54 21 150 Removing and installing/replacing rear window for hard top

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NOTE: For gluing the rear window, cements for cold and hot processing are permitted.

Cold Processing:

Comply with instructions on gluing windows, refer to 51 31 ... INSTRUCTIONS ON GLUING WINDSCREEN .

Warm Processing:

Open aluminum membrane at rear end of cartridge.

Place cartridge in cartridge oven.

Heat glue cartridges to 80° C for one hour in oven.

Fig 1: Placing Cartridge In Cartridge Oven

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Comply with instructions on gluing windows, refer to 51 31 ... INSTRUCTIONS ON GLUING WINDSCREEN .

Remove hard top, refer to 54 21 001 REMOVING HARD TOP .

Remove molded roof lining from hard top, refer to 54 21 100 REMOVING AND INSTALLING/REPLACING MOLDED ROOF LINING ON HARD TOP .

Fig 2: Removing Hard Top

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Disconnect plug (1) for rear window heater (2) on left and right.

Fig 3: Disconnecting Plug

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Pull out seal (1) from transition area of gutter (2).

Fig 4: Pulling Out Seal

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Mask trunk lid corners and hard top with fabric adhesive tape (e.g. Tesa).

Rear window.
Glue bead.
Hard top flange.
Fabric adhesive tape.

Fig 5: Masking Trunk Lid Corners And Hard Top With Fabric Adhesive Tape

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Fit knife to the tool.

NOTE: If necessary, resharpen knife with machine running.

Fig 6: Fitting Knife To Tool

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CAUTION: When reusing the rear window: Do not damage wires for rear window heater.

Carefully insert knife between hard top and rear window.

Fig 7: Inserting Knife Between Hard Top And Rear Window

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Guide web of knife parallel to rear window.

Fig 8: Guiding Web Of Knife Parallel To Rear Window

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Cut through glue bead all around as close as possible to the rear window glass.

Hard top cutout.
Glue bead.
Knife.
Rear window.

Fig 9: Cutting Through Glue Bead

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Lift out rear window with special tool 51 3 010.

Fig 10: Installing Special Tool

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Remove residual adhesive in hard top cutout to a thickness of approx. 0.5 mm.

To avoid damage to paintwork in hard top cutout, cut off residual adhesive with universal knife (razor sharp).

Pull off adhesive tapes all round.

Fig 11: Removing Residual Adhesive

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CAUTION: To ensure long-term corrosion protection, it is essential to touch up damage to paintwork (scratches and large-surface damage).

Refer to 51 31 ... INSTRUCTIONS ON GLUING WINDSCREEN .

When reusing the rear window:

Scrape away glue residue on rear window to depth of 0.5 mm with scraper.

Fig 12: Scraping Glue Residue On Rear Window

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Mount and press seal on to rear window glass at bottom.

Mount and press seal on to rear window glass at top and sides.

Fig 13: Pressing Seal On Rear Window Glass

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CAUTION: The basic filler must have hardened!

Treat rear window and hard top in adhesive area with BMW-approved materials, refer to 51 31 ... INSTRUCTIONS ON GLUING WINDSCREEN .

NOTE: Note specified ventilation time.

Fig 14: Treating Rear Window And Hard Top In Adhesive Area

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Cut nozzle to size.

= 9 mm.
= 6 mm.

NOTE: To apply a uniform glue bead, use cartridge pistol.

Check expiry date of glue!

Fig 15: Measuring Cutting Nozzle Size

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If necessary, apply a test bead before gluing.

Cartridge must be arranged vertically against rear window.

Fig 16: Applying Test Bead Before Gluing

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CAUTION: There must be no adhesive on the connection contacts of the rear window heater.

Shape of adhesive bead:

= 9 mm.
= 6 mm.

CAUTION: Apply glue bead quickly and insert window. Skin formation time of glue, maximum 10 minutes.

Fig 17: Measuring Shape Of Adhesive Bead

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Maintain uniform distance (A) between glue bead and seal.

Distance (A) = 3 mm

Fig 18: Measuring Distance Between Glue Bead And Seal

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Install rear window carefully using special tool 51 3 010. Seal must fit uniformly on the sides. Push up rear window glass until seal bears uniformly on the roof flange.

Align rear window to roof flange and evenly at sides. Press-fit rear window and secure in this position with fabric adhesive tape (e.g. Tesa).

Fig 19: Installing Special Tool

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CAUTION: Before hardening, remove contamination by residual adhesive with Sika remover 208. Do not press out rear window glass again for this purpose. Hardened glue can only be removed by machine.

Assemble car.

After the hardening time, remove adhesive tapes.

NOTE: Leaks can be found by spraying water on the sealing lips or with an ultrasonic leak detector and then eliminated by using a suitable nozzle.