51 34 191 Replacing left or right fixed door window in rear window frame

WARNING: This page is about a different car, the 2008 BMW 535xi. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

IMPORTANT: The "INSTRUCTIONS FOR WINDOW CEMENTING " serve as the basis for these repair instructions and must be followed without fail.

Necessary preliminary tasks:

Remove DECORATIVE STRIP ON WINDOW FRAME of rear door
Remove trims on window frame of rear door. See REMOVING AND INSTALLING/REPLACING TRIM FOR WINDOW GUIDE OF LEFT OR RIGHT REAR DOOR and REMOVING AND INSTALLING/REPLACING TRIM ON WINDOW FRAME OF REAR DOOR, REAR LEFT OR RIGHT .
Tape off inside of door around side window with fabric adhesive tape.

Fit straight blade with adjustable roller on tool and set dimension (X).

Adjust dimension (X) differently according to different position of adhesive bead.

Adjust lower dimension only for areas (C and F).

NOTE:

Prior to each use, regrind the blade with a grinding stone while the machine is running (new blades also).

Fig 1: Identifying Straight Blade With Adjustable Roller

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Door window and body flange all round with fabric adhesive tape (e.g. Tesa).

Adjust blade starting roller differently in areas (A) to (D) (risk of damage).

A = 14 mm

B = 12 mm

C= 30 mm

D= 30 ... 40 mm (110 mm from "C" with scalpel)

E = 40 mm

Carefully cut into corner points with scalpel.

Fig 2: Locating Cutting Start Points

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Carefully insert knife blade between body and door window.

Run handle of knife parallel to door window.

Remove door window with special tool 51 3 220 outwards.

Only when reusing the door window:

Remove frame
Cut off residual adhesive to a thickness of approx. 0.5 mm
Detach fabric adhesive tape all round
Clean door window with spirit

Fig 3: Inserting Knife Blade Between Body And Door Window

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Attach new frame (1) to door window.

Following parts on frame (1) must not be damaged or missing:

2 Spacer (X-direction)

3 Spacer (Y-direction)

4 Spacer (Z-direction)

Fig 4: Locating Spacers On Frame

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Cut nozzle to size.

A = 8 ± 1 mm

B = 15 ± 1 mm

C= 4 mm

D= 2.5 mm

Fig 5: Cutting Nozzle Dimensions

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Overview of door window bonding, fixed, rear (E61):

Fig 6: Overview Of Door Window Bonding, Fixed, Rear (E61)

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OVERVIEW OF DOOR WINDOW BONDING, FIXED, REAR (E61):

1	Glue bead	A	8 ± 1 mm (width of adhesive bead)
2	Ceramic layer	B	15+1-2 mm (height of adhesive bead)
3	Primer coat	C	12 ± 1 mm (width of primer trace)
4	Application point of glue bead	D	0 mm (spacing from 3 to 5)
5	Frame	E	1.5 ± 1 mm (spacing from 1 to 5)
R			15 mm (from adhesive bead)

Attach special tool 51 3 010 to tool trolley. Moisten suction surfaces and secure door window. In addition, secure special tool 51 3 220 .

Almost vertical part (B) of cement bead (1) must face frame (5).

Partially apply adhesive bead (1) to frame (5).

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

Seal (1) must be fitted.

Carefully remove door window (with frame) with special tool 51 3 220 :

first at bottom
align sideways
position at top

Assemble vehicle immediately after installing door window.

If adhesive has hardened, covers can no longer be fitted.

Fig 7: Locating Seal

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