51 31 200 Removing and installing/replacing rear window

Necessary preliminary tasks 

• Remove ROOFLINER FOR ROOF SHELL 

Move rear roof shell (1) forwards until frame (1) can be engaged in openings (2) on left and right with a suitable tool.

Fig 1: Moving Rear Roof Shell

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Fig 2: Frame Engaged On Openings

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Disconnect heated rear window plug connections (1) on left and right.

Fig 3: Identifying Rear Window Plug Connections

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

Cut out rear window with ROLL OUT 2000 .

Lift out rear window with special tool 51 3 010 .

Installation: 

Bond rear window with hardtop closed.

Fig 4: Identifying Wire Starter From Roll Out 2000 At Line

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Fitting 6 spacer buffers: 

Fig 5: Identifying Upper And Lower Spacer Buffer Dimension

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• Dia. 9.5 mm and 3.8 mm high

Y ₁ = applicable to all upper spacer buffers (1)

Y ₂ = applicable to all lower spacer buffers (1)

Overview of bonding agent application (primer) 

Apply bonding agent in marked area (1), but not beyond the ceramic glass screen print.

Fig 6: Identifying Bonding Agent On Applied Marked Area

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Overview of adhesive bead trace, top and side 

Adhesive bead trace (1) runs inside clinch points (2).

Adhesive bead trace 

A = 7 ⁺² mm (width, adhesive bead trace)

B = 7 ⁺¹ mm (height, adhesive bead trace)

Fig 7: Identifying Adhesive Bead Trace (Top)

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Overview of adhesive bead trace, bottom 

Adhesive bead trace (1) runs in sheet recess of cross-member (2).

Spread bead joint (3) with special tool 00 9 322 .

Adhesive bead trace 

A = 7 ⁺² mm (width, adhesive bead trace)

B = 7 ⁺¹ mm (height, adhesive bead trace)

Fig 8: Identifying Adhesive Bead Trace (Bottom)

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Attach special tool 51 3 010 twice to tool trolley. Moisten suction surfaces 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 CEMENTING

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 only where the glass ceramic material offers a sufficient overlap and the body flange offers sufficient space.

• The adhesive bead is not permitted in the window radii and in the cowl panel area

Stick two yellow plastic adhesive tapes (1) to roof at distance (A) from outside corners.

Length: 400 mm

A = 150 mm

Fig 9: Identifying Plastic Adhesive Tapes Position Onto Roof

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Gap dimensions 

A = Centre rear window (2) to roof shell (1) laterally.

B = Rear window (2) to trim strip, convertible top compartment lid (3), see 41 00... BODY GAP DIMENSIONS . .

Fig 10: Identifying Gap Dimension For Centre Rear Window To Roof Shell

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Checking pre-tension on rear window 

In order to avoid wind noises, rear window (1) must be lower than roof outer skin (2).

Position special tool 51 0 010 in middle of vehicle depending on measurement (A) and check underprotrusion of rear window (1).

A = 2 mm

X = measurement stages 1... 4 mm

Fig 11: Checking Pre-Tension On Rear Window Using Special Tool 51 0 010

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Installation: 

Underprotrusion dimension "A" is decreased by approx. 4 mm continuously from window center to window edge on left and right.