51 31 200 Removing and installing/replacing rear window

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2010 BMW 535xi, 2010 BMW 535i, 2009 BMW 535xi, 2009 BMW 535i, and 2008 BMW 535xi. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

IMPORTANT:

The "NOTES ON WINDOW BONDING; WORK STEPS FOR REMOVING AND INSTALLING WINDOW GLASS " serve as the basis for these repair instructions and must be followed without fail.

Cover rear side panels with protective covers.

When reusing the rear window:

Do not damage wires for rear window heater/antenna.

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

Necessary preliminary tasks:

Remove PANELS FOR ROOF PILLAR at rear left/right
Remove AUXILIARY BRAKE LIGHT
Remove AERIAL/ANTENNA AMPLIFIER
Remove rubber frames for rear window. See REPLACING RUBBER FRAME (TOP/SIDE) FOR REAR WINDOW and REPLACING RUBBER FRAME (BOTTOM) FOR REAR WINDOW .

Release screw (1) on left/right.

Disconnect plug connection (2) on left/right.

Fig 1: Identifying Screw And Plug Connection

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Tape off edges of rear lid and body all round with fabric adhesive tape (e.g. Tesa).

Rear window
Glue bead
Body opening
Fabric adhesive tape

Fig 2: Locating Edges For Taping

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IMPORTANT:

Tape off body in area of piercing point with fabric adhesive tape (risk of damage).

Push wire starter from ROLL OUT 2000 at line (1) through adhesive bead.

Fig 3: Identifying Piercing Point

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Replacement only:

Attach a 24 mm U-shape blade to tool.

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

Insert blade carefully between rear lid and rear window.

Guide web of knife parallel to rear window.

Cut through cement bead as closely as possible to rear window.

Lift out rear window with special tools 51 3 010 .

Pull off adhesive tapes all round.

Fig 4: Identifying U Shaped Blade

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Overview of rear window bonding (E60):

Fig 5: Overview Of Rear Window Bonding (E60):

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OVERVIEW OF REAR WINDOW BONDING (E60): TABLE

1	Glue bead	A	7 ± 1 mm (width of adhesive bead)
2	Ceramic layer	B	11_-2 mm (height of adhesive bead)
3	Primer coat	C1	2 ± 1 mm (spacing from 1 to 5)
4	Application point of glue bead	C2	3 ± 1 mm (spacing from 1 to 6)
5	Rubber frame at top with aluminium section	D	17 _-1 mm (width of primer trace all round)
6	Rubber frame at bottom with aluminium section	E	0 mm (spacing from 3 to 5 and 6)
7	Connections for heated rear window	F	95 mm (spacing from 4 to 5)
8	Connections for TV and radio antennas	R1	approx. 1.5 mm (radius of 1)
9	Connections for additional stop light	R2	approx. 16 mm (radius of 3)
R3			approx. 20 mm (radius of 1)

Attach special tool 51 3 010 twice to tool trolley. Moisten suction surfaces and secure rear window from outside.

If reusing removed rear window, remove residual adhesive down to 0.5 mm.

Secure cables of heated rear window/antenna(s) with adhesive tape.

Install rubber frames (5 and 6), paying attention to center markings in so doing.

Virtually vertical part (B) of adhesive bead (1) must point to window edge or rubber frame.

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

Installation:

Adhesive area for yellow plastic adhesive tapes (1) must be free from grease and dust.

Carefully install rear window with special tools 51 3 010 as follows:

position at top at distance (A) to roof edge
align sides evenly
insert at bottom and press down
press upwards until distance (A) to roof edge is obtained
secure with yellow plastic adhesive tapes (1)
press down at bottom until rubber frame is uniformly in place

A = 5 mm (use special tool 51 3 032 )

Fig 6: Locating Rear Window In Frame

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Preload on top of windscreen to prevent wind noise:

Rear window (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 rear window (1).

Rear window underprotrusion (A):

A = 3.2 ± 1 mm

X = Measurement stages 1... 4 mm

Fig 7: Using Special Tool (51 0 10) To Check Underprotrusion

Courtesy of BMW OF NORTH AMERICA, INC.