51 31 000 Removing and installing windshield (Protection)

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.

Provision of work accessories:

Special tool 51 9 002 with accessories
Special tool 51 3 010
Special tool 51 3 130

CAUTION: Danger of injury!
The weight of the windshield is considerably greater than on the normal version. The above-mentioned special tools are therefore absolutely essential.
A second person is necessary to help remove and install the windshield.

Support pedestal for windshield
Materials for repairing paintwork damage in body area, refer to 51 31... REMOVING WINDSCREEN WITH "ROLL OUT 2000"
Materials for gluing windshield and rear window, refer to 51 31... REMOVING WINDSCREEN WITH "ROLL OUT 2000"
Electric cutting tool^*
Blade for electric cutting tool (hook 24 mm and 36 mm)^*
Scalpel for heavy-duty applications^*
Cartridge gun^*
Fabric adhesive tape^*
Sika remover 208^*
Spirit^*
Yellow plastic adhesive tape^*
Sidol^*

^* Sourcing reference: BMW Part

Remove engine hood.

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 cover from windshield. 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

Courtesy of BMW OF NORTH AMERICA, INC.

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

Lower front headlining slightly.

Disconnect left and right plug connections for heated windshield and fix cable to windshield.

Fig 2: Disconnecting Left And Right Plug Connections For Heated Windshield And Fix Cable To Windshield

Courtesy of BMW OF NORTH AMERICA, INC.

Mark area of cable entries on windshield.

Fig 3: Marking Area Of Cable Entries On Windshield

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 4: Removing Seal For Left/Right Windshield/Side Panel

Courtesy of BMW OF NORTH AMERICA, INC.

Remove grommets (1) for cover finisher on windshield.

Fig 5: Removing Grommets For Cover Finisher On Windshield

Courtesy of BMW OF NORTH AMERICA, INC.

Removal:

Removal of windshield is described separately from installation. Assembly sequence for removal and installation is different.

Remove gasket from windshield.

Fig 6: Removing Gasket From Windshield

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Mask body all around with fabric adhesive tape (sourcing reference: BMW Part).

Windshield
Glue bead
Body opening
Fabric adhesive tape

Fig 7: Identifying Fabric Adhesive Tape
Courtesy of BMW OF NORTH AMERICA, INC.

CAUTION: When reusing the windshield:
Do not damage wires for windshield heating.

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

NOTE: If necessary, resharpen knife with machine running.

Fig 8: Resharpening Knife With Machine Running

Courtesy of BMW OF NORTH AMERICA, INC.

Carefully insert knife between body and windshield.

Fig 9: Inserting Knife Between Body And Windshield

Courtesy of BMW OF NORTH AMERICA, INC.

Guide handle of knife parallel to windshield.

Fig 10: Identifying Guide Handle Of Knife Parallel To Windshield

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Cut through glue bead as close as possible to windshield in area of A-pillar on left and right and roof edge.

Body opening
Glue bead
Knife
Windshield

Fig 11: Cutting Through Glue Bead As Close As Possible To Windshield In Area Of A-Pillar
Courtesy of BMW OF NORTH AMERICA, INC.

Fit knife (36 mm blade length, sourcing reference: BMW Part) to the tool.

NOTE: If necessary, resharpen knife with machine running.

Carefully insert knife at cowl panel between body and windshield.

Guide handle of knife parallel to windshield.

Cut through adhesive bead as close as possible to windshield in area of cowl panel.

Fig 12: Inserting Knife At Cowl Panel Between Body And Windshield

Courtesy of BMW OF NORTH AMERICA, INC.

Suspend special tool 51 9 002 (suction lifter) from conventional workshop lifting equipment.

Switch on vacuum pump.

Firmly attach special tool 51 9 002 to outside of windshield in center in upper third.

Fig 13: Identifying Conventional Workshop Lifting Equipment

Courtesy of BMW OF NORTH AMERICA, INC.

CAUTION: Follow operating instructions for special tool 51 9 002.
The pointer of the vacuum gauge must be in the green area.
Do not shorten connecting hose between suction hoist and vacuum pump (minimum length 5 m).
Replace with original hose only.

Fig 14: Connecting Hose Between Suction Hoist And Vacuum Pump

Courtesy of BMW OF NORTH AMERICA, INC.

Raise windshield slightly with suction hoist. If necessary, remove any residual traces of bonding carefully.

Lift out windshield and place on assembly stand.

Pull off adhesive tapes all around.

Fig 15: Lifting Out Windshield And Place On Assembly Stand

Courtesy of BMW OF NORTH AMERICA, INC.

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"

Installation

Installation of windshield is described separately from removal. Assembly sequence for removal and installation is different.

Installation check on reused and new windshields:

Examine heated windshield cable for damage, repair if necessary.
Check heated windshield connections for continuity.
Carry out function check on windshield heating with car battery.
Check sound insulation around circumference of windshield, request new part if necessary.
Locate heated windshield cable in position.

When installing a new windshield:

CAUTION: Static charge! Unroll protective foil on outside and inside, do not pull off.

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

NOTE: Cut off residual glue carefully with a scalpel to avoid damaging the paint finish in body cutout.

Fig 16: Removing Glue Residue In Body

Courtesy of BMW OF NORTH AMERICA, INC.

