51 31 200 Removing and installing rear window (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

CAUTION: Danger of injury!
The weight of the rear window 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 rear window.

Support pedestal for rear window
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)^*
Scalpel for heavy-duty applications^*
Cartridge gun^*
Fabric adhesive tape^*
Sika remover 208^*
Spirit^*
Yellow plastic adhesive tape^*
Sidol^*

^* Sourcing reference: BMW Part. Remove trunk lid.

Remove both panels 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... 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: Heating Glue Cartridges

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NOTE: Cover rear side panels with protective covers.

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

Fig 2: Disconnecting Right Plug Connection

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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: Identifying Version With Antenna For Car Telephone

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CAUTION: Use only approved adhesive tape. The rear window coating will be damaged if the wrong adhesive tape is used.

Secure cable (heated rear window/antenna) to rear window with adhesive tape.

Mark cable entries on outside of rear window.

Removal:

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

Detach seal from rear window at bottom.

Fig 4: Removing Seal From Rear Window At Bottom

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Detach seal from rear window at side and top from left to right.

Fig 5: Removing Seal From Rear Window At Side And Top From Left To Right

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Mask body all around rear window aperture with fabric adhesive tape (e.g. Tesa).

Fig 6: Identifying Body All Around Rear Window Aperture With Fabric Adhesive Tape

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Attach blade (24 mm length) to electric cutting tool (sourcing reference: BMW Part).

NOTE: Sharpen blade while machine is running with a grindstone (even with new blades).

Fig 7: Attaching Blade To Electric Cutting Tool

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When reusing the rear window:

CAUTION: Do not damage cable for rear window heating/antenna.

Carefully insert blade between body and rear window at top in center.

Fig 8: Inserting Blade Between Body And Rear Window At Top In Center

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Guide web of knife parallel to rear window.

Fig 9: Identifying Guide 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.

Body opening
Glue bead
Knife
Rear window

Fig 10: Cutting Through Glue Bead All Around As Close As Possible To Rear Window Glass
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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 rear window in center in upper third.

Fig 11: Identifying Firmly Special Tool

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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).
Replacement with original hose only.

Fig 12: Replacing With Original Hose

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Raise rear window with special tool 51 9 002 (suction hoist) slightly and, if necessary, carefully remove residual traces of bonding.

Lift out rear window and place on assembly stand.

Fig 13: Lifting Out Rear Window And Place On Assembly Stand

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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"

Installation

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

Installation check on reused and new rear windows:

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

When installing a new rear window:

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 old glue carefully with a heavy-duty scalpel to avoid damaging the paint finish in body cutout.

Fig 14: Removing Glue Residue In Body Cutout

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CAUTION: Clean freshly cut residual bead with alcohol only.
Do not under any circumstances use Sika bonding agent 205/5 or glass primer 205/5.

Place rear window on a suitable surface (support pedestals) with inside facing upwards.

When reusing the rear window:

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

Fig 15: Removing Residual Glue On Rear Window With Heavy-Duty Scalpel

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

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!

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

(A) = 25 mm (top/side)

(A) = 27 mm (bottom)

NOTE: Note ventilation time!

Fig 16: Treating Body Around Glued Area With BMW - Approved Materials

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

Fig 17: Fitting Gasket At Bottom Of Rear Window And Press Into Place

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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 18: Sealing Strip And Rear Window Are Marked In Center

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CAUTION: Use only approved adhesive tape. The rear window coating will be damaged if the wrong adhesive tape is used.

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

Fig 19: Identifying Adhesive Area For Plastic Adhesive Tapes

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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

Cut nozzle to size.

8 mm
10_-1 mm

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

Fig 20: Applying Uniform Glue Bead

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If applicable, produce a sample bead before gluing.

Cartridge must be arranged vertically against rear window.

Fig 21: Arranging Vertically Against Rear Window

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CAUTION: No glue must be applied to contacts on rear window heating/antenna.

Shape of glue bead:

8 mm
10_-1 mm

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

Fig 22: Applying Adhesive Bead Swiftly

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When applying adhesive bead, observe distance (A), (B) and (C) to seal.

1 mm
1 mm
1 mm

Turn rear window over and place on a suitable surface with inside facing downwards.

Do not touch adhesive bead.

Fig 23: Turning Rear Window Over And Place On A Suitable Surface With Inside Facing Downwards

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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 rear window in center in upper third.

Fig 24: Identifying Firmly Attach Special Tool

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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).

Replacement is with original hose only.

Fig 25: Ensuring Pointer Of Vacuum Gauge Is In Green Area

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Lift rear window with special tool 51 9 002 over body cutout.

First install rear window carefully at top, align sides uniformly and then install at bottom and press into place.

Seal must locate uniformly down each side (center carefully). Press rear window upwards until distance from seal to roof is uniform.

Fig 26: Lifting Rear Window With Special Tool

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NOTE: Align rear window with special tools 51 3 010.

Remove special tool 51 9 002.

CAUTION: Use only approved adhesive tape. The rear window coating will be damaged if the wrong adhesive tape is used.

Fig 27: Aligning Rear Window With Special Tools

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Secure rear window in this position at top with yellow plastic adhesive tapes (sourcing reference: BMW Part). If necessary, brace with wooden wedge.

Press down rear window all around.

Remove special tools 51 3 010.

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

Assemble car.

After the hardening time, remove support and adhesive tape.

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

Version with GPS navigation:

If necessary, recalibrate magnetic field probe by using BMW scan tool..

Fig 28: Recalibrating Magnetic Field Probe

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