54 37 300 Removing and installing/replacing rear window

IMPORTANT: The "INSTRUCTIONS ON WINDOW BONDING " serve as the basis for this repair instruction and must be observed without fail.

Special tools required:

IMPORTANT: The "INSTRUCTIONS ON WINDOW BONDING " serve as the basis for this repair instructions and must be observed without fail.
Cover front side panels with protective covers.
When reusing the rear window:
Avoid damaging lines for heated rear window/-aerial.
Do not damage decorative seal.

Necessary preliminary tasks:

Remove REAR ROOF SHELL .
Remove ROOFLINER FOR ROOF SHELL .

NOTE: Removal is performed with ROLL OUT 2000 .

Paintwork must not be damaged.
All add-on parts must not be damaged.

Roof shell, right side:

Unlock plug connection (1) on wave trap and disconnect.

Unlock plug connections (2) on aerial amplifier and disconnect.

Unclip wiring harness.

Fig 1: Identifying Roof Shell Plug Connection

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Roof shell, left side:

Unlock plug connection (1) on wave trap and disconnect.

Fig 2: Identifying Roof Shell Plug Connection

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NOTE: To avoid rear window breakage, the flat wire puller/awl (1) must be used.

Slide the flat wire puller/awl (1) from the ROLL OUT 2000 between the roof shell and the rear window through the adhesive bead from the inside.

Fig 3: Identifying Flat Wire Puller/Awl

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IMPORTANT: For cutting operations in the vicinity of electrical cables (1), a protective guard consisting of ROLL OUT 2000 must be inserted between the electrical cables (1), the cutting wire and the panel.
Components and panel will be damaged if the guard is not used.

Cut out rear window with ROLL OUT 2000 .

Lift out rear window with special tool 51 3 010 .

Fig 4: Identifying Rear Window Electrical Cables

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NOTE: If the decorative seal is damaged, the rear window must be replaced.

Fitting 4 spacer buffers:

Only the following spacer buffers may be used:

Dia. 9.5 mm and 3.8 mm high

IMPORTANT: To avoid rear window breakage and leaks, the remnants of the disassembled spacer buffers must be removed.
Position new spacer buffers outside the adhesive bead.
Use the position of the old spacer buffer on the body. (Outside external bore holes)

Fig 5: Identifying Rear Window Spacer Buffers

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Installation note:

Place roof shell on a completely flat surface.

Roof shell must not sag or warp.

Place special tool 51 0 020 in the top left and right corners of the rear window.

Position and clamp the tool precisely to attach the rear window edge.

NOTE: Position gauge on the rear window edge and not on the decorative seal.

Fig 6: Identifying Special Tool (51 0 020)

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Overview for rear window bonding (E93):

Fig 7: Overview Of Rear Window Bonding (E93)

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Attach special tool 51 3 010 twice to tool trolley. Moisten suction faces and secure rear window from outside.

If reusing the removed rear window, remove the adhesive residue with a blunt scraper or knife.

Observe treatment of adhesive area in body aperture and on rear window, see INSTRUCTIONS ON WINDOW BONDING .

Position and width of bead joint:

Overlapping and closed.
Not visible from outside and inside.
The contact point becomes noticeable through an increase in the adhesive volume (approx. 1.5 - 2 x bead width after crushing).
Position adhesive bead joint only where the ceramic glass offers a sufficient overlap and the body flange offers sufficient space.
The adhesive bead joint is not permitted in the disc wheels and in the upper cowl panel area.
Spread bead joint with special tool 00 9 322 .

IMPORTANT: 5 mins after the adhesive has first been applied, the position of the rear window can no longer be changed as the adhesive has already hardened too much.
If this time period is not adhered to, the window may become loose.
Window bonding not OK = new window bonding required.

Fig 8: Positioning Rear Window (51 0 020) On Roof Shell

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Position rear window 51 0 020 on roof shell using special tool and press down evenly.

X: Limit position of gauge on roof shell.

Y Center using the roof shell as a visual reference.

Z: Push rear window flush to roof shell

Check that rear window (1) is flush with roof outer skin (2).

Z: 0 to -1 mm short length.

Push the rear window in if necessary.

Fix rear window to roof shell with yellow plastic adhesive tape.

NOTE: After pressing, do not move the rear window any more as this could cause the window to come loose (release of tension).
Bonding is otherwise not OK and new bonding is required.

Fig 9: Checking Rear Window

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Adhesion time is dependent on the adhesive and must be strictly observed.