING WINDSCREEN

Warm processing:

Open aluminum membrane at rear end of cartridge. Place cartridge in cartridge oven.

Heat glue cartridges to 80°C for one hour in oven (sourcing reference: BMW Parts Service).

Comply with instructions on gluing windows, refer to 51 31... INSTRUCTIONS ON GLUING WINDSCREEN

Fig 1: View Of Oven

NOTE: Cover engine compartment (top) and side panels with protective covers.

Lower front headliner slightly.

Disconnect left and right plug connections for windshield heating and fix cable to windshield.

Fig 2: Disconnecting Left & Right Plug Connections

Mark area of cable entries on windshield.

Fig 3: Identifying Area Of Cable Entries On Windshield

Partially remove seal and let it hang down.

Fig 4: Removing Seal

Lift out expanding rivets and pull finisher (1) upwards to remove.

Seal hose connection for windshield wash nozzles on hood lid.

Fig 5: Removing Expanding Rivets & Finisher

Removal: Removal of windshield is described separately from installation. Assembly sequence for removal and installation is different.

CAUTION: Seal is reinforced with aluminum strip.
Turning carefully, wind seal out (windshield breakage).

Fig 6: Removing Wind Seal

Mask body all around with fabric adhesive tape (sourcing reference: BMW Parts Service).

Windshield
Glue bead
Body aperture
Fabric adhesive tape

Fig 7: Masking Windshield Body All Around With Fabric Adhesive Tape

CAUTION: When reusing the windshield:
Do not damage wires for windshield heating.

Fit knife (24 mm blade length, sourcing reference: BMW Parts Service) to the tool.

NOTE: If necessary, resharpen knife with machine running.

Fig 8: Fitting Knife To Tool

Carefully insert knife between body and windshield.

Fig 9: Inserting Knife Between Body & Windshield

Guide handle of knife parallel to windshield.

Fig 10: Guiding Handle Of Knife Parallel To Windshield

Cut through glue bead as close as possible to windshield in area of A-pillar on left and right and roof edge.

Body aperture
Glue bead
Knife
Windshield (illustration does not correspond to actual glass thickness)

Fig 11: Cutting Glue Bead To Windshield In Area Of A-Pillar On Left & Right & Roof Edge

Fit knife (36 mm blade length, sourcing reference: BMW Parts Service) to the tool.

NOTE: If necessary, resharpen knife with machine running.

Fig 12: Fitting Knife To Tool

Carefully insert knife at cowl panel between body and windshield.

Guide handle of knife parallel to windshield.

Cut through adhesive bead as close as possible to windshield in area of cowl panel.

Fig 13: Cutting Adhesive Bead To Windshield In Area Of Cowl Panel

Suspend special tool 51 9 002 (suction lifter) from conventional workshop lifting equipment.

Switch on vacuum pump.

Firmly attach special tool 51 9 002 to outside of windshield in center in upper third.

Fig 14: Attaching Special Tool 51 9 002 To Outside Of Windshield In Center In Upper Third

CAUTION: Follow operating instructions for special tool 51 9 002.
The pointer of the vacuum gauge must be in the green area.
Do not shorten connecting hose between suction hoist and vacuum pump (minimum length 5 m).
Replacement with original hose only.

Fig 15: Identifying Position Of Vacuum Gauge Pointer

Raise windshield slightly with suction hoist. If necessary, remove any residual traces of bonding carefully.

Lift out windshield and place on assembly stand.

Switch off vacuum pump.

Pull off adhesive masking tape all around.

Fig 16: Raising Windshield With Suction Hoist

CAUTION: To ensure long-term corrosion protection, it is absolutely essential to repair paintwork damage (scratches and large-surface damage), refer to 51 31... INSTRUCTIONS ON GLUING WINDSCREEN

CAUTION: The basic filler must have hardened!

Treat body around glued area with BMW-approved materials (repair kit, sourcing reference: BMW Parts Service), refer to 51 31... INSTRUCTIONS ON GLUING WINDSCREEN

NOTE: Note specified ventilation time!

Fig 17: Identifying Windshield Glued Area

Installation:

Installation of windshield is described separately from removal. Assembly sequence for removal and installation is different.

Installation check on reused and new windshields:

Examine windshield heating cable for damage, repair if necessary.
Check windshield heating connections for continuity.
Carry out function check on windshield heating with car battery.
Check sound insulation around circumference of windshield, request new part if necessary.

