51 31 200 Removing and installing/replacing rear window

Special tools required:

IMPORTANT: INSTRUCTIONS FOR WINDOW BONDING are an essential part of these repair instructions and must be followed without fail.
ALL the sheet metal panels and add-on parts adjoining the rear window must be fitted with protective covers.

NOTE: Removal is carried out with ROLL OUT 2000 ; only use an oscillating blade for replacement work.

Necessary preliminary tasks:

NOTE: Disconnect aerial diversity plug connector.
Remove both heated rear window plug connectors and affix to the rear window using adhesive tape.

Replacement (broken rear window):

Cut at top and bottom with a straight blade and at sides with U-shape blade.

IMPORTANT: When reusing the rear window:
Avoid damaging wires for heated rear window/aerial.
Cut through adhesive bead all round and as closely as possible to rear window.

Replacement (broken rear window):

Fit straight blade with adjustable roller (Sourcing Reference: BMW Parts Department) on tool and set dimension (X).

Adjust dimension (X) differently according to different position of adhesive bead.

Dimension "X":

Top 22 mm

Bottom 18 mm

Regrind blade with a grinding stone while machine is running (new blades also).

Fig 1: Identifying Special Tool Adjustment Dimension

Courtesy of BMW OF NORTH AMERICA, INC.

Close rear lid.

Attach a 36 mm U-shape blade (sourcing reference: BMW Parts Department) to tool.

Regrind blade with a grinding stone while machine is running (new blades also).

Insert knife carefully between tailgate and rear window.

Guide blade parallel to rear window and cut through adhesive bead as closely as possible to rear window.

Fig 2: Identifying U-Shape Blade

Courtesy of BMW OF NORTH AMERICA, INC.

Fitting spacer buffers (spacers):

IMPORTANT: To avoid rear window breakage and leaks:
Completely remove remnants of disassembled spacer buffers.

Stick on new semicircular spacer buffers (1) in the corners.

Stick on 2 spacer buffers (5x5x20 mm), top and 2 spacer buffers, bottom uniformly distributed on sheet metal flange.

IMPORTANT: Version with rear window aerial:
Do not allow any adhesive to come into contact with the connecting contacts of the heated rear window/aerial.

Fig 3: Identifying Semicircular Spacer Buffers

Courtesy of BMW OF NORTH AMERICA, INC.

Overview of rear window bonding:

Fig 4: Checking Rear Window Bonding Dimensions

Courtesy of BMW OF NORTH AMERICA, INC.

Attach special tool 51 3 010 twice to tool trolley. Moisten suction faces and secure rear window from outside. If reusing removed rear window, remove residual adhesive down to 0.5 mm.

Almost vertical part (B) of adhesive bead (1) must be facing window edge.

Spread bead joint with special tool.00 9 322

NOTE: Bonding surfaces for yellow plastic adhesive tape must be free from grease and dust.

Attach two pieces of yellow plastic adhesive tape to surface of tailgate over rear window at a distance of 250 mm to outer corners.

Make sure tailgate is fully closed.

Carefully working on rear window with special tool 51 3 010 :

position at bottom on tailgate
Align sides evenly
insert at top and press down
secure vertically with yellow plastic adhesive tape

NOTE: Do NOT open tailgate before adhesive has hardened.
Reassemble the vehicle.
Remove adhesive tape strips after the hardening time.