51 31 200 Removing and installing rear window (Protection)

Provision of work accessories: 

• Special tool 51 9 002 with accessories
• Special tool 51 3 010
• Special tool 00 9 316

• Support pedestal for rear window
• 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) *
• 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 trunk lid, refer to 41 62 000 REMOVING AND INSTALLING LUGGAGE COMPARTMENT LID .

Remove both panels for rear roof pillar, refer to 51 43 251 REMOVING AND INSTALLING OR REPLACING TRIM FROM REAR LEFT OR RIGHT ROOF PILLAR .

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 

Disconnect right plug connection (1) (locking circuit).

Disconnect left plug connections (1) (rear window heating/antenna).

Version with antenna for car telephone: If necessary unfasten plug connection.

The following two work steps must be carried out with a 2nd person:

Remove retainer (1) and lift out left and right gas struts (2).

Loosen screw (3).

Release screw (4) and remove trunk lid.

Place trunk lid on the protective cover (1) and secure with fabric adhesive tape (2) on left/right sides.

Secure cable (rear window heating/antenna) to rear window with adhesive tape.

Mark cable entries on outside of rear window.

Removal: 

Removal of rear window is described separately from installation. Assembly sequence for removal and installation is different.

Detach seal from rear window at bottom.

Detach seal from rear window at side and top from left to right.

Mask body all around rear window aperture with fabric adhesive tape (e.g. Tesa).

1. Rear window
2. Glue bead
3. Body aperture
4. Fabric adhesive tape
   Fig 8: Masking Body All Around Rear Window Aperture With Fabric Adhesive Tape

   

Attach blade (24 mm length) to electric cutting tool (sourcing reference: BMW Parts Service).

When reusing the rear window:

Carefully insert blade between body and rear window at top in center.

Guide web of knife parallel to rear window.

Cut through glue bead all around as close as possible to the rear window glass.

1. Body aperture
2. Glue bead
3. Knife
4. Rear window
   Fig 12: Cutting Glue Bead All Around To Rear Window Glass

   

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 rear window in center in upper third.

Raise rear window with special tool 51 9 002 (suction hoist) slightly and, if necessary, carefully remove residual traces of bonding.

Lift out rear window and place on assembly stand. Switch off vacuum pump.

Installation: 

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

Installation check on reused and new rear windows:

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

When installing a new rear window:

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

Place rear window on assembly stand with inner side facing upwards, turn over if necessary.

When reusing the rear window:

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

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

Treat rear window in glued area (A) with BMW-approved materials (2) (repair kit, sourcing reference: BMW Parts Service), refer to 51 31... INSTRUCTIONS ON GLUING WINDSCREEN 

(A) = 21 mm

Mount and press seal on to rear window glass at bottom.

Fit seal (1) at top in center of rear window and press downwards.

Pull adhesive tape off body aperture all around. Mask headliner on roof connection with paintwork masking tape.

Treat body around adhesive surface with materials approved by BMW (repair kit, Sourcing Reference: BMW Parts Service), refer to 51 31... INSTRUCTIONS ON GLUING WINDSCREEN 

Cut nozzle to size.

1. 7 mm
2. 10_-1 mm

If applicable, produce a sample bead before gluing. Cartridge must be perpendicular to rear window.

Shape of glue bead.

1. 7 mm
2. 10_-1 mm

Maintain distance (A), (B) and (C) between glue bead and seal.

1. 1 mm
2. 1 mm
3. 1 mm

Turn rear window on assembly stand so that outer side faces upwards.

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 rear window in center in upper third.

Lift rear window with special tool 51 9 002 over body cutout.

First install rear window carefully at top, align sides uniformly and then install at bottom and press into place.

Remove special tool 51 9 002.

Align rear window with special tool 51 3 010. Gasket must locate uniformly down each side (center carefully). Press rear window upwards until there is a uniform gap between gasket and roof of 5 mm.

Measure gap (A) at top left and right and secure rear window with plastic adhesive tapes (1) (sourcing reference: BMW Parts Service).

(A) = 5 mm

If necessary, lay lower sealing lip (1) of seal (2) with special tool 00 9 316 (sealing lip wedge) at top corners in rounded recess of body cutout.

Assemble car.

After the hardening time, remove support and adhesive tape.

Version with GPS navigation:

If necessary, recalibrate magnetic field probe.

Refer to description of operation in DIS (Diagnosis and Information System).