51 31 000 Removing and installing/replacing windscreen

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2010 BMW 528xi, 2010 BMW 528i, 2009 BMW 528xi, 2009 BMW 528i, and 2008 BMW 528xi. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

00 9 322 . See MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS .
51 0 010 . See BODY EQUIPMENT - SPECIAL TOOLS .
51 3 010

IMPORTANT: The Instructions for window cementing serve as the basis for this repair instruction and must be observed without fail.
Vehicles with head-up display (HUD):
Check whether the HUD marking at bottom right appears on the windscreen (malfunction).
Left-hand drive cars up to build date 02/2006:
Check whether cover for light module is installed.
If not installed, cover must be retrofitted.

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

Necessary preliminary tasks:

Remove rubber frame for windscreen
Remove interior rear-view mirror
Remove rain/light sensor . See 61 35 177 REMOVING AND INSTALLING (REPLACING) RAIN/LIGHT SENSOR .
If necessary, remove fogging/condensation sensor . See 64 11 970 REPLACING FOGGING SENSOR .
If necessary, remove camera for Lane Departure Warning. See 66 51 030 REMOVING AND INSTALLING/REPLACING CAMERA FOR LANE DEPARTURE WARNING .
Remove cover for cowl panel .
Cover front side panels with protective covers.

Replacement:

If necessary, replace optical element for solar rain/light sensor . See 61 35 683 REPLACING OPTICAL ELEMENT FOR SOLAR RAIN/LIGHT SENSOR .

IMPORTANT: Tape off body in area of piercing point with fabric adhesive tape (1).

Push wire starter (2) from Roll Out 2000 through adhesive bead.

Fig 1: Identifying Adhesive Tape And Wire Starter

Courtesy of BMW OF NORTH AMERICA, INC.

Replacement only:

Mount U-shape blade on tool:

24 mm blade length for sides and top.

36 mm blade length for bottom and bottom/sides.

Regrind blade with a grinding stone while machine is running (new blades also).

Carefully insert blade between body cutout and windscreen.

Guide handle of knife parallel to windscreen.

Cut through adhesive bead as closely as possible to windscreen.

Fig 2: Identifying U-Shape Blade

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NOTE: When cutting is carried out at the bottom, the engine hood must be in the service position.
Wires and hoses remain connected.

Move engine bonnet/hood into service position.

Cut through windscreen adhesive bead at bottom.

Lift out windscreen with special tools 51 3 010 .

Pull off adhesive tapes all round.

Fig 3: Lifting Out Windscreen With Special Tools

Courtesy of BMW OF NORTH AMERICA, INC.

Fitting spacer buffers (spacers):

Two different spacer buffers are fitted.

Square spacer buffer (shape B = 12.7 x 10 mm height stop, wind noises)
Semicircular spacer buffer (form A = ø 11 x 5 mm)

A = 3.8 mm

Fig 4: Identifying Square Spacer Buffer Height

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IMPORTANT: To avoid windscreen breakage and wind noises:
Completely remove remnants of removed spacer buffers and maintain installation location exactly.

Cut square spacer buffer (1) at top to approx. 9 mm (radius outlet).

Stick on one square spacer buffer (1) in each case on left/right at spacing (A).

A = approx. 50 mm

NOTE: Marking (2) is no longer present.

Fig 5: Identifying Square Spacer Buffer Position

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Stick on two new semicircular spacer buffers (2) in each case as follows:

at distance (A or B) from middle of cowl panel
at distance (C or D) at end of metal radius (5)

A approx. 300 mm
B approx. 665 mm
C approx. 18 mm
D approx. 30 mm

Fig 6: Identifying Semicircular Spacer Buffer Distance

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1 Windscreen
4 Glue bead
5 Outlet radius

Version with HUD:

Installation:

Before bonding, install windscreen with seal at top and check HUD ; if necessary, press expanding foam tape down with hand roller. See 62 30... ADJUSTING HEAD-UP DISPLAY (DISPLAY ADJUSTMENT) .

IMPORTANT: Press down expanding foam tape (6) shortly before installing windscreen (2) (with hand roller if reusing) or stick on if replacing. A relaxed expanding foam tape could crush adhesive bead (4) (leaks, wind noises).

Fig 7: Expanding Foam Tape On Cowl Panel And Sound Insulation

Courtesy of BMW OF NORTH AMERICA, INC.

Replacement:

Stick expanding foam tape (6) 1/3 on cowl panel (5) and 2/3 on sound insulation (7).

Expanding foam tape (6) may only be stuck up to measurement (A) on side frame (8).

A approx. 6.5 mm

Dashboard trim panel
Windscreen
Semicircular spacer buffer
Glue bead
Cowl panel (plate)
Expanding foam tape (sound insulation, cowl panel)
Sound insulation, bulkhead upper section
Side frame

Overview for windscreen cementing (E60, E61):

Fig 8: Overview For Windscreen Cementing (E60, E61)

Courtesy of BMW OF NORTH AMERICA, INC.

Attach special tool 51 3 010 twice to tool trolley. Moisten suction surfaces and tension windscreen from outside.

If reusing the removed windscreen, remove adhesive residue down to 0.5 mm and press expanding foam tape down with hand roller.

Install rubber frame (6), paying attention to center marking on rubber frame and mirror base.

Virtually vertical part (B) of adhesive bead (1) must be positioned to window edge (5) or rubber frame (6).

Markings (G, H) are on windscreen in bottom corners. Apply primer or adhesive at correct distance to windscreen edge (5) (wind noises, leaks).

Spread cement bead (4) with special tool 00 9 322 .

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

Fig 9: Identifying Distance Between Yellow Plastic Adhesive Tapes And Outside Corners Of Roof

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Working on windscreen (1) carefully with special tool 51 3 010 :

position at top
align sides evenly
insert at bottom and press down
press upwards until seal rests evenly on roof
secure in terms of height in this position at top with two yellow plastic adhesive tapes (2)

Fig 10: Identifying Windscreen And Special Tool 51 3 010
Courtesy of BMW OF NORTH AMERICA, INC.

Preload on top of windscreen to prevent wind noise:

Windscreen (1) must be lower than roof outer skin (2). This is the only way to prevent wind noises.

Position special tool 51 0 010 in middle of vehicle depending on measurement (A) and check underprotrusion of windscreen (1).

Windscreen underprotrusion (A):

A = 3.2 ± 1 mm

X = Measurement stages 1... 4 mm

Fig 11: Identifying Underprotrusion Of Windscreen

Courtesy of BMW OF NORTH AMERICA, INC.

Version with HUD:

Installation:

Check and if necessary adjust HUD. See 62 30... ADJUSTING HEAD-UP DISPLAY (DISPLAY ADJUSTMENT) .