41 00 513 Fix bolts on the new part

Note: On BMW and MINI bodies, various welded and pushed in bolts
are being used.

Single ball/double ball (version 1):

Grind off any residues of the single ball (1), if applicable.
Drill hole with diameter 7 mm.

Set blind rivet nut (1).

Screw in single ball with thread until a height of 5 mm (double ball 10 mm) is

[Link]
reached.

Single ball/double ball (version 2):

Grind off any residues of the single ball (1), if applicable.
Clean area with solvent cleaner R1.

Clean bonding surface of repair element single ball (1) with solvent
cleaner R1.
Bond repair element optionally with adhesive K1, K5 or window pane
adhesive at the same position.
Coarse threaded bolt (version 1):
Grind off any residues of the coarse threaded bolt (1), if applicable.

Spot weld coarse threaded bolt to same position.

[Link]
Coarse threaded bolt (version 2):
Grind off any residues of the coarse threaded bolt (1), if applicable.
Drill hole with diameter 7 mm.
Set blind rivet coarse threaded bolt using riveting pliers.
51 00 ... Notes on component bonding with adhesive tape
Unless specified otherwise in vehicle-specific or component-specific instructions, the following notes apply.
Follow repair notes for bonded gaskets for rubber seals.

1. General notes
Bonding at room and object temperature of >+18 °C.
Newly painted parts may only be bonded after a drying time of at least 24 hours.
Optimal bonding/attachment to the background surface is achieved after approx. 48 hours. Components
must not be exposed to mechanical strain beforehand (car wash, strength test, etc.).
Do not touch bonding area.
It is not the length of time that pressure is applied but rather the force of pressure applied that is crucial.
Detaching the adhesive tape after pressing destroys the adhesive layer.

2. Auxiliary materials and tools

Cleaning agent R1 or cleaning agent R2
Sika Activator 205
Fluff-free cleaning cloths
Pressure roller

[Link]
3. Preparations
Remove all adhesive residue or clean new part thoroughly
Clean the areas to be bonded immediately before bonding to remove silicone and grease residues.
Treat adhesive strips on glass or painted surfaces with Sika activator 205.

Note:
Sika activator 205 apply extremely thinly. It must not be coated beyond the bonding surface.
Note: air drying time: ≥ 1 minute

4. Bonding
4.1 Components without preassembled adhesive tape
Pull off liner* from adhesive tape
Position adhesive tape on component and stick on
Press down adhesive tape over entire adhesive area
Continue with Point 4.2

* Liner is the protective film on the adhesive tape.

4.2 Components with pre-fitted adhesive tape

Pull off liner* from adhesive side (if adhesive area is large, do not pull off liner completely)
Align component in correct position on vehicle
Press down component over entire adhesive area
Minimum contact pressure ≥ 15 N/cm² (firm thumb pressure reaches approx. 35 N/cm².)

* Liner is the protective film on the adhesive tape.

51 00 ... Notes on installation of rubber window seals
1. Work safety when handling lubricant G14*
Wear safety goggles, protective gloves and if necessary an apron.
Do not eat, drink or smoke in the area of processing/application
Ensure rooms are well ventilated.
Keep away from heat and ignition sources
In event of skin contact: Wash areas of skin affected with soap and water immediately, change work
clothing which has been fouled with lubricant immediately (keep spare work clothing in reserve)
In event of eye contact: Rinse eyes immediately with plenty of water and seek medical advice
Observe the safety data sheet

2. General notes
Use approved lubricant for installation only
Application only at room and object temperatures between 18 and 25 °C
Lubricant dries at different rates depending on the quantity, temperature and ventilation and becomes
sticky
Lubricant can only be used for fitting and not for fault elimination (e.g. grating)
Newly painted parts may only be brought into contact with the lubricant after cooling

[Link]
Optimal bonding to the surface is achieved after approx. 48 h. The rubber window seal must not be
exposed to mechanical strain beforehand. (car wash, strength test, etc.).

Attention!
To avoid groaning noises, do not use soapy water (low-surface-tension water with washing-up liquid) or
lubricant containing silicone.

3. Auxiliary materials and tools

Cleaning agent R1 or cleaning agent R2, cleaning cloth, plastic scraper, needle
LubricantG14*
(*Sourcing reference: Electronic Parts Catalogue)

4. Preparations
Heat and remove anti-friction agent residues with a hot air blower or clean new part thoroughly
Immediately prior to fitting, clean the work area in order to remove silicone and grease residues

Note:
Air drying time approx. 1 min:

5. Assembly
Apply a thin coating of lubricant to the rear side of the rubber window seal only
Perform fitting within 30 min of applying lubricant
Lubricant dries after fitting and becomes sticky
61 35 ... Overview of additional work for the removal and installation
or replacement of electronic components in the body area/windscreen
Component Removal and Removal Replacement Replacement Remarks
installation and
installation Programming/encoding Use of the
Calibration/Initialisation
required Use of the Calibration/Initialisation Special tool
required
(diagnosis system Special tool necessary
must be connected) (diagnosis system
necessary must be connected)
Front section:
(including bumper
panel)
Park Distance No No No No
Control ultrasonic
sensor
Parking No No No No
Manoeuvring
Assistant
ultrasonic sensor

[Link]
Active pedestrian No No No No Must be
protection sensor replaced
after the
active
pedestrian
protection
has been
activated!
Impact
absorber
must also be
replaced!
Active pedestrian No No No No Must be
protection actuator replaced
after the
active
pedestrian
protection
has been
activated!
Rear area:
(including bumper
panel):
Rear view camera No No Yes No
Park Distance No No No No
Control ultrasonic
sensor
Windscreen:
KAFAS camera no* No no* No *Necessary
after
replacement
of the
windscreen
Camera-based no* No Yes No *Necessary
driver support after
systems camera replacement
of the
(F60 only) windscreen
Rain sensor
(separate
document)

[Link]
51 00 ... Overview of consumables (Electronic Parts Catalogue)
Designation, repair Designation, Electronic Part number, Electronic Remarks
instructions Parts Catalogue Parts Catalogue
Cleaning agent R2 Cleaning agent R2 83 19 0 417 324 500 ml
Lubricants G14 Lubricants G14 83 23 2 360 412 900 ml / Notes
Sika Activator 205 Aktivator 205 83 19 0 030 155 250 ml

Yellow plastic adhesive Adhesive tape 83 19 9 410 979 A = 66 mm;

tape B = 50 mm
Double-sided adhesive Adhesive tape 54 11 2 290 978 L = 50 mm/W = 12 mm
tape
Masking tape Masking tape 81 22 9 400 181 L = 50 mm /
W = 19 mm
Masking tape Masking tape 81 22 9 400 388 L = 50 mm /
W = 30 mm

Eraser disk Scotch Brite eraser disk 51 91 0 402 946 with shaft

[Link]
Cutting cord Cutting cord 81 43 2 344 272 Notes
Adhesive set K6 Adhesive set K6 83 19 2 317 925
Window glass adhesive Window glass adhesive, cold, 83 19 2 289 286
1 hour
Profile rubber adhesive 83 19 2 232 322
Set of felt pads Set of felt pads 51 45 2 353 024
41 00 ... Replacing blind rivets

Special tools required:

2 348 128
72 1 210

Important!
Lay out protective mats to protect the interior equipment against swarf
from the drilled-out rivets and damage.
Lay out protective mats in the relevant working area:
Instrument panel
Entrance area
Passenger compartment

[Link]
Schematic diagram of folding pack holder for head airbag:
Drill off rivet plate down to rivet shank with a 10 mm twist drill bit.

Described for grab handle holder:

Drill off rivet plate down to rivet shank with a 10 mm twist drill bit.
Drill out all blind rivet protusions (1) up to the body.

Installation note:
Apply primer to paintwork damages on side frame.
Note:
Depending on accessibility, the rivet heads will have to be removed using
special tool 2 348 128 or 72 1 210 .
In areas that cannot be reached using special tools, cavity foam HS3must
first be applied around the rivet head before the rivet head is then punched
out immediately..

[Link]
Removal of rivet head with special tool 2 348 128:
Press off rivet heads (1) using special tool 2 348 128 and remove.

Removal of rivet head with special tool 72 1 210:

Shank (1) of special tool 72 1 210 is flexible and can be adapted to the
relevant body contours.
Note:
Insert butyl in the collecting tray (2) to secure rivet heads and prevent them
from falling out.
Insert special tool 72 1 210 through bore hole in body next to attachment
points.
Position special tool from rear on rivet head in cavity.
Note:
A second person will be needed to help hold the special tool on the rivet
head during the driving-out operation.
Make sure collecting tray is correctly fitted on rivet head.

