Warm Processing:

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

Fig 1: Placing Cartridge In Cartridge Oven

Heat glue cartridges to 80°C for one hour in oven.

Comply with instructions on gluing windows, refer to 51 31 ... REMOVING WINDSCREEN WITH "ROLL OUT 2000" .

NOTE: Cover rear side panels with protective covers.

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

Fig 2: Disconnecting Right Plug Connection

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

Fig 3: Disconnecting Left Plug Connections (Rear Window Heating/Antenna)

Version with antenna for car telephone:

If necessary unfasten plug connection.

NOTE: Place protective covers on side walls and middle of trunk lid.

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.

Fig 4: Removing Trunk Lid

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

Fig 5: Placing Trunk Lid On Protective Cover

CAUTION: Use only approved adhesive tape. The rear window coating will be damaged if the wrong adhesive tape is used.

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.

Fig 6: Detaching Seal From Rear Window At Bottom

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

Fig 7: Detaching Seal From Rear Window Side And Top From Left To Right

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

Rear window.
Glue bead.
Body aperture.
Fabric adhesive tape.

Fig 8: Identifying Rear Window, Glue Bead, Body Aperture And Fabric Adhesive Tape

Attach blade (24 mm length) to electric cutting tool.

NOTE: Sharpen blade while machine is running with a grindstone (even with new blades).

Fig 9: Attaching Blade To Electric Cutting

When reusing the rear window:

CAUTION: Do not damage cable for rear window heating/antenna.

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

Fig 10: Inserting Blade Between Body And Rear Window Top In Center

Guide web of knife parallel to rear window.

Fig 11: Identifying Web Of Knife Parallel To Rear Window

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

Body aperture.
Glue bead.
Knife.
Rear window.

Fig 12: Identifying Body Aperture, Glue Bead, Knife And 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.

Fig 13: Attaching Special Tool 51 9 002 To Outside Of Rear Window

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 14: Identifying Pointer Of Vacuum Gauge

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.

Fig 15: Lifting Out Rear Window

CAUTION: To ensure long-term corrosion protection, it is absolutely essential to repair paintwork damage (scratches and large surface damage), refer to 51 31 ... REMOVING WINDSCREEN WITH "ROLL OUT 2000" .

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:

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

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

Fig 16: Removing Glue Residue In Body

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.

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.

Fig 17: Identifying Heavy-Duty scalpel

CAUTION: Use only approved adhesive tape. The rear window coating will be damaged if the wrong adhesive tape is used.

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

Treat rear window in glued area (A) with BMW-approved materials (2) (repair kit), refer to 51 31 ... REMOVING WINDSCREEN WITH "ROLL OUT 2000" .

= 21 mm.

Fig 18: Identifying Rear Window In Glued Area

NOTE: Note specified ventilation time.

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

Fig 19: Pressing Seal On To Rear Window Glass At Bottom

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

NOTE: Seal (1) and rear window are marked in the middle (2).

Fig 20: Sealing At Top In Center Of Rear Window

CAUTION: The basic filler must have hardened!

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), refer to 51 31 ... REMOVING WINDSCREEN WITH "ROLL OUT 2000" .

NOTE: Note specified ventilation time!

Cut nozzle to size.

7 mm.
10_-1 mm.
NOTE: To apply a uniform glue bead, use cartridge pistol, operated with compressed air or electric power.

Fig 21: Cutting Nozzle To Size

Check expiration date of glue!

If applicable, produce a sample bead before gluing.

Cartridge must be perpendicular to rear window.

Fig 22: Identifying Cartridge Perpendicular To Rear Window

CAUTION: Version with rear window antenna: No glue must be applied to contacts on rear window heating/antenna.

Shape of glue bead.

7 mm.
10_-1 mm.
CAUTION: Apply glue bead quickly and insert window. Skin formation time of glue, maximum 10 minutes.

Fig 23: Identifying Shape Of Glue Bead

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

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

Fig 24: Identifying Rear Window On Assembly

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.

Fig 25: Attaching Special Tool 51 9 002 To Outside Of Rear Window

Fig 26: Identifying Pointer Of Vacuum Gauge

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.

Fig 27: Lifting Rear Window With Special Tool 51 9 002 Over Body Cutout

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.

Fig 28: Aligning Rear Window With Special Tool 51 3 010

CAUTION: Use only approved adhesive tape. The rear window coating will be damaged if the wrong adhesive tape is used.

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

Measure gap (A) at top left and right and secure rear window with plastic adhesive tapes (1).

= 5 mm.

Fig 29: Measuring Gap (A) At Top Left And Right And Securing Rear Window With Plastic Adhesive Tape (1)

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.

Fig 30: Laying Lower Sealing Lip (1) Of Seal (2) With Special Tool 00 9 316 At Top Corners

CAUTION: Remove dirt from residual glue with Sika remover 208 (sourcing reference) before glue is hard. Do not press out rear window glass again for this purpose. Hardened glue can only be removed by machine.

Assemble car.

After the hardening time, remove support and adhesive tape.

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.

Version With GPS Navigation:

If necessary, recalibrate magnetic field probe.

Refer to DESCRIPTION OF OPERATION in DIS (Diagnosis and Information System).

Fig 31: Identifying DIS