51 31 200 Removing and installing rear window

WARNING: This page is about a different car, the 2003 BMW 525i, 2002 BMW 525i, and 2001 BMW 525i. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: When gluing the rear window, glues for cold and hot processing are permitted.
Cover rear side panels with protective covers.
Removing and installing both trim pieces for rear roof pillar, refer to 51 43 251 REMOVING AND INSTALLING OR REPLACING TRIM FROM REAR LEFT OR RIGHT ROOF PILLAR .

Cold processing:

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

Warm processing:

Open rear end of aluminum membrane in cartridge before installing in cartridge oven.

Heat glue cartridges to 80 °C for one hour in oven (sourcing reference: BMW Parts Service).

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

Fig 1: Opening Rear End Of Aluminum Membrane In Cartridge

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Disconnect right plug connection (1) (wave trap).

Fig 2: Disconnecting Right Plug Connection (Wave Trap)

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Disconnect left plug connection (1) (rear window heating/antenna).

Version with antenna for car telephone:

If necessary unfasten plug connection.

Fig 3: Disconnecting Left Plug Connection (Rear Window Heating/Antenna)

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Raise trunk lid by about 65 cm and hold in this position (e.g. attach welding wire with two hooks between lock and lock pin).

Fig 4: Raising Trunk Lid

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Remove seals (1) and (2).

Fig 5: Removing Seals

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Mask edges of trunk lid and all round body with fabric adhesive tape (e.g. Tesa).

Rear window
Glue bead
Body opening
Fabric adhesive tape

Fig 6: Masking Edges Of Trunk Lid & All Round Body With Fabric Adhesive Tape

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Fit knife (24 mm blade length, sourcing reference: BMW Parts Service) to the tool.

NOTE: If necessary, resharpen knife with machine running.

Fig 7: Fitting Knife

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Carefully insert knife between body and top center of rear window.

Fig 8: Inserting Knife Between Body & Top Center Of Rear Window

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Guide web of knife parallel to rear window.

Fig 9: Guiding Web Of Knife Parallel To Rear Window

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CAUTION: When reusing the rear window:
Avoid damaging lines for rear window heating/antenna.
When cutting through the glue bead beside the trunk lid, it must be opened for a short period by a 2nd person (risk of damage).

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

Body opening
Glue bead
Knife
Rear window

Fig 10: Cutting Through Glue Bead All Around

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Lift out rear window using special tool 51 3 010.

Fig 11: Lifting Out Rear Window Using Special Tool

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Cut off old glue in body opening but for a thickness of approx. 0.5 mm.

Cut off old glue carefully with an universal knife (sharp as a razor blade) to avoid damaging the paint finish in body opening. Pull off adhesive tapes all round.

Fig 12: Pulling Off Adhesive Tapes All Round

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CAUTION: To provide long-term corrosion inhibition, damage to paintwork (scratches and large areas of damage) should always be touched up,
refer to 51 31... INSTRUCTIONS ON GLUING WINDSCREEN

When reusing the rear window:

Remove glue residue on rear window with knife to approx. 0.5 mm.

Fig 13: Removing Glue Residue On Rear Window With Knife

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Secure cable (1) (rear window heating/antenna) with adhesive tape.

Treat rear window around glued area (A) with materials approved by BMW (repair kit, Sourcing Reference: BMW Parts Service),

refer to 51 31... INSTRUCTIONS ON GLUING WINDSCREEN

NOTE: Note ventilation time!

(A) = 25 mm (top/side)

(A) = 27 mm (bottom)

Fig 14: Treating Rear Window Around Glued Area

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Fit gasket at bottom of rear window and press into place.

Fig 15: Fitting Gasket At Bottom Of Rear Window

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Fit seal (1) at top in center of rear window and press downwards.

NOTE: Sealing strip (1) and rear window are marked in center (2).

Fig 16: Fitting Seal At Top In Center Of Rear Window

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CAUTION: The basic filler must have hardened!
Mask headlining on roof connection with paintwork masking tape.

Treat body in glued area with materials approved by BMW (repair kit, Sourcing Reference: BMW Parts Service),

refer to 51 31... INSTRUCTIONS ON GLUING WINDSCREEN

NOTE: Note ventilation time!

Cut nozzle to size.

(A) 8 mm

(B) 10_-1 mm

NOTE: To apply uniform glue bead, use cartridge pistol, operated with compressed air or electric power (refer to BMW Parts Service).

Note expiry date of glue!

Fig 17: Cutting Nozzle

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If applicable, produce a sample bead before gluing.

Cartridge must be arranged vertically against rear window.

Fig 18: Producing A Sample Bead Before Gluing

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CAUTION: Version with rear window antenna:
No glue must come into contact with the connection contacts of the rear window heating/antenna.

Shape of glue bead:

(A) 8 mm

(B) 10_-1 mm

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

Fig 19: Applying Glue Bead Quickly & Inserting Window

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Maintain distance (A), (B) and (C) between glue bead and seal.

(A) 1 mm

(B) 1 mm

Fig 20: Maintaining Distance Between Glue Bead & Seal

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Install rear window carefully using special tool 51 3 010. The gasket must make uniform contact all round (center). Press rear window upwards until gasket is at uniform distance from roof all round.

Secure rear window with fabric adhesive tape (e.g. Tesa). If necessary, brace with wooden wedge.

Fig 21: Installing Rear Window

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CAUTION: Remove dirt from residual glue with Sika-Entferner 208 (sourcing reference: BMW Parts Service) before glue is hard. 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 support and adhesive tape.

NOTE: Leaks are localized by spraying under the sealing lips or by using an ultrasonic leak tester (Sourcing Reference: BMW Parts Service) and are sealed using an appropriate nozzle.

Fig 22: Identifying Diagnosis & Information System

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If necessary, recalibrate magnetic field sensor,

refer to function description in DIS (Diagnosis and Information System).