Drive out stem with hammer and 6 mm punch.

Carefully feed special tool out of body so that rivet head does not fall out of
collecting tray.

Note:
If the rivet falls out of the collecting tray into the side frame when the special
tool is fed out, this area must be generously filled with foam.
For details of procedure for filling cavities with foam, see further operations.
Use cavity preservation (refer to BMW Group Parts) for foam filling.
Cavity foam (refer to BMW Group Parts) may also be used if required.

[Link]
Fit tube to foam can.
Push the hose in through the pillar holes.
Fill cavity with a filling material.
Warning!
Empty foam can completely onto cardboard and after hardening
dispose of foam and can in residual waste.
Can may burst if not completely emptied.

Overview of rivet gun:

Riveting of gas generator housing and holders for folding pack with rivet gun
(refer to BMW Workshop Catalogue).
The interchangeable head is changed for the different work operations.
Riveting of gas generator housing with:
1.) 17/36 nosepiece and short shank
Riveting of holders for folding pack:
2.) 17/40 nosepiece and long shank
00 Safety information for working on vehicles with automatic engine start-
stop function (MSA)

Warning!
If the engine hood/bonnet contact is pulled upwards (workshop mode),
the information "switch closed" is output. The automatic engine start‐
stop function is active.
An automatic engine start is possible.

Observe safety precautions when working on MSA vehicles.

Before carrying out practical work on the engine, always ensure that the
MSA functionality is deactivated so as to prevent automatic engine starting
while work is being carried out in the engine compartment.

MSA function is deactivated by:

Deactivate MSA by means of button (1) in passenger compartment

[Link]
Open seat belt buckle and driver's door

Open engine bonnet/hood and ensure that engine hood/bonnet contact

is not in workshop mode
Workshop mode
A = 10 mm
Basic setting (engine hood/bonnet open)
B = 7 mm
To make sure that the engine hood/bonnet contact is at the basic
setting, if necessary press the hood/bonnet contact up to the limit
position before starting work and slowly release.

When working with diagnosis tools:

Observe instructions in diagnosis tool
Note:
For further information on automatic engine start‐stop function (MSA):
Refer to the Service Information (bulletin) (for manual
transmissions) Service Information (bulletin) 61 01 07 335
Refer to the Service Information (bulletin) (for automatic transmissions
or twin-clutch gearboxes) Service Information (bulletin) 61 01 10 629

[Link]
51 00 ... Safety instructions for working on cars with airbag systems

Warning!
If work is carried out in area of airbag systems, e.g. on:
Door trim panels
Interior trims
Instrument panel etc.
the ignition must be turned off in each case.
The ignition must always be off.
The ignition key must be removed from the ignition lock.
This eliminates the risk of injury.

[Link]
51 00 ... Service position of engine compartment lid

Special tools required:

2 353 020

Warning!
Danger of injury and damage!
Engine compartment lid must be held by a second person helping.

Note:
Graphic shows F01.

If necessary, open engine compartment lid.

Remove ball socket (1).
Unclip gas pressure spring (2) in direction of arrow from ball stud (3).

[Link]
Push special tool 2 353 020 over gas pressure spring (1).
Clip ball socket of special tool 2 353 020 onto ball stud (2).
51 71 ... Remove and install/replace left or right lower front brake air duct

Necessary preliminary tasks:

Remove front bumper panel
Right side only:
Release fluid fuel tank for windscreen washer system

Removal:

Undo expander rivet or screws (1).

Release screw (2).
Feed out air duct (3) from guide (4) and remove.

[Link]
Installation:

Feed in air duct (3) with guide (4) into holder.

Secure air duct (3) with screw (2).
Secure expanding rivet or screws (1).

Required follow-up work:

Secure washer fluid reservoir for window washer system
Install front bumper panel
51 11 156 Removing and installing (replacing) front bumper panel

Removal:

Remove gasket (1) upwards.

Unfasten screws (2).

[Link]
Release screws on bumper panel (1) at bottom.

Note:
Front wheel removed for purposes of clarity.

Loosen screws (1) on wheel arch panel (2).

Fold wheel arch cover (2) partially back.
Release screws (1) on bumper panel (2).
Detach bumper panel (2) at side.

Note:
The following tasks must be carried out with a second person assisting:

Tilt bumper panel (1) upwards.

Unlock and detach plug connections on the following components depending
on the version.
Ultrasonic sensors PDC
Ultrasonic sensors for PMA

[Link]
Fog lights
Temperature sensor
Remove bumper panel (1) towards front.

Replacement:
Remount holder for fog light
Remount ornamental grille for bumper panel in centre
Remount fog light
Remount middle front radiator grille
Remount the front badge.
If applicable, remount ultrasonic sensor for PMA
Remount PDC ultrasonic sensor with wiring [Link] necessary

Installation:

Note:
The following tasks must be carried out with a second person assisting:

Attach bumper panel (1) to bottom support.

Connect and lock plug connections on the following components depending
on version:
Ultrasonic sensors PDC
Ultrasonic sensors for PMA
Fog lights
Tilt bumper panel (1) upwards and place in position.
Attach bumper panel (2) at side.
Tighten screws (1) on bumper panel (2).

Install wheel arch panel (2).

Tighten screws (1) of wheel arch panel (2).

[Link]
Tighten bottom screws on bumper panel (1).

Tighten down screws (2).

Tightening torque 51 11 1AZ.
Install gasket (1).
51 11 183 Removing and installing (replacing) ornamental grille for bumper
panel (side)

Special tools required:

00 9 325

Removal:

Release ornamental grille (1) from the latch mechanisms with special
tool 00 9 325 along the line and pull off towards the front.
Release plug connection and remove the ornamental grille (1).

[Link]
Equipment specification with closed front ornamental grille:
Remove the wheel arch cover at the front.
Loosen the trim (1) at the latch mechanisms.

Installation:
Connect plug connection and the feed in ornamental grille (1).
Press ornamental grille (1) into latch mechanisms.
Note:
Latch mechanisms must not be damaged or missing.

Equipment specification with closed front ornamental grille:

Secure the trim (1) to the latch mechanisms.
Secure the wheel arch cover at the front.

[Link]
51 11 156 Removing and installing front bumper panel \PREMIUM

RISK OF DAMAGE
Scratches.

Tools and sharp-edged components can cause scratches.

Protect working area.
Handle tools and components carefully.

1 – Remove front bumper panel

Remove seal (1) upwards.
Loosen screws (2).

[Link]
Loosen the bottom screws on the bumper panel (1).

NOTICE
To provide a better overview: Schematic diagram with partially hidden
components.

Release screws (1) on the wheel arch trim panel (2).

Partially fold the wheel arch trim panel (2) back.

NOTICE
To provide a better overview: Schematic diagram with partially hidden
components.

Release screws (1) on the bumper panel (2).

Detach the bumper panel (2) on the side.
 TECHNICAL INFORMATION
Conduct the following operation with the assistance of a second person.

Tilt top of bumper panel (1) down.

Unlock all plug connections and disconnect.
Remove bumper panel (1) towards front.

2 – Install bumper panel, front

Attach the bumper panel (1) in the support at the bottom.

TECHNICAL INFORMATION
Conduct the following operation with the assistance of a second person.

Connect all connectors and lock.

Tilt bumper panel (1) up and position it.

[Link]
Attach bumper panel (2) on the side.

NOTICE
To provide a better overview: Schematic diagram with partially hidden
components.

Tighten screws (1) on the bumper panel (2).

Bumper panel on side wall
Screw Tightening torque 3 Nm

NOTICE
To provide a better overview: Schematic diagram with partially hidden
components.

Correctly position the wheel arch trim panel (2).

Tighten screws (1) on the wheel arch trim panel (2).
Wheel arch cover
Screw Tightening torque 3 Nm
 Tighten bottom screws on the bumper panel (1).
Bumper trim, lower
Screw Tightening torque 2,5 Nm

Tighten down screws (2).

Bumper panel on air duct, top
Screw Tightening torque 4,6 Nm

Install new gasket (1).

[Link]
Additional Information

Overview of Tightening Torques

Bumper panel on side wall Used in step 2

Screw Tightening torque 3 Nm

Wheel arch cover Used in step 2

Screw Tightening torque 3 Nm

Bumper trim, lower Used in step 2

Screw Tightening torque 2,5 Nm

Bumper panel on air duct, top Used in step 2

Screw Tightening torque 4,6 Nm

51 11 760 Removing and installing/replacing deformation element for
bumper, front left (right)

Necessary preliminary tasks:

Remove radiator air duct

Removal:

Release screws (1 to 3).

Remove deformation element (4).

