51 31 000 Removing and installing front windshield

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2003 BMW 540i, 2002 BMW 540i, 2001 BMW 540i, 2000 BMW 540i, and 1999 BMW 540i. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: To bond windshield:
Adhesives for cold and hot working are permitted.
Remove front lid.
Remove interior rearview mirror, refer to 51 16 060 REMOVING AND INSTALLING OR REPLACING INTERIOR REARVIEW MIRROR .
If necessary, remove rain sensor, refer to 61 35 175 REMOVING AND INSTALLING/REPLACING RAIN SENSOR .
Remove both sun visors and counter supports, refer to 51 16 080 REMOVING AND INSTALLING OR REPLACING SUN VISOR AND LEFT OR RIGHT COUNTER SUPPORT .
Remove both panels for front roof pillar (A-pillar finishers), refer to 51 43 201 REMOVING AND INSTALLING OR REPLACING TRIM FOR FRONT LEFT OR RIGHT ROOF .
Remove cowl panel cover (task is described in Removing wiper console), refer to 61 61 270 REMOVING AND INSTALLING COMPLETE WIPER CONSOLE .

Cold processing:

Comply with instructions on gluing windows, refer to 51 31... REMOVING WINDSCREEN WITH "ROLL OUT 2000"

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 (sourcing reference: BMW Part).

Comply with instructions on gluing windows, refer to 51 31... REMOVING WINDSCREEN WITH "ROLL OUT 2000"

Fig 1: Opening Aluminum Membrane At Rear End Of Cartridge

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NOTE: Cover engine compartment (top) and side panels with protective covers.

Lower front headlining slightly.

Remove seal (1) for left/right windshield/side panel.

Fig 2: Removing Seal For Left/Right Windshield/Side Panel

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Remove grommets (1) for cover finisher on windshield.

Fig 3: Removing Grommets For Cover Finisher On Windshield

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Remove gasket from windshield.

Fig 4: Removing Gasket From Windshield

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Mask body all round with fabric adhesive tape (e.g. Tesa).

Windshield
Glue bead
Body opening
Fabric adhesive tape

Fig 5: Identifying Fabric Adhesive Tape
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Fit knife (24 mm blade length, sourcing reference: BMW Part) to the tool.

NOTE: Resharpen knife with machine running.

Fig 6: Resharpening Knife With Machine Running

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Carefully insert knife between body and windshield.

Fig 7: Inserting Knife Between Body And Windshield

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Guide handle of knife parallel to windshield.

Fig 8: Identifying Guide Handle Of Knife Parallel To Windshield

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Cut through glue bead all around and as close as possible to windshield glass.

Body opening
Glue bead
Knife
Windshield

Fig 9: Cutting Through Glue Bead All Around And As Close As Possible To Windshield Glass
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Lift out the windshield using special tool 51 3 010.

Pull off adhesive tapes all round.

Fig 10: Lifting Out Windshield Using Special Tool

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CAUTION: To ensure long-term corrosion protection, it is absolutely essential to repair paintwork damage (scratches and large-surface damage), refer to 51 31... REMOVING WINDSCREEN WITH "ROLL OUT 2000"

Immediately before installing windshield:

Remove glue residue in body cutout to approx. 0.5 mm.

To avoid damaging paintwork in body cutout, carefully remove glue residue with a scalpel.

CAUTION: Clean freshly cut residual bead with 2-Propanol only, do not under any circumstances use Sika bonding agent 205/5.

Fig 11: Removing Glue Residue In Body Cutout To Approx. 0.5 Mm

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When reusing the windshield:

Remove glue residue on windshield with a scalpel (1) for heavy-duty applications to approx. 0.5 mm.

Fig 12: Identifying Scalpel

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CAUTION: The basic filler must have hardened!

Treat body around glued area with BMW-approved materials (repair kit, sourcing reference: BMW Part), refer to 51 31... REMOVING WINDSCREEN WITH "ROLL OUT 2000"

NOTE: Note ventilation time!

Fig 13: Identifying Glued Area

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Stick on 1 spacer buffer (2) in each case in center and at distances (A) and (B) from center of cowl panel.