When installing a new windshield:

CAUTION: Static charge! Unroll protective foil on outside and inside, do not pull off.

Place windshield on support pedestal with inside facing upwards.

When reusing the windshield:

Remove residual glue on windshield with a heavy-duty scalpel (1)to approx. 0.5 mm.

Fig 18: Identifying Scalpel

Fit seal (1) to top of windshield and press into place.

NOTE: Seal (1) and windshield are marked in the center (2).

(3) Mirror base

Fig 19: Identifying Marking Of Seal & Windshield

Secure cable (1) (rear window heating) with adhesive tape.

Treat windshield in glued area (A) with materials approved by BMW (repair kit, sourcing reference: BMW Parts Service), refer to 51 31... INSTRUCTIONS ON GLUING WINDSCREEN

(A) = 21 mm

NOTE: Note specified ventilation time!

Fig 20: Securing Cable (Rear Window Heating) With Adhesive Tape

Immediately before installing windshield:

Remove glue residue in body cutout to approx. 0.5 mm thickness.

NOTE: Cut off old glue carefully with a heavy-duty scalpel to avoid damaging the paint finish in body cutout.

CAUTION: Clean freshly cut residual bead with alcohol only.
Do not under any circumstances use Sika bonding agent 205/5 or glass primer 205/5.

Fig 21: Removing Glue Residue

Installation of spacer buffers:

Two different spacer buffers are fitted. Adhere precisely to installation position (broken windshield).

Square spacer (height stop, wind noises)
Semicircular spacer buffer (spacing for adhesive bead)

(A) 3.8 mm

CAUTION: Wind noises may result if measurement (A) is not 3.8 mm.

Fig 22: Identifying Square & Semicircular Spacer

CAUTION: To avoid breaking windshield:
Before sticking on new spacer buffers, remove remains of old spacer buffers completely.
Stick on semicircular spacer buffers (1) "outside" in molding (2) on left/right.

(3) Expanding foam tape

NOTE: Expanding foam tape (3) over gap between sound insulation and cowl panel must be fitted from left to right, fit if necessary.

Fig 23: Sticking Semicircular Spacer Buffers "Outside" In Molding On Left/Right

In direction of travel, left:

Stick on semicircular spacer buffers (1) "center/outside" between bores (2).

NOTE: Attach semicircular spacer buffer (1) to end of metal radius (3).

(4) Expanding foam tape

Fig 24: Attaching Semicircular Spacer Buffer To End Of Metal Radius

In direction of travel, right:

Stick on semicircular spacer buffers (1) "center/outside" between bores (2).

NOTE: Attach semicircular spacer buffer (1) to end of metal radius (3).

(4) Expanding foam tape

Fig 25: Attaching Semicircular Spacer Buffer To End Of Metal Radius

Attach semicircular spacer buffer (1) "centrally" at distance (A) on right side (left side in direction of travel) at same height as bore (2).

(A) 25 mm

(3) Expanding foam tape

Fig 26: Identifying Distance For Attaching Semicircular Spacer Buffer

Aligning windshield:

Turn windshield on assembly stand so that inner side faces downwards.

Suspend special tool 51 9 002 (suction lifter) from conventional workshop lifting equipment.

Switch on vacuum pump.

Firmly attach special tool 51 9 002 to outside of windshield in center in upper third.

Fig 27: Attaching Special Tool 51 9 002 To Outside Of Windshield In Center

Fig 28: Identifying Position Of Vacuum Gauge Pointer

Lift windshield with special tool 51 9 002 over body cutout.

First position windshield carefully at top and align sides evenly.

Lower windshield at bottom and in so doing press upwards on left and right with two special tools 51 3 010 until seal contacts roof uniformly.

Fig 29: Lifting Windshield With Special Tool 51 9 002

Preload on top of windshield to prevent wind noise:

Fig 30: Identifying Preload On Top Of Windshield

When installing the windshield (4), make sure that it lies lower with respect to roof outer skin (1). This is the only way of ensuring sufficient pretension between the sealing lip (2) and the roof (prevention of wind noise). Check installation position of windshield (4) in middle of vehicle with special tool 51 3 210. A clearance (A) is permitted.

(3) Later adhesive bead

Print on special tool = "S" (Anti-theft windows)

Adapt pretension and installation position if necessary with spacer buffers.