[Link]
Installation:

Insert deformation element (4).

Tighten screws (1 to 3).

Screw Tightening torque

(1) 51 11 4AZ
(2) 51 71 12AZ
(3) 51 11 2AZ

Required follow-up work:

Install radiator air duct
51 11 ... Removing and installing/replacing holder for fog light

Necessary preliminary tasks:

Remove front bumper panel

Removal:

Release screw (1).

Release catches (2).
Release latch mechanisms along line.
Remove holder for fog light (3).

[Link]
Installation:

Replacement:
Remount sheet metal nuts
Remount temperature sensor (right)
Mount holder for fog light (3).
Engage latch mechanisms (2).
Engage latch mechanisms along line.
Tighten screw (1).

Required follow-up work:

Install front bumper panel
51 11 180 Removing and installing/replacing ornamental grille for bumper
panel (centre)

Necessary preliminary tasks:

Remove front bumper panel

Removal:

Release ornamental grille (1) at latch mechanisms.

Remove the ornamental grille (1).

[Link]
Installation:

Note:
Latch mechanisms must not be damaged or missing.

Install ornamental grille (1).

Engage ornamental grille (1) at latch mechanisms.

Required follow-up work:

Install front bumper panel
51 11 050 Removing and installing/replacing support for front bumper panel

Necessary preliminary tasks:

Remove front bumper panel
Remove headlight
Remove impact absorber from support

REMOVAL:

Release screws (1) and remove associated holder from below.

Unfasten screws (2).
Release screws (3) from fanfare holder.
Feed out support (4) towards front and remove.

[Link]
INSTALLATION:

Replacement:
Release screws (1) on left and right.
Remount holder (2).
Feed in support (4).
Mount holder from below and tighten screws (1).
Tightening torque: 51 11 4AZ.
Tighten down screws (2).
Tightening torque: 51 71 13AZ.
Tighten screws (3) of fanfare holder.

Required follow-up work:

Install impact absorber on support
Install headlight
Install front bumper panel

[Link]
51 11 060 Removing and installing/replacing support for front lower bumper
panel

Necessary preliminary tasks:

Remove front bumper panel

Removal:

Release screws (1).

Detach holder of air duct (2) upwards out of support (3).
Remove carrier (3).

[Link]
Installation:

Insert support (3).

Attach holder of air duct (2) in support (3).
Tighten down screws (1).
Tightening torque 51 11 10AZ.

Required follow-up work:

Install bumper panel, front
51 11 780 Replace the front deformation element on the bottom left

Necessary preliminary tasks:

Remove support for the front bottom bumper panel

Removal:

Release screws (1 to 3).

Remove deformation element (4).

[Link]
Installation:

Install deformation element (4).

Tighten screws (1 to 3).

Screw Tightening torque

(1) 51 11 6AZ
(2) 51 11 6AZ
(3) 51 11 15AZ

Required follow-up work:

Install front bottom support for bumper panel
51 11 781 Replace the front deformation element on the bottom right

Necessary preliminary tasks:

Remove support for the front bottom bumper panel

Removal:

Release screws (1 to 3).

Remove deformation element (4).

[Link]
Installation:

Install deformation element (4).

Tighten screws (1 to 3).

Screw Tightening torque

(1) 51 11 6AZ
(2) 51 11 6AZ
(3) 51 11 15AZ

Required follow-up work:

Install front bottom support for bumper panel
51 11 158 Replacing base plate for number/license plate
Only use the vehicle-specific number plate baseplate.
The installation of other license plate baseplates is not permissible.
Refer to Service Information Attaching front number plate.
The number plate must be precisely mounted on the number plate baseplate.
If a number plate baseplate is not offered for the corresponding national-market version, the number plate must be
screwed directly onto the bumper using a drilling template.
Incorrect assembly leads to a malfunction of the sensors of the driver assist systems.

Removal:

Release screws (1).

Remove holder (2) towards front.

[Link]
Installation:

Position support (1) above the guides (2).

Note:
Tighten screws by hand, to prevent overtightening.
The permissible torque must not be exceeded!

Tighten screws of support in specified order 1 - 5.

Tightening torque 51 11 8AZ.

[Link]
51 00 ... Overview of consumables (Electronic Parts Catalogue)
Designation, repair Designation, Electronic Part number, Electronic Remarks
instructions Parts Catalogue Parts Catalogue
Cleaning agent R2 Cleaning agent R2 83 19 0 417 324 500 ml
Lubricants G14 Lubricants G14 83 23 2 360 412 900 ml / Notes
Sika Activator 205 Aktivator 205 83 19 0 030 155 250 ml

Yellow plastic adhesive Adhesive tape 83 19 9 410 979 A = 66 mm;

tape B = 50 mm
Double-sided adhesive Adhesive tape 54 11 2 290 978 L = 50 mm/W = 12 mm
tape
Masking tape Masking tape 81 22 9 400 181 L = 50 mm /
W = 19 mm
Masking tape Masking tape 81 22 9 400 388 L = 50 mm /
W = 30 mm

Eraser disk Scotch Brite eraser disk 51 91 0 402 946 with shaft

[Link]
Cutting cord Cutting cord 81 43 2 344 272 Notes
Adhesive set K6 Adhesive set K6 83 19 2 317 925
Window glass adhesive Window glass adhesive, cold, 83 19 2 289 286
1 hour
Profile rubber adhesive 83 19 2 232 322
Set of felt pads Set of felt pads 51 45 2 353 024
51 12 156 Removing and installing rear bumper panel

Necessary preliminary tasks:

Remove both rear lights

Removal:

Release screws (1).

[Link]
Release screws (1) on left and right.

Release left and right screws (1).

Release screws (1) on bumper panel (2) on left and right.
Release retaining lugs (3) on left and right.
Pull bumper panel (2) straight towards rear with aid of a second person.
Unfasten plug connection.
Remove the bumper panel (1).

Installation:

Hold bumper panel (2) in position with the aid of a second person.
Connect plug connections.

[Link]
Attach bumper panel (1).
Engage retaining lugs (3) on left and right.
Tighten screws (1) on bumper panel (2) on left and right.
Tightening torque 51 12 5AZ.

Tighten screws (1) on left and right.

Tightening torque 51 12 4AZ.

Tighten the screws (1) on the left and right.

Tightening torque 51 12 4AZ.
Tighten down screws (1).
Tightening torque 51 12 5AZ.

Required follow-up work:

Install both rear lights

[Link]
51 12 828 Removing and installing/replacing guide for bumper, rear left or
right

Necessary preliminary tasks:

Remove bumper panel

Removal:

Release screws (1).

Unscrew nuts (2).
Remove guide (3).

[Link]
Installation:

Install guide (3).

Tighten down screws (1).
Tightening torque 51 12 3AZ.
Tighten down nuts (2).
Tightening torque 51 12 3AZ.

Required follow-up work:

Mount bumper panel
51 12 825 Removing and installing/replacing guide for rear centre bumper

Necessary preliminary tasks:

Remove bumper panel

Removal:

Unclip wiring harness from holder.

Release nuts (1) and the screw (2) and feed out guide (3) towards top.

[Link]
Installation:

Feed in guide (3) and tighten nuts (1).

Tightening torque 51 12 2AZ.
Tighten down screw (2).
Tightening torque 51 12 7AZ.
Clip wiring harness in holder.

Required follow-up work:

Mount bumper panel
51 12 050 Removing and installing/replacing support for rear bumper panel

Necessary preliminary tasks:

Remove bumper panel

Removal:

Unscrew nuts (1).

Remove support (2).

[Link]
Installation:

Mount support (2).

Tighten down nuts (1).
Parts: Replace nuts.
Tightening torque 51 12 1AZ.

Required follow-up work:

Mount bumper panel
51 12 460 Replacing rear bumper panel trim strip

Special tools required:

00 9 325

Removal:

Release all latch mechanisms of trim strip (1) with special tool 00 9 325 .
Remove trim strip from bumper panel.

[Link]
Installation:

Mount trim strip on bumper panel.

Engage all latch mechanisms of trim strip (1).
51 13 116 Remove and install the cowl panel cover
(rear) \PREMIUM

PRELIMINARY WORK

1 – Remove the seal for the rear bonnet

NOTICE
Schematic diagram is for example purposes. Some parts may differ in certain details.

Pull off rear bonnet seal (1) towards the top and remove.

[Link]
2 – Removing front cowl panel cover
Guide the front cowl panel cover (1) out toward the top and remove it.

3 – Remove left and right wiper arm

NOTICE
Description is for left component only. Procedure on the right side is identical.

