51 31 103 Replacing rear window in left (or right) splitdoor

Special tools required:

IMPORTANT: INSTRUCTIONS FOR WINDOW CEMENTING 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:

Disconnect plug connection (1).

Guide cable (2) back and secure with adhesive tape to rear window.

IMPORTANT: Pay attention to cable (2) when cutting in this area.

Fig 1: Identifying Plug Connection And Cable

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Push wire starter from ROLL OUT 2000 at line (1) through cement bead.

Fig 2: Identifying Wire Starter Pushing Location

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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:

Open rear lid and secure rear window against falling out.

Attach a 24 mm U-shape blade to tool.

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

Insert blade carefully between rear lid and rear window.

Fig 3: Identifying U-Shape Blade

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

Fitting 4 dual-lock tapes:

IMPORTANT: To avoid windscreen breakage and leaks:
Remove remnants of dual-lock tapes (1) completely and observe installation position exactly.

Fig 4: Identifying Remnants Of Dual-Lock Tapes

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Stick new dual-lock tapes (1) between markings on splitdoor.

Dual-lock tapes on rear window must match these dual-lock tapes.

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.

Overview for rear window cementing (R55):

Fig 5: Overview For Rear Window Cementing (R55)

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Attach special tool 51 3 010 twice to tool trolley. Moisten suction surfaces and secure rear window from outside. Secure third special tool 51 3 010 to rear window from outside.

If reusing removed rear window, remove residual adhesive down to 0.5 mm.

Mount retaining strip (7) and cover (8) on rear window.

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

Spread adhesive bead with special tool 00 9 322 .

Using special tool 51 3 010 , carefully fit rear window (1) at bottom with cover strip (2) on splitdoor (3) and align to door window frame (do not press down firmly yet).

Close splitdoor (3) carefully.

Fig 6: Fitting Rear Window Using Special Tool

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Align rear window (1) according to measurements (A, B and C) and engage in dual-lock tapes.

Rear window (1) must overlap window frame (3).

Gap dimension between rear windows (1)
4.5 ±1.5 mm (parallelism deviation 0.5 mm)
Rear window negative protrusion
0 ±1.5 mm
Rear window (1) to roof (2)

4 ±1.5 mm

Fig 7: Aligning Rear Window

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

Secure rear window (1) with yellow plastic adhesive tape (2).

Fig 8: Securing Rear Window With Yellow Plastic Adhesive Tape

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