Repeat alignment of windshield if necessary several times.

Lift windshield with special tool 51 9 002 out of body cutout and place on assembly stand.

Switch off vacuum pump.

Turn windshield on assembly stand so that inner side faces upwards.

Fig 31: Lifting Windshield With Special Tool 51 9 002

Cut nozzle to size.

Dimensions:

7⁺¹ mm
11_-2 mm

NOTE: For an even application of adhesive bead:
Use a cartridge gun (operated pneumatically or electrically, sourcing reference: BMW Parts Service).

Check expiration date of glue!

Fig 32: Identifying Dimension For Cutting Nozzle

If necessary, apply a test bead before gluing.

Cartridge must be held perpendicularly to the windscreen glass.

NOTE: Approx. 1 1/4 adhesive cartridges are required for the windshield.

Fig 33: Identifying Position Of Cartridge To Windshield Glass

Effect of differing adhesive quantities:

DIFFERING ADHESIVE QUANTITIES EFFECT

Insufficient adhesive:	Excessive adhesive:
Windshield positioned too low in body cutout	Windshield positioned too high in body cutout
Stresses may occur (risk of broken windshield)	Wind noise may occur

Shape of glue bead:

7⁺¹ mm
11_-2 mm

CAUTION: Apply adhesive bead swiftly (and uniformly) and install windshield. Maximum skin formation time of adhesive is 10 minutes.
Maintain distance (X) to edge of windshield, refer to measurement (A) to (C) in next work step.

Fig 34: Identifying Glue Bead Shape

Maintain the distance (A) of the upper glue bead to the gasket, (B) at side and (C) bottom along the windshield edge.

1 mm
2 mm
4 mm

Uniformly apply cement beads in corners of seal at top and at break in sealing lip.

Fig 35: Identifying Distance Of Upper Glue Bead To Gasket

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

Attach two yellow plastic adhesive tapes (1) (Tesa) to roof at a distance (A) from outer corners.

Length: 400 mm

Width: 50 mm

(A) 250 mm

Fig 36: Identifying Adhesive Area Of Plastic Adhesive Tapes

Switch on vacuum pump.

Firmly attach special tool 51 9 002 to outside of windshield in center in upper third.

Fig 37: Attaching Special Tool 51 9 002 To Outside Of Windshield In Center

Fig 38: Identifying Position Of Vacuum Gauge Pointer

Lift windshield with special tool 51 9 002 over body cutout.

First position windshield carefully at top and align sides evenly.

Lower windshield at bottom and in so doing press upwards on left and right with two special tools 51 3 010 until seal contacts roof uniformly.

Fig 39: Lifting Windshield With Special Tool 51 9 002

Secure windshield (1) in this position on top with yellow plastic adhesive tapes (2) (sourcing reference: BMW Parts Service) and press down all around.

Switch off vacuum pump.

Remove special tools 51 3 010 and 51 9 002.

Fig 40: Securing Windshield Position On Top With Yellow Plastic Adhesive Tapes

To avoid wind noises: The windshield is pretensioned at the top.

Pretension is created with special tool 51 3 130 (three HR foam blocks).

1 piece (1): 40 x 70 x 70 mm (W x H x D)

2 pieces (2): 40 x 30 x 70 mm (W x H x D) Position of HR foam blocks:

HR foam blocks (1), middle, at distance (A) from top.

HR foam blocks (2), distance (A) from top, distance (B) at side.

(A) 100 mm

and

(B)

Fig 41: Identifying Dimensions For Positioning HR Foam Blocks

Open both front doors.

Secure HR foam blocks (2) with yellow plastic adhesive tape (1) (Tesa).

Pretension windshield with yellow plastic adhesive tape (1) until it is correctly positioned at top.

NOTE: Do not stick yellow plastic adhesive tape (1) above A-pillar finisher (3) or ITS head airbag.

Fig 42: Securing HR Foam Blocks With Yellow Plastic Adhesive Tape (Tesa)

CAUTION: Hardened glue can only be removed by machine.
Remove contamination caused by residual adhesive immediately with Sika remover 208 (sourcing reference: BMW Parts Service). Do not press out windscreen glass again for this purpose.

Assemble car.

After hardening time, remove support.

NOTE: Leaks are detected by spraying water under the sealing lips or by using an ultrasonic leak tester and can then be sealed with an appropriate nozzle.