▶ Remove the wiper arm

RISK OF DAMAGE
Damage to wiper console

While removing the wiper arms without using special tool, the wiper console can break.
Removing the wiper arms must be carried out only using the prescribed special tool.
Do not lift off wiper arm, else the wiper console may break on the predetermined breaking point for the pedestrian protection.
 Remove the protective cap (1).
Loosen nut (2).

Pull off the wiper arm (1) using special tool .

[Link]
4 – Remove the gutter strip on the windscreen on the left and right

NOTICE
Description is for left component only. Procedure on the right side is identical.

▶ Remove the gutter strip on the windscreen

Unclip the gutter strip (1) from the clips (2) beginning at the roof to the top.
Feed the gutter strip (1) out of the guide (3).
MAIN WORK

5 – Remove the rear cowl panel cover

Disengage and guide out the rear cowl panel cover (1) towards the top.

6 – Install the rear cowl panel cover

Feed in and engage the rear cowl panel cover (1).

[Link]
POSTPROCESSES

7 – Install the gutter strip on the windscreen on the left and right

NOTICE
Description is for left component only. Procedure on the right side is identical.

▶ Install the gutter strip on the windscreen

Check the clamps (2) for damage and renew if necessary.
Insert the gutter strip (1) with the guide (3).
Align the gutter strip (1) at the roof and clip it in.

8 – Install left and right wiper arm

 NOTICE
Description is for left component only. Procedure on the right side is identical.

▶ Install the wiper arm

TECHNICAL INFORMATION
The wiper system must be in zero position.
After installing the cowl panel cover and before fitting the wiper arm:
Activate the wiper system once to ensure that it has the correct installation position.

Connect the wiper arm (3).

Correctly position the wiper arm
(2) in relation to the window edge
(1).

[Link]
NOTICE
Description is for left component only. Procedure on the right side is
identical.

Tighten nut (2).

Windscreen wiper arm
Combination Tightening torque 35 Nm
hexagon nut

Connect the protective cap (1).

9 – Installing front cowl panel cover

 Insert the cowl panel cover front (1) to the rear and install.
Check cowl panel cover at front is correctly seated (1).

10 – Install the seal for the bonnet

NOTICE
Schematic diagram is for example purposes. Some parts may differ in certain details.

Install bonnet seal at rear (1).

Ensure that the rear bonnet seal (1) is fitted correctly.

[Link]
Additional Information

Overview of Tightening Torques

Windscreen wiper arm Used in step 8

Combination hexagon nut Tightening torque 35 Nm

Overview of Special Tools

Overview Technical Data

51 13 115 Remove and install/replace the cowl panel cover (front)

Necessary preliminary tasks:

Remove rear bonnet seal

Note:
Bonnet shown removed for purposes of clarity.

Removal:

Lift off cowl panel cover (1).

[Link]
Installation:

Feed in cowl panel cover (1) towards [Link]:

Check front cover is correctly seated relative to rear cover.

Required follow-up work:

Install rear bonnet seal
51 13 115 Remove and install/replace the cowl panel cover
(front) \PREMIUM

PRELIMINARY WORK

1 – Remove the seal for the rear bonnet

NOTICE
Schematic diagram is for example purposes. Some parts may differ in certain details.

Pull off rear bonnet seal (1) towards the top and remove.

[Link]
MAIN WORK

2 – Removing front cowl panel cover

Guide the front cowl panel cover (1) out toward the top and remove it.

3 – Installing front cowl panel cover

Insert the cowl panel cover front (1) to the rear and install.
Check cowl panel cover at front is correctly seated (1).
POSTPROCESSES

4 – Install the seal for the bonnet

NOTICE
Schematic diagram is for example purposes. Some parts may differ in certain details.

Install bonnet seal at rear (1).

Ensure that the rear bonnet seal (1) is fitted correctly.

[Link]
51 13 305 Removing and installing / replacing left or right roof railing

Necessary preliminary tasks:

F45/48/49:
Remove headlining
F46:
Lower roofliner
The right luggage compartment wheel arch trim panel need not be
dismantled

Removal:

Unscrew nuts (1).

[Link]
Remove roof rails (1).

Installation:
Note:
Gaskets and threaded bolts on the roof rails must not be damaged.

Position roof rails.

Tighten down nuts (1).
Parts: Replace nuts (1).
Tightening torque 51 13 1AZ.

Required reworking:
Fit the headlining

[Link]
51 13 116 Removing and installing cowl panel cover (rear)

Necessary preliminary tasks:

Remove front cowl panel cover
Removing the wiper arm on the left or right
Removing the gutter strip on the windscreen on the left and right

Note:
Bonnet shown removed for purposes of clarity.

Removal:

[Link]
Disengage cover (1) upwards and feed out.

Installation:

Feed in cover (1) and engage.

Required follow-up work:
Mount left or right wiper arm
Install front cowl panel cover
Installing the gutter strip on the windscreen on the left and right

[Link]
51 13 280 Removing and installing/replacing trim strip on roof frame at left or
right

Special tools required:

00 9 321

Removal:

Lever out trim strip (1) with special tool 00 9 321 at the rear.
Unclip trim strip (1) from the clamps (2) towards the top.

[Link]
Installation:

Note:
Clips (1), gaskets (2) and supports (3) must not be damaged or missing.
The position of the clips (1) is determined with the tabs on the body.
Place the trim strip onto the roof loosely and check if clips (1) are correctly
positioned with the tabs on the roof.
Replacement:
Do not attach clips (1) and supports (3) until the trim strip has been painted.
Note:
The front of the trim strip (1) must be flush with the roof outer skin.

Position trim panel (1) and clip into clamps (2).

[Link]
51 13 146 Replacing front radiator grille, middle left or right

Removal:

Disconnecting longitudinal bars of the kidney grille (break off).

Release latch mechanisms on front ornamental grille (1) from outside.
Remove front ornamental grille (1) forwards.
Note:
The bumper panel must be disassembled to ensure the removal will not
cause any damage.

[Link]
Installation:

Install front ornamental grille (1).

Engage latch mechanisms on front ornamental grille (1).
51 14 ... General notes for labelling with adhesive films
In the event of a repair the adhesive films must be partially or completely replaced. The basic procedure for all areas
of the vehicle is described below.
In addition, vehicle-specific repair instructions are available.
1. Preparation:
Wash and dry vehicle. Rework with compressed air as required in area of joints.
Clean complete component surface with glass cleaner (BMW part number 83 12 0 396 775). Also clean the inside of
the component in areas, in which adhesive films are applied.
Only carry out repair work with clean hands!
Important!
Labels can only be applied to recently painted components after a waiting period of 2 weeks. The paint hardening is
only fully completed after this time.
2. Procedure for applying labels:
All adhesive films in the repair kit are marked with numbers. Prepare the required plastic films prior to start of
repairs.

[Link]
The templates included in the repair kit assist orientation. A straight line running over the different components is the
top priority.
Pull off the templates positioning of the adhesive films.
Only throw away templates after completion of all repair work, as some templates are used several times.
Templates are always
applied along the light
edge (1). The light edge
is the reflection of the
light source in radius
(see arrow).

Roughly align the adhesive film using a template.

For large adhesive films, pull off the first 20 cm of protective film and fold back the edge.
Align and lightly press down the adhesive film. Use only one finger for this and not the entire hand so that air pockets
are unable to form under the adhesive film.
Pull off the remaining protective film and press down the adhesive film from front to rear and from inside to outside.
If faults are made in applying the adhesive film, it can be pulled off and repositioned several times. When no further
corrections have to be made, use a squeegee to press down the adhesive film firmly from inside to outside.
Lay protruding ends of the adhesive film around the component edge and press down firmly.
Carefully pull off backing
film (1) at an acute
angle.

[Link]
51 14 008 Replacing letter/number combination on front left or right side
panel

General procedure is described in:

"Replacing rear model designation"
Use same procedure as for the front side panel.

[Link]
51 14 111 Replacing model name plate, rear

Note:
This document describes a general procedure for replacement and new
bonding of model designations/lettering using the 335i (F30) as an example.
The procedure can be used for all models, positions and installation
locations.
The model designation is attached with adhesive and can not be reused.

Refer to instructions for securing components with adhesive tape!

Consumables:

Cutting cord
Masking tape 19 mm or 30 mm
Yellow plastic adhesive tape
Eraser disk

[Link]
Cleaning agent R2

Replacing model designation (new or newly painted tailgate):

Note:
Transfer position of model designation (1) from old tailgate by making an
adhesive tape template.
For paintwork, keep adhesive tape template up to installation.

Stick masking tape (2) to nearby reference edges of tailgate and therefore
determine position of model designation (1).
Pull off masking tape (2) completely and stick to same reference edges of
new/painted tailgate.
Check position, realign if required.
Refer to "Installation" operation for further procedure.

