51 31 200 Removing and installing/replacing rear window

Special tools required:

IMPORTANT: The "INSTRUCTIONS ON CEMENTING WINDSCREEN " serve as the basis for this repair instruction and must be observed without fail.
Cover front side panels with protective covers.
When reusing the rear window:
Avoid damaging lines for rear window heating/aerial.

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

Necessary preliminary tasks:

Disconnect left and right plug connections (1).

Secure cable (2) with adhesive tape to rear window.

IMPORTANT: Risk of damage!
Pay attention to cable (2) when cutting in this area.

Fig 1: Identifying Plug Connections And Cable

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Disconnect plug connection (1).

Secure cable (2) with adhesive tape to rear window.

IMPORTANT: Risk of damage!
Pay attention to cable (2) when cutting in this area.

Fig 2: Identifying Plug Connection And Cable Of Rear Window

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Replacement only:

Tape off body-cutout all round with fabric adhesive tape.

Attach a 24 mm U-shape blade (sourcing reference: BMW Parts Service) to tool.

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

Carefully insert blade between body-cutout and rear window.

Guide web of knife parallel to rear window.

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

Fig 3: Identifying Rain/Light Sensor

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

Fig 4: Pushing Wire Starter

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Overview for rear window cementing (E82):

Fig 5: Overview For Rear Window Cementing (E82)

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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.

IMPORTANT: To avoid window glass breakage and leaks:
Completely remove remnants of spacer buffers (7) and maintain installation location exactly.
Stick new spacer buffers (7) to marking on rear window.
Almost vertical part (B) of adhesive bead (1) must be facing window edge.
* In lower area of rear window, adhesive bead (1) runs at a distance of 12.5 mm (outside) to 23.0 mm (middle) to PVC spray-coating (5). If reusing the removed rear window, follow course of existing adhesive bead (1). If replacing, follow adhesive bead (1) of marking (6).
Spread adhesive bead with special tool 00 9 322 .

Open rear lid.

Carefully working on rear window with special tool 51 3 010 :

position at top at distance (A or B) to roof edge
align sides evenly
insert at bottom and press down
if necessary, press rear window upwards and adjust gap dimension (A or B)

Fig 6: Identifying Roof Edge Distance
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A = 5.4 mm

B = 4.5 ± 1 mm
secure in terms of height in this position at top with yellow plastic adhesive tape

NOTE: Adhesive area for plastic adhesive tapes must be free from grease and dust.

Preload on top of windscreen to prevent wind noise:

NOTE: 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 center of car depending on dimension (A) and check underprotrusion of rear window (1); adjust if necessary.

Rear window underprotrusion (A):

Fig 7: Identifying Rear Window Underprotrusion Dimension

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A= 3.9 ± 1.0 mm

X = Measurement stages 1... 4 mm