CAUTION: Clean freshly cut residual bead with 2-Propanol only (sourcing reference: BMW Part).
Do not under any circumstances use Sika bonding agent 205/5 or glass primer 205/5.

Place windshield on support pedestal with inside facing upwards.

When reusing the windshield:

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

Fig 17: Identifying Heavy-Duty Scalpel

Courtesy of BMW OF NORTH AMERICA, INC.

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 18: Treating Body Around Glued Area With BMW - Approved Materials

Courtesy of BMW OF NORTH AMERICA, INC.

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

Dimensions:

486 mm
446 mm
6 mm

Windshield
Spacer buffer
Glue bead
Expanding foam tape
Windshield

Fig 19: Measuring Distances On Two Point Spacer Buffer
Courtesy of BMW OF NORTH AMERICA, INC.

Stick on one spacer (1) 350 mm each on left and right of center.

Thickness of spacers = 3.2 mm

NOTE: The spacers are contained in the repair kit for bonded windshields (spacers for E30 Touring).

Fig 20: Sticking On One Spacer

Courtesy of BMW OF NORTH AMERICA, INC.

Fig 21: Identifying Bonded Windshields Component

Courtesy of BMW OF NORTH AMERICA, INC.

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 up to distance (A, B, C) from edge of windshield with BMW-approved materials (repair kit, sourcing reference: BMW Part), refer to 51 31... REMOVING WINDSCREEN WITH "ROLL OUT 2000"

27 mm
25 mm
25 mm

Fig 22: Treating Windshield Up To Distance From Edge Of Windshield With BMW - Approved Materials
Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Note ventilation time!

Fit gasket to windshield and press firmly into place.

NOTE: Adhesive area for plastic adhesive tapes (1) must be free of grease and dust.

Press down two yellow adhesive tapes (1) (sourcing reference: BMW Part) onto roof at a distance (A) from outer corners.

Length approx. 400 mm

Width 50 mm

approx. 250 mm

Fig 23: Pressing Down Two Yellow Adhesive Tapes
Courtesy of BMW OF NORTH AMERICA, INC.

Cut nozzle to size.

7⁺¹ mm
11_-2 mm

Fig 24: Cutting Nozzle To Size

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: To apply a uniform glue bead, use cartridge pistol, operated with compressed air or electric power (sourcing reference: BMW Part).
Check expiry date of glue!

If necessary, apply a test bead before gluing.

Cartridge must be held perpendicularly to the windshield glass.

Fig 25: Applying Test Bead Before Gluing

Courtesy of BMW OF NORTH AMERICA, INC.

CAUTION: No glue must be applied to contacts of windshield heating.

Shape of glue bead:

7⁺¹ mm
11_-2 mm

CAUTION: Apply adhesive bead swiftly. Skin forms on adhesive after max. 10 minutes. Do not touch adhesive bead.

Fig 26: Identifying Shape Of Glue Bead

Courtesy of BMW OF NORTH AMERICA, INC.

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

10 mm
8 mm
8 mm

Place windshield on a suitable surface with inside facing downwards.

Fig 27: Applying Glue Bead At Distance Along Edge Of Windshield

Courtesy of BMW OF NORTH AMERICA, INC.

Suspend special tool 51 9 002 (suction lifter) from conventional workshop lifting equipment.

Switch on vacuum pump.

Firmly attach special tool 51 9 002 to outside of windshield in center in upper third.

Fig 28: Identifying Conventional Workshop Lifting Equipment

Courtesy of BMW OF NORTH AMERICA, INC.

Fig 29: Connecting Hose Between Suction Hoist And Vacuum Pump

Courtesy of BMW OF NORTH AMERICA, INC.

Lift windshield with special tool 51 9 002 over body cutout.

First position windshield carefully at top and align sides evenly.

Lower windshield at bottom and in so doing press upwards on left and right with two special tools 51 3 010 until seal contacts roof uniformly.

Fig 30: Identifying First Position Of Windshield

Courtesy of BMW OF NORTH AMERICA, INC.

Secure windshield (1) in this position on top with yellow plastic adhesive tapes (2) (sourcing reference: BMW Part) and press down all around.

Remove special tools 51 3 010 and 51 9 002.

Fig 31: Removing Special Tools

Courtesy of BMW OF NORTH AMERICA, INC.

To avoid wind noises: The windshield is pretensioned at the top.

Pretension is created 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)

Position of HR foam blocks:

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

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

100 mm
100 mm

Fig 32: Identifying Position Of HR Foam Blocks
Courtesy of BMW OF NORTH AMERICA, INC.

Preload on top of windshield to prevent wind noise:

Fig 33: Checking Installation Position Of Windshield In Middle Of Vehicle With Special Tool

Courtesy of BMW OF NORTH AMERICA, INC.

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.

Print on special tool = "S" (Anti-theft windows)

(A) = 0... 0.6 mm

Open both front doors.

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

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

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

Fig 34: Identifying HR Foam Blocks With Yellow Plastic Adhesive Tape

Courtesy of BMW OF NORTH AMERICA, INC.

CAUTION: Hardened glue can only be removed by machine.
Remove contamination caused by residual adhesive immediately with Sika remover 208 (sourcing reference: BMW Part). Do not press out windshield glass again for this purpose.

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.