Replacing model designation:

Mark position of model designation (1) with yellow plastic adhesive tape (2).
Coat separating string or strong yarn with tensides (e.g. washing-up liquid).
Cut through adhesive layer and remove model designation (1).
Refer to "Installation" operation for further procedure.
Installation:
If required, remove adhesive layer residues with grinding wheel and/or
cleaning agent R2.
Clean the adhesive area.
Number and letter combinations (1) of the model designation are not
connected to each other and are supplied on a backing film (2).
Remove liner (3) (protective film for bonding surface).
Place model designation at marked position and press down firmly.
Remove backing film (2) and template.

[Link]
51 14 011 Replacing rear BMW badge

Special tools required:

00 9 323

Important!
The notes on component bonding with double-sided adhesive tape
serve as the basis for this repair instruction and must be observed
without fail.
The BMW badge must be replaced after it is removed.

Removing badge:
Heat BMW badge (1) with hot air blower and carefully lever out with special
tool 00 9 323 .

[Link]
Fitting badge:
Installation note:
Grommets (1) must not be damaged.

Pull liner* off adhesive tape (2), position badge over guide pins (3) and press
down firmly.
* Liner is the protective film on a new badge.
51 14 001 Replacing the front BMW badge

Special tools required:

00 9 327

Important!
The notes on component bonding with double-sided adhesive tape
serve as the basis for this repair instruction and must be observed
without fail.

Tape off working area around the BMW badge (1) with adhesive tape.
Carefully warm up the BMW badge (1) with a hot air blower (temperature
approx. 40 - 55 °C ) and lift it out with the special tool 00 9 327 .

[Link]
Installation note:
Pull liner* off adhesive tape (2).
Position BMW badge (1) over guides (3) and press down firmly.
* Liner is the protective film on a new plate.
51 16 992 Disassembling and assembling lock barrel (lock barrel removed)

Sort supplied retainers (1) according to graphic.

(X) Embossed number on retainer (1)
(Y) Installation position in lock barrel

Insert spring (1) into first position of lock barrel (2).Note:

Lock barrel version (2) differs according to vehicle.

[Link]
Insert retainer (1) with lowest stamped number (X) in first position (Y) in lock
barrel (2) so that it snaps into place [Link]:
Number of retainers (1) differs according to vehicle.

Insert ignition key (1) in lock barrel (3) and check whether retainer (2) is flush
with housing.
(A) OK
(B) not OK
If retainer (2) is not OK, press retainer (2) out of lock barrel (3) with a suitable
tool (1).
Repeat work operations with retainer (2) with next higher number (X) until
correct retainer (2) has been found.
Carry out all further positions in lock barrel as described in the process
above.

[Link]
51 16 001 Remove and install (replace) exterior mirror at the front door on
the left or right

Necessary preliminary work:

Remove front door trim panel

Removal:

Release window frame cover (1) on clips (2).

If necessary, disconnect related plug connections.
Remove window frame cover (1).

[Link]
Attention!
Secure exterior mirror against falling out.

Unlock plug connection and disconnect.

Release screws (1).

Release and remove the mirror (1) at the clamp (2).

Installation:
Replacement
Remount mirror electronics

Note:
Sound insulation on the mirror base must not be damaged or missing.

Install the mirror (1) and engage at the clamp (2).

Tighten down screws (1).

Tightening torque 51 16 1AZ.

[Link]
Note:
Due to self-tapping screws, the tightening torque in the new condition of
exterior mirror increases by 2 Nm.

Connect and lock plug connection.

Run a function check.

Install window frame cover (1).

If necessary, connect related plug connections.
Clip in the window frame cover (1) at the clips (2).

Required reworking:
Installing front door trim panel
61 31 083 Remove and install (replace) tailgate lock switch

Special tools required:

64 1 020

Removal:

Lever out tailgate lock switch (1) using SWZ 64 1 020 .

[Link]
Unlock connector (1) to tailgate lock switch (2) and disconnect.

Installation:

Connect the plug (1).Installation note:

Locking clamps on the tailgate lock switch (2) may not be damaged or
missing.
Fit tailgate lock switch (1) in the door trim panel.

[Link]
51 16 150 Removing and installing (replacing) front storage compartment

Special tools required:

64 1 020

When working on trim panel components, make sure that the sensitive
surfaces are not scratched or damaged.

Removal:

Remove storage compartment (1) using special tool 64 1 020 towards the

[Link]
top, lever it out of the clips (2) and remove it towards rear.

Installation:

Install storage compartment (1) and engage it in the clips (2).

61 31 ... Removing and installing (replacing) fuel filler door release switch

Special tools required:

64 1 020

Removal:

Lift out the fuel filler flap release switch (1) from the door trim panel (2) using
special tool 64 1 020 .
Unlock and disconnect associated connector.

[Link]
Installation:

Connect associated connector.

Insert the fuel filler flap release switch (1) into the door trim panel (2).
61 31 082 Removing and installing (replacing) switch for central locking
system

Necessary preliminary tasks:

Remove front door trim panel

Removal:

Release switch for central locking system (1) at latch mechanisms.

Remove switch for central locking system (1) from the door trim panel (2).

[Link]
Installation:

Join switch for central locking system (1) in the door trim panel (2).Note:
Make sure switch for central locking system (1) is correctly engaged in the
door trim panel (2).

Required reworking:
Install front door trim panel
51 16 480 Removing and installing or replacing front grab handle

When working on trim panel components, make sure that visible surfaces are
not scratched or damaged (e.g. by sharp-edged tools).

Removal:

Fold grab handle (1) downwards.

Disengage and remove locking wedges (2) with angle screwdriver (3), as
shown.

[Link]
Release bottom and top release tab (1) with screwdriver.
Remove grab handle (2) and place to side.

Installation:

Insert grab handle (1) into body.

Engage locking wedges (2) on both sides of grab handle (1).
Note:
Only after grab handle (1) is snapped in correctly can locking wedges (2) we
fully locked in position in grab handle (1).
[Link]
51 16 045 Removing and installing or replacing retaining ring on left or right
exterior mirror

Special tools required:

2 405 562

Necessary preliminary tasks:

Remove protective cap from exterior mirror
Remove mirror drive

Removal:

[Link]
Fold exterior mirror forwards.
Loosen screws (1) from retaining ring (3) with special tool 2 405 562 .
Loosen screws (2) from retaining ring (3).
Feed out retaining ring (3).

Installation:

Note:
Make sure retaining ring (1) is correctly mounted on turn indicator (2) and
housing (3).
Insert retaining ring (3).
Tighten down screws (2).
Tightening torque 51 16 4AZ.
Tighten down screws (1) with special tool 2 405 562 .
Tightening torque 51 16 4AZ.
Fold exterior mirror back.

Required follow-up work:

Install mirror drive
Install protective cap on exterior mirror

[Link]
51 16 080 Removing and installing or replacing sun visor and left or right
counter support

When working on trim panel components, make sure that visible surfaces are
not scratched or damaged (e.g. by sharp-edged tools).

Removal:

Detach sun visor from counter support (1).

Lift off cover (2).
Pull the front sun visor (1) downwards and remove it to the front out of the
guide.

[Link]
Lever out cover on counter support (1) and release screw underneath.
Remove counter supports (1).

Installation:
Feed the sun visor (1) in towards the rear in the guide and engage it
upwards.
Install cover (2).

Install the counter support (1) and tighten the screw.

Engage cover.
Attach the sun visor in the counter support.
Note:
If need be, perform function check on lighting.

[Link]
51 16 206 Removing and installing/replacing centre armrest

Necessary preliminary tasks:

Remove rear centre console trim

Removal:

Release nuts (1) and remove centre armrest upwards.

[Link]
Installation:

Replacement:
If necessary, remount base plate
Install centre armrest and tighten nuts (1).
Tightening torque 51 16 5AZ.

Required follow-up work:

Install rear centre console trim
51 16 160 Removing and installing/replacing centre console cover

Special tools required:

64 1 020

Necessary preliminary tasks:

Remove cover for selector lever

Removal:

Lever storage compartment (1) upwards out of clips (2) using special

[Link]
tool 64 1 020 and remove to the rear.

Important!
Risk of damage!
To avoid scratching the centre console cover (1) when removing the
selector lever (2), mask the selector lever (2) with yellow plastic
adhesive tape.

Note:
Selector lever position D makes removal of the cover (1) easier.

Lever cover (1) out of clamps (2) and feed out upwards past the gearshift
lever.

Release screws at marked points.

