51 31 000 Removing and installing/renewing windscreen

Special tools required:

IMPORTANT: The "INSTRUCTIONS ON WINDOW BONDING " serve as the basis for these repair instructions and must be observed without fail.
Cover front side panels with protective covers.

Necessary preliminary tasks:

Remove INSIDE MIRROR
Remove SUN VISORS and counter supports
Remove PANELS FOR ROOF PILLAR at front
Remove COVER FOR COWL PANEL

Replacement:

Remove RUBBER FRAME FOR WINDSCREEN
Remove RETAINING STRIP FOR COWL PANEL COVER
Tape off body aperture all round with fabric adhesive tape

Mount U-shape knife (sourcing reference: BMW Parts Department) on tool:

24 mm blade length.

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

Carefully insert blade between body aperture and windscreen.

Guide handle of knife parallel to windscreen.

Cut through adhesive bead as closely as possible to windscreen.

Fig 1: Identifying Rain/Light Sensor

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NOTE: When cutting is carried out at the bottom in the event of replacement, the engine compartment lid must be in the service position.

Move ENGINE COMPARTMENT LID 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 2: Pulling Off Adhesive Tapes

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Installation note:

No spacer buffers are fitted because a retaining strip is mounted at the bottom.

For version with diesel engine:

If necessary, replace defective EXPANDING FOAM TAPE .

Replacement:

Version with visible vehicle identification number:

Stick 60 mm long expanding foam tape 5 mm above inspection glass for vehicle identification number onto ceramic layer.

Build date up to approx. 09/2004:

IMPORTANT: Risk of water ingress into vehicle interior through fan.

Installation note:

On versions with cut-out (1) on flange (2), butyl tape (3) must be fitted on left and right (to stop water ingress).

Lay two lengths of 6 mm dia.* round butyl tape one over the other and form into a trapezium shape so that a butyl bead with length "A" and thickness "B" is created.

Fig 3: Identifying Butyl Tape And Flange

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A = 66 ± 2 mm

B = 12 mm

Butyl tape (3)* must be fixed between the windscreen adhesive bead and the bulkhead cross-member outlet.

Butyl tape (3) must not completely dissect adhesive bead (risk of leakage).

* Sourcing reference: BMW Parts Department

Overview for windscreen bonding (E81/E82/87/E88):

Fig 4: Overview For Windscreen Bonding

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

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

If necessary, fit new retaining strip (5) and rubber frame (6), paying attention to center markings in the process.

Insert positioner (8) for retaining strip (5) must be removed after it has been fitted on the windscreen but before the windscreen itself is installed.

If necessary, press expanding foam tape down with hand roller.

Virtually vertical part (B) of adhesive bead (1) must be positioned to rubber frame (6) and retaining strip (5).

Spread bead joint 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 5: Identifying 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 sealing rests evenly on roof
secure in terms of height in this position at top with two yellow plastic adhesive tapes (2)

Fig 6: Identifying Windscreen And Special Tool 51 3 010
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Build date up to 09/2004 with butyl tape:

Press windscreen down harder in left/right corners (butyl tape creates resistance against retaining strip).

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 center of vehicle depending on dimension (A) and check underprotrusion of windscreen (1).

Windscreen underprotrusion (A):

E81/E82/E87:

A = 2 ± 1 mm

Fig 7: Identifying Window Glass Dimension

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E88:

A = 4 ± 1 mm

X = Measurement stages 1... 4 mm