Warm Processing:

Open aluminum membrane at rear end of cartridge.

Place cartridge in cartridge oven.

Fig 1: Placing Cartridge In Cartridge Oven

Heat glue cartridge for one hour in cartridge oven at 80°C. Refer to 51 31 ... REMOVING WINDSCREEN WITH "ROLL OUT 2000" .

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)

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: Releasing Screw And Remove 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

Pull seal downwards to remove.

Fig 6: Pulling Seal Downwards

Pull seal off from left to right.

Fig 7: Pulling Seal Off From Left 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

Fit knife (24 mm blade length) to the tool.

NOTE: If necessary, resharpen knife with machine running.

Fig 9: Identifying Knife Blade And Tool

Carefully insert knife between body and top center of rear window.

Fig 10: Inserting Knife Between Body And Top Center Of Rear Window

Guide web of knife parallel to rear window.

Fig 11: Identifying Knife Parallel To Rear Window

CAUTION: When reusing the rear window:
Do not damage lines for rear window heating/antenna.

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

Lift out rear window using special tool 51 3 010.

Fig 13: Lifting Out Rear Window Using Special Tool 51 3 010

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" .

Immediately before installing rear window:

Remove glue residue from body aperture to thickness of approx. 0.5 mm.

Fig 14: Removing Glue Residue From Body

To avoid damaging paintwork in body cutout, carefully remove glue residue with a scalpel.

Pull off adhesive masking tape all around.

CAUTION: Clean freshly cut residual bead with spirit only, do not, under any circumstances, use Sika bonding agent 205/5.

When reusing the rear window:

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

Fig 15: Identifying Scalpel

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.

NOTE: Note specified ventilation time!

Fig 16: Treating Rear Window In Glued Area

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

Fig 17: Mounting And Press 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 18: Sealing And 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 glued area with BMW-approved materials (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.

Fig 19: Cutting Nozzle To Size

NOTE: For an even application of adhesive bead: Use pneumatically or electrically powered cartridge gun.

Note expiry date of glue!

If necessary, apply a test bead before gluing.

Cartridge must be perpendicular to rear window.

Fig 20: Identifying Cartridge Perpendicular 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.

Fig 21: Identifying Shape Of Glue Bead

CAUTION: Apply glue bead quickly and insert window. Skin formation time of glues, maximum 10 minutes.

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

1 mm.
1 mm.
1 mm.

Fig 22: Identifying Glue Bead And Seal

Install rear window carefully using 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 23: Installing Rear Window

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 24: Measuring Gap (A) At Top Left

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 25: Laying Lower Sealing Lip Of Seal

CAUTION: Remove dirt from residual glue with Sika remover 208 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.

Fit trunk lid in accordance with old color print.

If necessary, adjust trunk lid to fit.

Remove adhesive tape after glue has hardened.

NOTE: Any leakages are located by spraying water under the sealing lips or by using an ultrasonic leak detector and sealed with the appropriate nozzle.