Disconnect plug connection (1).
Remove centre console trim (2).
Installation:

Replacement:
Remount the control panel of the heating and air conditioning system
Remount controller
Remount centre console operating unit

Position centre console cover (2) correctly.

Tighten screws at marked points.
Tightening torque 61 31 4AZ.
Connect plug connections (1) at centre console cover (2).

[Link]
Note:
Selector lever position D makes installation of the cover (1) easier.

Feed in cover (1) past gearshift lever and engage in clamps (2).
Engaging sequence:
1. Centre
2. Rear (Controller area)
3. Front

Feed in storage compartment (1) and engage in clips (2).

Required follow-up work:

Install cover for selector lever
51 16 165 Removing and installing/replacing complete centre console

Necessary preliminary tasks:

Remove centre console cover
Remove rear centre console cover
Remove USB audio interface connecting socket

Attention!
Read and comply with notes on handling wiring harnesses and cables.

Removal:

[Link]
Version without centre armrest:
Lift out cover (1) and release screws underneath.
Version with centre armrest:
Remove the centre armrest.

Release screw (1).

Disconnect plug connection (2).
Unclip trim panel (1) as shown from centre console at bottom.

Disconnect plug connection (1).

Release aerial (2).
Loosen screws (3).
Lift up centre console at rear and feed out towards rear.

[Link]
Installation:

Replacement:
Remount interior aerial for Comfort Access.
Remount 12 V power socket.
Lift up centre console at rear and feed in towards front.
Connect plug connection (1).
Attach aerial (2).
Tighten down screws (3).
Tightening torque 51 16 7AZ.

Clip in trim panel (1) onto centre console at bottom.

Tighten screw (1).
Tightening torque 51 16 7AZ.
Connect plug connection (2).

Version with centre armrest:

Install the centre armrest.
Version without centre armrest:
Tighten screws and install cover (1).
Tightening torque 51 16 7AZ.

[Link]
Required follow-up work:
Fit centre console cover
Install rear centre console trim
Install connecting socket for USB audio interface
51 16 041 Removing and installing/replacing cover cap on left or right
exterior mirror

Necessary preliminary tasks:

Remove mirror glass

Compress the latch mechanisms (1) in the sequence (A), (B) and (C) and at
the same time pull the protective cap outwards.

[Link]
Installation note:
Latch mechanisms (1) and guides (2) on protective cap (3) must not be
damaged or missing.
51 16 383 Removing and installing/replacing damper for glove box

Necessary preliminary tasks:

Remove right glove box with housing

Removal:

Release damper (1) from retaining bracket (2).

Twist judder damper (1) by approx. 90° and remove it.

[Link]
Installation:

Insert judder damper (1) and twist by approx. 90°.

Engage damper (1) on retaining bracket (2).

Required follow-up work:

Install right glove box with housing
51 16 040 Removing and installing/replacing housing on left or right exterior
mirror

Necessary preliminary tasks:

Remove protective cap on exterior mirror
Remove mirror drive

Removal:

Release screws (1).

[Link]
Release screw (1).
Remove housing (2) carefully and disconnect plug connection at side
repeater (3).

Installation:
Note:
Screw holes (1) must not be damaged.

Replacement:
Feed side repeater (2) out of housing (3) in direction of arrow.

Carefully feed in housing (2) and connect plug connection to side repeater
(3).
Tighten screw (1).
Tightening torque 51 16 3AZ

[Link]
Note:
Make sure retaining ring (1) is correctly mounted on side repeater (2) and
housing (3).

Tighten down screws (1).

Tightening torque 51 16 3AZ

Required follow-up work:

Install protective cap on exterior mirror
Install mirror drive
51 16 063 Removing and installing/replacing interior mirror (as of 07/2011)

Important!
Work may only be carried out at a room/object temperature of
18 ... 28 °C.
If this can not be guaranteed (cold/hot countries), it is necessary to
equalise the temperature of the windscreen, mirror base and inside
mirror (e.g. vehicle left to stand indoors or in the shade for at least 30
minutes).

Important!
To avoid windscreen breakage:
When removing mirror base, never turn or disengage towards front or
rear.

Unclip end caps (1) in direction of arrow using a suitable tool and remove.

[Link]
Installation note:
Latch mechanisms (1) and guides (2) on both end caps (3) must not be
damaged.
For end caps (3) with tabs (4), the spacers must be bonded onto the tabs (4).
Important!
Risk of damage!
When removing mirror base, never turn or disengage towards front or
rear.
Interior mirror is held by clamp (3) and latch mechanism in area (A) on
mirror base (2).

If necessary, disconnect plug connection on inside mirror (1).

Jerkily pull off inside mirror (1) parallel to windscreen from mirror socket (2).
Installation note:
Retaining clips (3) must not be bent or damaged.
Interior mirror (1) must engage correctly in mirror base (2) in area (A).

Version with compass:

Check compass function if replacing or after disconnecting inside mirror plug
connection or battery.
If necessary, calibrate compass in interior rearview mirror.
Version with high-beam assistant without KAFAS (camera-based driver
support systems):

[Link]
Normalisation or initialisation is not necessary.
High-Beam Assistant is automatically aligned under the following conditions:
Driving on a motorway/ordinary road at night for approx. 50 km and
Clearly visible road markings

Replacement:
Carry out vehicle programming/coding.
51 16 063 Removing and installing/replacing interior mirror (overview)

Important!
Interior mirrors with modified mirror base will be installed as of series
launch F20 and for all subsequent series launches.
Observe new repair instructions!

Further introduction date:

F01, F02, F03, F06, F07, F10, F11, F12, F13, F18 07/2012
F25 03/2012

Note:
If the document for the selected model is not required or not approved, the
following message will be displayed when clicking on the "cross-reference":
"No documents with further information available for the currently selected
vehicle context".

Distinguishing feature:

[Link]
(A) previous version, small mirror base (1) with round base plate on
windscreen.
(B) new version, large mirror base (2) with square base plate on
windscreen.
Note:
Dismantling of mirror cap is identical on both versions.

Version with mirror arm end cap:

Previous version.

Version with mirror arm end cap:

New version.
Version with rain sensor:
Previous version.
New version.

Version with Autobeam:

Previous version.
New version.

[Link]
Version with Toll interior mirror for Japan:
Previous version.
New version.
51 16 163 Removing and installing/replacing rear centre console cover

Special tools required:

00 9 325

When working on trim panel components, make sure that the sensitive
surfaces are not scratched or damaged.

Removal:

Lever out and remove trim (1) from the clamps (2) using special tool 00 9 325

[Link]
.

Installation:

Engage trim (1) in clamps (2).

51 16 450 Removing and installing/replacing rear left/right grab handle

Operation is identical to:

Removing and installing/replacing front grab handle.

[Link]
51 16 366 Removing and installing/replacing right glove box with housing

When working on trim panel components, make sure that visible surfaces are
not scratched or damaged (e.g. by sharp-edged tools).

Necessary preliminary tasks:

Remove side panel on instrument panel on right
Remove side trim panel from footwell on right A-pillar
Remove instrument panel trim, bottom left

Removal:

[Link]
Release screw (1).

Release screw (1).

Release screws (1).
Remove glove box (2) inwards and disconnect associated plug connections.

Installation:

When replacing, swap over the following parts:

Glove box damper

[Link]
Glovebox light

Install glove box (2) and connect the corresponding plug connections.
Tighten down screws (1).

Tighten screw (1).

Tighten screw (1).

Required follow-up work:

Install instrument panel trim, bottom right
Install side panel on instrument panel, right
Install footwell side trim panel on right A-pillar

[Link]
61 31 014 Removing and installing/replacing Start/Stop switch

Special tools required:

00 9 340

Removal:

Lift out start/stop button (1) using special tool 00 9 340 .

[Link]
Unlock and disconnect the connector (1).

Installation:

Note:
The retaining clips on the start/stop button (2) must not be damaged or
missing.

Connect the connector (1).

Join start/stop button (1) with instrument panel trim.

[Link]
61 31 172 Removing and installing/replacing switch for electromechanical
parking brake

Necessary preliminary work:

Disconnect battery earth lead
Partially remove the centre console trim

Removal:

Unlock connector (1) and disconnect (see next figure).

Release all screws (2).
Remove switch for electromechanical parking brake (3).

[Link]
Installation:

Join switch for electromechanical parking brake (3).

Tighten all screws (2).
Tightening torque 61 31 4AZ.
Connect the connector (1).

Required reworking:
Connect battery earth lead
Install the centre console trim
51 16 210 Removing and installing/replacing trim for selector lever

Special tools required:

00 9 340

Removal:

Pry out cover (1) using special tool 00 9 340 all around and remove upwards.

[Link]
Installation:

Position cover (1) and clip in all round.

