51 31 200 Removing and installing/replacing rear window

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Special tools required:

51 3 010

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

Notes on window bonding:
- See SAFETY AT WORK .

- See INFORMATION ON VEHICLE PROTECTION .

- See MATERIALS FOR WINDOW BONDING .

- See GENERAL NOTES ON THE HEAD-UP DISPLAY .

- See TOUCHING UP PAINTWORK DAMAGE .
GENERAL PROCEDURE for dismantling/installation of affixed window glass

When reusing the rear window:
Avoid damaging lines for heated rear window/- aerial.

NOTE: Removal is performed with ROLL OUT 2000 . Work with oscillating blade only when replacing (window breakage).

Prerequisite:

Vehicle must be standing on its wheels on a level floor
REAR LID CORRECTLY ADJUSTED TO FIT

Necessary preliminary tasks:

Remove TRIM for rear lid at top
Remove TRIM FOR REAR LID, MIDDLE
Remove REAR LID COVER, TOP OUTER

Disconnect ribbon cable (1) at wave trap (3).

Unlock plug connection (2) for heated rear window and disconnect.

Secure cable to rear window with adhesive tape.

Fig 1: Identifying Ribbon Cable, Wave Trap And Plug Connection

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IMPORTANT: Slide protective cover between rear window frame and body and secure with adhesive tape.
Tape off body in area of piercing point with fabric adhesive tape (risk of damage).

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

Open small boot lid.

Cut out rear window.

Fig 2: Identifying Wire Starter From Roll Out 2000 At Line

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Only replace

Rear window is cut out with two different lengths of blade (risk of damage).

Top/bottom Blade length 24 mm

Side Blade length 45 mm

NOTE: First, cuts are made at top and bottom.

Only replace

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

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

Carefully insert knife between body aperture and rear window.

Guide web of knife parallel to rear window.

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

IMPORTANT: Carefully cut in area of electric connections (risk of damage).

Fig 3: Identifying U Shape Knife

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Fitting 5 spacer buffers and 2 spacer strips (spacers):

Fig 4: Fitting Spacer Buffers And Strips

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NOTE: Five spacer buffers (4) (5x5x20 mm)* are fitted between marks (5)
Completely remove remnants of removed spacer buffers and maintain installation position exactly.
Spacer strips (1) on left and right are stuck starting from mark (2) along sheet metal edge.
* Sourcing reference: BMW Parts Department
Dual Locks must be stuck exactly to marks (3) of tailgate and to rear window (next operation) (positioning of rear window).

Overview of rear window bonding:

Fig 5: Overview Of Rear Window Bonding

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Installation note:

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

install first at bottom (small tailgate open)
Align sides evenly
center in rear window to distances (A) and (B)
press on rear window and engage Dual Lock.
secure in this position with yellow plastic adhesive tapes

A = 4±1.5 mm

B = 4±2 mm

Fig 6: Adjusting Center Rear Window Distances

Courtesy of BMW OF NORTH AMERICA, INC.