51 31 200 Removing and installing/replacing rear window

Special tools required:

51 0 010

IMPORTANT: The following notes form the basis for these repair instructions and must be adhered to at all times:

Notes on window bonding. See 41 00... SAFETY AT WORK , 99 00... TOUCHING UP PAINTWORK DAMAGE , 51 31... NOTES ON WINDOW BONDING REPAIR KIT and 51 31... MATERIALS FOR BONDING WINDOW .
GENERAL PROCEDURE for dismantling/installing bonded window glass

When reusing the rear window:

Avoid damaging lines for heated rear window/-aerial.

NOTE: Removal is performed with ROLL OUT 2000 or SPIDER .

The following new parts/consumables are required (sourcing reference BMW Parts Department).

Material	Quantity
Rear window (with replacement)	1
Spacer buffer 5x5x20 mm	10
Small repair kit	1

Necessary preliminary tasks:

Remove TRIM PANEL FOR ROOF PILLAR at rear (C-pillar) left/right
Remove AUXILIARY BRAKE LIGHT

Unfasten plug connection (1) and disconnect.

Unfasten cable strap (2).

Secure cable to rear window with adhesive tape.

NOTE: Carry out work on the right side in the same way as for the left side illustrated here.

Fig 1: Rear Window Cable Strap And Plug Connection

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Unfasten plug connection (1) and disconnect.

Secure cable to rear window with adhesive tape.

Fig 2: Rear Window Plug Connection

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Secure tailgate (1) in half-opened position with tensioning strap (2).

Tape off area (A) on the left/right with yellow plastic adhesive tape.

Fig 3: Tailgate Adhesive Tape Applying Area

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IMPORTANT: Tape off body in area of piercing point with fabric adhesive tape (risk of damage).

Slide wire or string at line (1) through adhesive bead.

When sliding in wire/string, do not damage sealant on body.

Fig 4: Rear Window Line

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Fitting spacer buffers (spacers):

IMPORTANT: Spacer buffers are installed to avoid rear window breakage.
Completely remove the damaged spacer buffers (1).
Bond new spacer buffer (1) to marks (2).

Fig 5: Rear Window Spacer Buffers

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Overview of rear window bonding:

Fig 6: Overview Of Rear Window Bonding

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Cut	A - A/B - B	C - C	D - D
a [mm] = Position adhesive bead	10 ±2	9 ±1	14 ±2
b [mm] = Width adhesive bead	7 ±1	7 ±1	7 ±1
h [mm] = Height adhesive bead	12 - 2	12 - 2	12 - 2

NOTE: A tolerance band is printed on the ceramic (two dashed lines) that marks the position of the adhesive bead. Place adhesive bead centrally on tolerance band.

x = approx. 250 mm (bead joint distance (1) to rear window outer edge)

Installation note:

Carefully perform the following steps with the rear window (1) using a suction lifter:

Feed in under tailgate
Mount on top and insert
Center rear window to distances (A) and (B)
secure in this position with yellow plastic adhesive tapes

Fig 7: Adjusting Rear Window
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5 ± 1 mm
4 ± 1.3 mm

Preload on top of windscreen to prevent wind noise:

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 vehicle depending on dimension (A) and check underprotrusion of rear window (1).

A = 3 ± 0.8 mm

X = Measurement stages 1... 4 mm

Fig 8: Positioning Special Tool (51 0 010)

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