67 13 001 Replacing drive unit for electrically operated left or right exterior
mirror

Necessary preliminary tasks:

Remove mirror glass

Removal:

Release screw (1).

Disconnect connector (2).
Remove the drive (3).

[Link]
Installation:

Connect connector (2).

Position drive (3) correctly.
Tighten screw (1).
Tightening torque 67 13 1AZ.
Note:
Make sure drive (3) is correctly fitted.

Required reworking:
Install mirror glass
51 16 026 Replacing mirror glass for exterior mirror (on front door)

Special tools required:

00 9 317

Warning!
Move mirror glass with hand carefully and slowly.
If mirror glass is damaged:
Wear protective goggles and cut-proof gloves.
Danger of injury by flaking-off glass splinters.

Important!
Bring exterior mirror to room temperature to prevent latch mechanisms
from breaking off.
Remove glue between mirror glass and edge of housing (risk of
damage).

[Link]
Secure mirror glass against falling out.

Removal:

Press mirror glass (1) at top by hand to full extent.

Note:
Secure mirror glass (1) against falling out.

Unclip mirror glass (1) at bottom with special tool 00 9 317 .

Unlock associated plug connections and disconnect.
Remove the mirror glass (1).

Installation:
Note:
Retaining lugs (1) must not be damaged.
Fit mirror glass (2) with retaining lugs (1) flush on mirror adjusting drive and
clip into place.
Ensure correct locking.
Make sure mirror adjusting drive functions correctly.

[Link]
41 63 000 Removing and installing the fuel filler flap

Note: The illustration is a schematic diagram and is to be applied to the

relevant vehicle type.

Open fuel filler flap.

Lift out the lock (2) and detach the fuel filler flap (1) in direction of arrow.

[Link]
41 63 003 Replace cover bowl

Necessary preliminary tasks:

Remove right rear wheel
Remove rear right wheel arch cover
Remove flap for fuel filler neck

Attention!
Deformation of the sheet metal flanges in the side panel and the wheel
arch results in permanent vehicle leakage. Carry out removal/installation
with great care.

Following new body parts are required (see Electronic Parts Catalogue):
(1) Cover bowl
Plastic nut for mounting fuel filler pipe

[Link]
Removal:

Press sealing cup (1) through to the outside.

Unclip tank ventilation line (1).
Release nuts (2) and (3).
Slacken the fuel filler pipe (4).
Installation note:
Renew plastic nut.

Lift out the retaining strap (1) and remove the lid.
Cut through protective tube in area (2) approx. 50 mm.
Pierce markings (3) with a small screwdriver.

[Link]
Insert screwdriver to a depth of max. 5 mm to unlock cover bowl latch
mechanisms.

Hold cover bowl slightly under tension in removal direction.

Unlock latch mechanisms individually with screwdriver (1) in direction of
arrow.
Unlock catches in following order:
1. Top left
2. Bottom left
3. Top right
4. Bottom right
Move screwdriver in opposite direction at both lower catches.
Press fuel filler pipe to rear.
Attention!
Do not damage sheet metal flange of side wall.

Carefully unscrew the cover bowl in direction of arrow up to the position

shown.

Unlock and disconnect plug connection (1) for actuator drive.

Release pull for emergency release at separation point (2).
Remove cover pot.

[Link]
Loosen controller drive (1) in the direction of the arrow to remove it.

Installation:

Following parts of cover housing not be damaged or missing:

1 Marks
2 Latch mechanisms, top/bottom
3 Spring
4 Catch
5 Lock
Insert controller drive (1) in the direction of the arrow and lock in [Link]:
Make sure the servo drive for fuel filler flap is correctly installed!
Check central locking system of the controller drive before installing the cover
bowl.

Clean contact surface (1) on body and ground connection at fuel filler pipe.
The ground connection must be guaranteed.

[Link]
Schematic diagram.
Turn sealing sleeve in area of hinge inwards and hold.

Carefully insert cover bowl up to the position shown and place sealing cup
over fuel filler pipe.
Press fuel filler pipe to rear when doing this.
Connect plug connection (1) for the controller drive.
Connect pull for emergency release at separation point (2).

Install cover [Link]!

Do not damage sheet metal flange of side wall.
Cover bowl must audibly snap into place 4 times.
There must be no visible gap between sealing lip and side panel in
area (1).

[Link]
Using fitting aid (1), pull sealing lip (2) over sheet metal flange of wheel arch
(3).

Check that sealing lip is correctly [Link]:

Shown without fuel filler pipe for clarity.
Schematic diagram.
Check seat of fuel filler pipe for correct installation position and correct if
necessary.
Tighten nuts (1) and (2).
Clip tank ventilation line (3) into holder.
Installation note:
Renew plastic nut.
Tightening torque 16 11 1AZ.

Required reworking:
Install flap for fuel filler neck
Installing the rear wheel arch cover on the right
Installing the rear wheel on the right

[Link]
51 21 004 Adjusting front left or right lock striker

Operation is described in:

Adjusting left or right front door.

[Link]
51 21 225 Removing and installing or replacing inside door opener in left or
right front door

Necessary preliminary tasks:

Remove Bowden cable for door opener
Remove switch for central locking

Note:
Door opener is welded to door trim panel only on initial installation. The door
opener is screw-connected on second installation. If applicable, release
screws instead of welding spots.

Removal:

[Link]
Important!
Risk of damage!
To avoid damaging contact surface, only drill/grind to the main surface
of the door trim panel.

Drill out/grind down welding spots.

Remove door opener from outside.
Remove welding remnants on door trim panel with a scalpel.

Installation:

Replacement:
Saw off weld pins (1) along moulding (2).
Insert door opener (2) in door trim [Link]:
Welding pins (1) must not protrude over door trim panel (2).

Secure armrest with the repair screws (1).

Tightening torque 51 41 4AZ.

[Link]
Required follow-up work:
Install switch for central locking system
Install Bowden cable for door opener
51 21 170 Removing and installing or replacing outer door handle from left
or right front door

Necessary preliminary tasks:

Remove cover on outside door handle

Pull out outer door handle (1) and feed out in direction of arrow.
Version with Comfort Access/light package:
Carefully manoeuvre out outer door handle (1) and unplug associated
electrical connector.

[Link]
Installation note:
Locator (1) must not be damaged.
Gaskets (2) must not be damaged.

Installation note:
When outer handle is removed the lock actuator (1) is held in fitting position
by retaining springs (2).
If the lock actuator is not in fitting position:
Use string (3) to pull lock actuator (1) outwards and hold in position.
Fit outer handle and insert into lock actuator correctly (1).
Remove string (3)
Carry out function check only with door open.

Replacement
Version with Comfort Access:
Check outer door handle for proper function before painting.
Connect all connectors to outer door handle and wait approx. 10 seconds.
Perform convenient closing/opening.

Paint outer door handle before installation.

Do not paint the marked area of the outer door handle.
Do not exceed drying temperature of 60 °C.

Version with light package:

Clip lighting unit (1) into outer door handle (2) in direction of arrow.

[Link]
Attach gasket (1) to outer door handle (2).
Ensure gasket (1) is seated correctly.
51 21 235 Removing and installing/replacing Bowden cable for inside door
opener on left or right front door

Necessary preliminary tasks:

Remove front door trim panel

Removal:

Release lock (1) and remove Bowden cable (2) upwards; the Bowden cable
feeds out automatically.

[Link]
Installation:

To install the Bowden cable, press inner door handle (1) in direction of
arrow.
Engage Bowden cable (2) in lock (1) towards front/bottom.

Required reworking:
Install front door trim panel

[Link]
51 21 140 Removing and installing/replacing complete lock barrel in left or
right front door

Necessary preliminary tasks:

Remove carrier for outer door handle

Detach trim (1) at catch (2) and remove.

[Link]
Twist lock barrel (1) in direction of arrow and remove.
51 21 370 Removing and installing/replacing cover at bottom left or right on
front door

Special tools required:

2 298 505

Removal:

Unclip the clips (2) along the dotted line using special tool 2 298 505 .
Remove cover (1).

[Link]
Installation:

Note:
The clips (2) of the cover (1) must not be damaged or missing.
Install the cover (1).
Clip in the clips (2) along the dotted line.

[Link]
51 21 180 Removing and installing/replacing cover on outside door handle

Lever out trim (1) and release screw underneath (2).Installation note:
Replace faulty cover (1).

Pull off cover (1) with outer door handle (2) opened slightly.

[Link]
Installation note:
Ensure gasket (1) is seated correctly.

Installation note:
Latch mechanisms (1) of cover (2) must not be damaged.

