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

Special tools required:

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

Necessary preliminary work:

Remove TRIM ON WINDOW FRAME

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

Adjust dimension (X) differently according to different position of adhesive bead, refer to Fig 2.

NOTE: Prior to each use, regrind the knife with a grindstone while the machine is running (new knives also).

Fig 1: Identifying Special Tool Adjustment Dimension

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Tape off door window glass and sheet metal flange all round with fabric adhesive tape (1) (e.g. Tesa).

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

A 15 mm

B 10 mm

C 25... 40 mm (65 mm from (B) with

= scalpel)

D 50 mm

E 45... 15 mm (60 mm from (A) with

= scalpel)

Fig 2: Applying Tape On Window Glass And Sheet Metal Flange

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Carefully cut into corner points with scalpel.

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.

Fig 3: Cutting Adhesive Bead (Inside)

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Only when reusing the door window:

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

Attach new frame (1) to door window (2).

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

(3) Catches

(4) Guides

(5) Spacers (X-, Y- and Z-directions)

Fig 4: Attaching New Frame To Door Window

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Remove remnants of (1) frame catch.

Installation note:

Seals (2) must be fitted.

Fig 5: Identifying Frame Catch Remnants And Seals

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Cut nozzle to size.

A = 8±1 mm
B = 13.5±1.5 mm
C = 3 mm
D = 2 mm

Fig 6: Identifying Nozzle Dimensions

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Overview of door window bonding, fixed, rear (E84):

Fig 7: Overview Of Door Window Bonding, Fixed, Rear

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Attach two special tools 51 3 010 to tool trolley. Moisten suction surfaces and secure door window. Attach additional special tool 51 3 220 .

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

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

Carefully position door window (with frame):

With special tool 51 3 220
first at bottom
Insert window frame in bore holes (1).
Clip catches on frame into penetrations (2)

Fig 8: Identifying Bore Holes And Frame Penetrations

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NOTE: Assemble vehicle immediately after installing door window. If adhesive has hardened, covers can no longer be fitted. Position door seal (1) and cover (2) especially cleanly.

Fig 9: Identifying Door Seal And Cover

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