Dimensions:

486 mm
446 mm
6 mm

Windshield
Spacer buffer
Glue bead
Expanding foam tape
Windshield

Fig 14: Measuring Distances Spacer Buffer

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Fig 15: Identifying Spacer Buffer Component

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Fit new expanding foam tape (4) over gap (1) between acoustic insulation (2) and windshield panel (3) from left to right.

There must be enough space for the glue bead in the middle between the expanding foam tape (4) and spacer section (5).

Treat windshield at distance (A, B, C) to edge of windshield across width of approx. 20 mm with materials approved by BMW (repair kit, sourcing reference: BMW Part), refer to 51 31... REMOVING WINDSCREEN WITH "ROLL OUT 2000"

7 mm
5 mm
5 mm

Fig 16: Measuring Treat Windshield Distance
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NOTE: Note ventilation time!

Fit gasket to windshield and press firmly into place.

Cut nozzle to size.

8 mm
11.2 mm

NOTE: For an even application of adhesive bead:
Use a cartridge gun (operated pneumatically or electrically, sourcing reference: BMW Part).
Check expiration date of glue!

Fig 17: Cutting Nozzle To Size

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If necessary, apply a test bead before gluing.

Cartridge must be held perpendicularly to the windshield glass.

Fig 18: Applying Test Bead Before Gluing

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Shape of glue bead:

8 mm
11. 2 mm

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

Fig 19: Identifying Shape Of Glue Bead

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Apply glue bead at distance (A, B, C) along edge of windshield.

10 mm
8 mm
8 mm

Fig 20: Applying Glue Bead At Distance Along Edge Of Windshield
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NOTE: Adhesive area for plastic adhesive tapes (1) must be free of grease and dust.

Attach two yellow plastic adhesive tapes (1) (sourcing reference: BMW Part)

to roof at distance (A) from outer corners.

Length: 400 mm

Width: 50 mm

250 mm

Fig 21: Measuring Roof Distance
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Using special tool 51 3 010, first position windshield at top, align evenly at sides, then install at bottom and press into place.

Press windshield upwards until seal on roof abuts uniformly.

Secure windshield in this position on top with two yellow plastic adhesive tapes (1) (Tesa).

Fig 22: Identifying First Position Of Windshield At Top

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The windshield is pretensioned at the top to prevent wind noises.

Pretension is generated with special tool 51 3 130 (three HR foam blocks).

1 piece (1): 40 x 70 x 70 mm (W x H x D)

2 pieces (2): 40 x 30 x 70 mm (W x H x D)

Fig 23: Measuring Distance Of HR Foam Block Middle

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Position of HR foam blocks:

HR foam block (1), middle, at distance (A) from top.

HR foam blocks (2), distance (A) from top and distance (B) at sides.

100 mm
100 mm

Preload on top of windshield to prevent wind noise:

Fig 24: Identifying Preload On Top Of Windshield To Prevent Wind

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When installing windshield (4), make sure that it lies lower to roof outer skin (1). This is the only way of ensuring sufficient preload between the sealing lip (2) and the roof (prevention of wind noise). Check installation position of windshield (4) in middle of vehicle with special tool 51 3 210; a clearance (A) is permitted.

Dimensions:

Standard windows = designation "N":

(A) = 0 - 1.5 mm

Anti-theft windows = designation "S":

(A) = 0 - 0.6 mm

Open both front doors.

Secure HR foam blocks (2) with plastic adhesive tape (1) (Tesa).

Pretension windshield with plastic adhesive tape (1) (Tesa) until it is correctly positioned at top.

NOTE: Do not stick plastic adhesive tape (1) above A-pillar finisher (3) or ITS head airbag.

Fig 25: Identifying HR Foam Blocks With Plastic Adhesive Tape

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CAUTION: Remove dirt from residual glue with Sika-Entferner 208 (sourcing reference: BMW Part) before glue is hard. Do not press out windshield glass again for this purpose. Hardened glue can only be removed by machine.

Assemble car.

After hardening time, remove support.

NOTE: Leaks are detected by spraying water under the sealing lips or by using an ultrasonic leak tester and can then be sealed with an appropriate nozzle.