51 31 000 Removing and installing/replacing windscreen

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IMPORTANT:

The "Instructions on cementing windscreen" 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
If necessary, remove FOGGING/CONDENSATION SENSOR
If necessary, remove 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

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 Wire Starter With Fabric Adhesive Tape

Courtesy of BMW OF NORTH AMERICA, INC.

Replacement only:

Mount U-shape blade (sourcing reference: BMW Parts Service) 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: Mounting U-Shaped 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: Sliding Special Tool Over Housing Of Gas Spring Strut

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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

IMPORTANT:

To avoid windscreen breakage and wind noises:

Completely remove remnants of removed spacer buffers and maintain installation location exactly.

Fig 4: Identifying Spacer Buffers

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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 Spacer Buffer

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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

1 Windscreen

4 Glue bead

5 Outlet radius

Fig 6: Attaching Spacer Buffers

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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.

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).

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

Fig 7: Attaching Expanding Foam Tape

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Overview for windscreen cementing (E60, E61):

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

Courtesy of BMW OF NORTH AMERICA, INC.

OVERVIEW FOR WINDSCREEN CEMENTING (E60, E61) - DESCRIPTION

1	Glue bead	C4	2 ± 1 mm (spacing from 1 to 6)
2	Ceramic layer	D1.2	20 ± 2 mm (width from 3) at bottom to G2
3	Primer coat	D3.4	14 ⁺² mm (width from 3) at side and top
4	Application point of glue bead	E1	11 mm (spacing from 3 to 5)
5	Window edge	E2	11 mm (spacing from 3 to 5)
6	Rubber frame, top	E3	0 mm (spacing from 3 to 5)
7	Sight glass for US chassis number	E4	0 mm (spacing from 3 to 6)
A	7 ± 1 mm (width of adhesive bead)	F	280 mm (spacing from 4 to 5)
B	11_-2 mm (height of adhesive bead)	G1...3	Artificial lines in 2 to 5 (for measurement of C)
C1	18 ± 1 mm (distance 1 to 5) at bottom to G1	H1.2	Artificial points in 2 (1 rests on H on inside)
C2	17 ± 1 mm (distance 1 to 5) at G2	R1	approx. 20 mm (radius of 1 at bottom)
C3	4 ± 1 mm (distance 1 to 5) G3 to R2	R2	approx. 16 mm (radius of 1 at top)

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 Adhesive Area For Plastic Adhesive Tapes

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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: Using Special Tool 51 3 010 On Windscreen

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.

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

Windscreen under-protrusion (A):

A= 3.2 ± 1 mm

X = Measurement stages 1... 4 mm

Fig 11: Installing Front Windscreen Application

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Version with HUD:

Installation:

Check and if necessary adjust HUD .