Replacing Rear Window
Removing and Installing Rear Window (Compact)
NOTE:
For cementing the rear window, cements for cold and hot processing are permitted.
Removing and installing side and top trim for trunk lid,
Additional work on version with rear window antenna:
Removing and installing lower trim for trunk lid,
Cold processing:
Comply with instructions on cementing windows,
Hot processing:
Open rear end of aluminium membrane in cartridge before installing in cartridge oven.
Heat cement cartridges to 80 °C for one hour in oven (Sourcing Reference: BMW Parts Service).
Comply with instructions on cementing windows,
NOTE: Cover rear side panels with protective covers.
Rear window cementing survey
Rear Window Cementing Survey:
If applicable remove antenna and/or rear window wiper arm.
Pull out seal.
Unfasten cables on trunk lid and lift oddments tray backwards to remove.
Disconnect left and right plug (rear window defogger).
Version with rear window antenna:
If necessary, disconnect connector.
Pull back trunk lid far enough to enable rear window to be cutout without damaging the paintwork.
Cover rear bumper (danger of damage).
Loosen left and right nuts and pull trunk lid backwards.
Mask rear window aperture on body and trunk lid with fabric adhesive tape (e.g. Tesa).
Fit long knife (36 mm blade length, Sourcing Reference: BMW Parts Service) to the tool.
NOTE: If necessary, resharpen knife with machine running.
Insert knife carefully between body and rear window glass.
Guide web of knife parallel to rear window.
CAUTION!
When reusing the rear window:
Avoid damaging lines for rear window heating/antenna.
Cut through cement bead all around as close as possible to the rear window glass.
1. Body opening
2. Cement bead
3. Knife
4. Rear window
Lift out rear window using special tool 51 3010.
Cut off old cement in body opening but for a thickness of approx. 0.5 mm.
Cut off old cement carefully with an universal knife (sharp as a razor blade) to avoid damaging the paint finish in body opening.
Pull off adhesive tapes all round.
CAUTION!
To provide long-term protection against corrosion, always touch up damage to paintwork (scratches and large areas of damage) without delay,
When reusing the rear window:
Scrape cement residue off rear window with scraper (Sourcing Reference: BMW Parts Service) to thickness of 0.5 mm.
Fit gasket at bottom of rear window and press into place.
Adjusting trunk lid height:
Ideal adjustment:
Special tool 41 6 200 must fit flush against roof outer skin panel and trunk lid.
Center trunk lid laterally and hand-tighten nuts on hinge - do not tighten down firmly. Fit special tool 41 6 200 (left and right over the hinge) with the long leg (2) facing the trunk lid.
Adjust height of trunk lid and tighten nuts.
CAUTION!
The basic filler must have hardened!
Treat rear window and body around cemented area with BMW-approved materials (repair kit, Sourcing Reference: BMW Parts Service),
NOTE: Note ventilation time!
Installation:
Lift out spacer buffer (as for windshield).
Attach two spacer sections at distance (A) from center of vehicle.
Attach center spacer buffer in such a way that dimension (B) does not contact sheet metal (leak).
(A) = 395 mm
(B) = 4 mm
Cut nozzle to size.
(A) = 7 mm
(B) = 9...11 mm
NOTE:
To apply uniform cement bead, use cartridge pistol (operated by compressed air or electric power, Sourcing Reference; BMW Parts Service).
Check expiry date of cement!
If applicable, produce a sample bead before cementing.
Cartridge must be arranged vertically against rear window.
Shape of cement bead:
(A) = 7 mm
(B) = 9...11 mm
CAUTION!
Apply cement bead quickly and insert window. Skin formation time of cement, maximum 10 minutes.
(A) Distance between cement bead (2) and bottom of gasket (1).
(B) Distance between cement bead (1) and edge of rear window.
(R) Hold down radius (R) in the corners.
Dimensions:
(A) 1 mm
(B) 18 mm
(R) 10 mm
Installation of rear window:
Installation Of Rear Window:
Secure special tool 41 6 200 with adhesive tape.
Install rear window carefully using special tool 51 3 010.
Center gap (A) against left/right edge of rear window.
Press rear window upwards against special tool 41 6 200 and secure with fabric adhesive tape.
CAUTION!
Remove dirt from residual cement with Sika-Entferner 208 (Sourcing Reference: BMW Parts Service) before cement is hard. Do not press out rear window glass again for this purpose. Hardened cement can only be removed by machine.
Checking height adjustment of trunk lid:
Ideal adjustment:
Special tool 41 6 200 must fit flush against roof outer skin panel and rear window.
Fit special tool 41 6 200 (left and right over the hinge) with the short leg (1) facing the rear window.
If necessary, adjust trunk lid.
After the hardening time, remove adhesive tapes.
Assemble car.
NOTE: Leaks can be found by spraying water on the sealing lips or with an ultrasonic leak detector (refer to BMW Parts Service) and then eliminated by using a suitable nozzle.