54 37 300 Removing and installing/replacing rear window roof shell

Special tools required :

Attention!

Notes on window bonding:
- SAFETY AT WORK

- INFORMATION ON VEHICLE PROTECTION

- MATERIALS FOR BONDING WINDOW

- NOTES ON WINDOW BONDING REPAIR KIT

- TOUCHING UP PAINTWORK DAMAGE

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	4
Small repair kit	1

Necessary preliminary tasks :

Remove REAR ROOF SHELL

Roof shell, right side :

Unfasten plug connection (1) and disconnect.

Secure cable to rear window with adhesive tape.

Fig 1: Identifying Plug Connection

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Roof shell, left side :

Unlock and detach plug connections (1 and 2).

Secure cable to rear window with adhesive tape.

Fig 2: Identifying Plug Connections

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

Fig 3: Identifying Flat Wire Puller/AWL

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

IMPORTANT: For cutting operations in the vicinity of electrical cables (1) a protective guard 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.

Fig 4: Locating Electrical Cables

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Cut out rear window.

Lift out rear window with SUCTION LIFTER .

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: Locating 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: Placing Special Tool (51 0 020) Upper Corners Of Rear Window

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Overview of rear window bonding :

Fig 7: Overview Of Rear Window Bonding

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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 sheet metal 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.

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

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

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

Fig 9: Checking Rear Window Flushness

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