Replacement:
Remove cover (2) from retaining plate (3).
51 21 092 Removing and installing/replacing door lock in left or right driver's
door (front passenger door)

Necessary preliminary tasks:

Remove support for outer door handle (only on driver's side)
Partially remove sound insulation on front door

REMOVAL:

Important!
Do not damage door lock seal when removing.

Unclip locking rod (1).

[Link]
Unfasten screws (2).
Disconnect plug connection on door lock (3).
Feed out door lock (3).

Replacement:
Remount Bowden cable (1).

INSTALLATION:
Insert door lock and screw in screws (3 and 4).
First tighten screws (3) and then tighten the screw (4) on the door lock (2).
Tightening torque 51 21 1AZ.
Connect plug connection on door lock (2).
Clip in locking rod (1).

Required reworking:
Install support for outer door handle (only on driver's side)
Install sound insulation in front door

[Link]
51 21 280 Removing and installing/replacing door stop on left or right front
door

Necessary preliminary tasks:

Remove sound insulation
Close door window completely

REMOVAL:

Feed out gasket (1) from screws (3).

Release screw (2).
Release screws (3).

[Link]
INSTALLATION:

Tighten screw (2).

Tightening torque 51 21 3AZ.
Tighten down screws (3).
Tightening torque 51 21 4AZ.
Mount gasket (1).

Required reworking:
Install sound insulation
51 21 125 Removing and installing/replacing support for left or right outer
door handle with lock barrel

Necessary preliminary tasks:

Remove outer handle
Partially remove front sound insulation

Removal:

Release screw (1).

Slide support (2) forwards and thread out inwards.

[Link]
Move support (1) forwards and detach actuator rod (2) from door lock (3).
Thread support (1) out from door.

Detach cable (1) and remove support.

Replacement:
If necessary, swap over lock barrel.

INSTALLATION:

Attach cable (1).

[Link]
Thread support (1) into door.
Attach actuator rod (2) to door lock (3).

Thread support (2) backwards into mounting.

Tighten down screw (1).

Required reworking:
Install outer door handle
Install sound insulation
51 21 126 Removing and installing/replacing support for left or right outer
door handle without lock barrel

Necessary preliminary tasks:

Remove outer handle
Remove front sound insulation

Removal:

Loosen screw (1).

Slide support (2) forwards and thread out inwards.
Thread support (2) out from door.

[Link]
Detach cable (1) and remove support.

Installation:
Attach cable (1).
Thread support (1) into door.

Thread support (2) backwards into mounting.

Tighten down screw (1).

[Link]
Required reworking:
Install outer door handle
Install sound insulation
51 22 126 Removing and installing/replacing support for outer door handle
in left or right rear door

Necessary preliminary tasks:

Remove outer handle
Remove the sound insulation on the door

Removal:

Release screw (1).

Slide support (2) forwards and feed out inwards.
Detach wiring harness from support (2).
Feed out support (1) from door.

[Link]
Disengage the lever (1) and twist by 90°, then detach cable (2).
Attach it to the counter support (3) first, then to the Bowden cable nipple.

Installation:
Attach cable (2).
Attach it to Bowden cable nipple first, then to counter support (3).
Twist the lever (1) 90° and engage.

Feed in support (2) into door.

Feed in support (2) into mounting towards the rear.
Tighten screw (1).
Tightening torque 51 22 6AZ.

[Link]
Required reworking:
Install outer door handle
Install the sound insulation on the door
51 22 090 Removing and installing/replacing the door lock in the left or right
rear door

Necessary preliminary tasks:

Remove outer window cavity cover strip
Partially remove sound insulation at rear door

Removal:

Open side window completely.

Partly release rubber window seal for door window glass (1).
Release screws (2) and carefully feed out the triangular trim (3) upwards and
remove it.

[Link]
Close side window completely.

Important!
Do not damage door lock seal when removing.

Unclip locking rod (1).

Unfasten screws (2).
Disconnect plug connection on door lock (3).
Feed out door lock (3).

Installation:
Replacement:
Remount Bowden cable (1).

Insert door lock and screw in screws (3 and 4).

First tighten screws (3) and then tighten the screw (4) on the door lock (2).
Tightening torque 51 22 1AZ.
Connect plug connection on door lock (2).
Clip in locking rod (1).

[Link]
Required reworking:
Install outer weather strip
Mount sound insulation on rear door
51 21 300 Removing and installing/replacing weather strip on outside of
front door

Special tools required:

00 9 324

Important!
Observe procedure for using special tool 00 9 324 .

Necessary preliminary tasks:

Remove exterior mirror.

[Link]
Important!
If reusing the existing window cavity cover strip (1), make sure it is not
bent.

Lever out weather strip (1) using special tool 00 9 324 (starting at B-pillar).
51 21 ... Removing weather strip with special tool 00 9 324 at front or rear

Special tools required:

00 9 318
00 9 324

Open side window completely.

Front door:
Insert special tool 00 9 324 at front (at A-pillar) in window cavity (1) (TOP
label pointing upwards).

Rear door:
Insert special tool 00 9 324 at rear (at C-pillar) in window cavity (2) (TOP
label pointing upwards).

[Link]
Note:
For purposes of clarity, graphic shows inner door panel and side window
removed.

Special tool 00 9 324 must be correctly guided under weather strip (1).
2 Short leg, bottom
3 Long leg, top (TOP)

Note:
Start at the front or rear, depending on the model.

Important!
Risk of damage!
Raise weather strip (3) no more than 5 mm in each levering operation,
otherwise the strip will be bent.

Position special tool 00 9 318 on door trim panel (1).

Push suitable tool (2) into the bore hole of special tool 00 9 324 and thus
lever out the weather strip (3) maximum 5 mm in upward direction.
Guide special tools 00 9 324 and 00 9 318 forward or backward step by step
until weather strip (3) is fully removed.
51 21 003 Replacing door detent (lock striker), front left or right

Release screws (1) and remove door detent (2).

Installation note:
If necessary, carry out basic adjustment by way of notches (3) on door
detent (2) and B-pillar.
Tightening torque 51 21 2AZ.

After installation:
Adjust door detent.

[Link]
51 21 233 Replacing the Bowden cable for the outside door handle on the
left or right front door

Operation is described in:

Remove and install/replace outside door handle supports at left or right.

[Link]
51 22 004 Adjusting rear left or right door lock striker

Operation is described in:

Adjusting left or right rear door.

[Link]
51 22 235 Removing and installing/replacing Bowden cable for inside door
opener on left or right rear door

Necessary preliminary tasks:

Remove door trim panel from rear door

Removal:

Release lock (1) and remove Bowden cable (2) upwards; the Bowden cable
feeds out automatically.

[Link]
Installation:

To install the Bowden cable, press the inner door handle (1) in direction of
arrow.
Engage Bowden cable (2) in lock (1) towards front/bottom.

Required follow-up work:

Install door trim panel at rear door

[Link]
51 22 233 Removing and installing/replacing Bowden cable for outer door
handle in left or right rear door

The Instructions on installation of rubber window seals serve as the basis for
these repair instructions and must be observed without fail.

Necessary preliminary tasks:

Remove support for outer door handle on rear door
Remove window cavity cover strip

Removal:

[Link]
Open side window completely.
Partly release rubber window seal for door window glass (1).
Release screws (2) and carefully feed out the triangular trim (3) upwards and
remove it.
Close side window completely.

Release screws (1 and 2).

Unclip locking rod (3).
Disconnect plug connection on door lock (4).
Feed out door lock (4) from the door and detach bowden cable (5) at the
same time.

Installation:
Attach Bowden cable (5).
Feed in door lock (4) into the door.
Tighten screws (1) first, then tighten screw (2).
Tightening torque 51 22 1AZ.
Clip in locking rod (3).
Connect plug connection on door lock (4).

Open side window completely.

Feed in triangular trim (3) and tighten screws (2).
Carefully mount rubber window seal (1).
Close side window completely.

[Link]
Required follow-up work:
Install the support for outer door handle on rear door
Install the weather strip
51 22 370 Removing and installing/replacing cover (gasket) on rear door at
bottom left or right

Removal:

Unclip clips (2) along broken line with special tool 2 298 505.
Remove cover (1).

[Link]
Installation:

Note:
Clips (2) of cover (1) must not be damaged or missing.

Install cover (1).

Clip in clips (2) along broken line.
51 22 180 Removing and installing/replacing cover on outside door handle

Lever out trim (1) and release screw underneath (2).Installation note:
Replace faulty cover (1).

Pull off cover (1) with outer door handle (2) opened slightly.

[Link]
Installation note:
Ensure gasket (1) is seated correctly.

Installation note:
Latch mechanisms (1) of cover (2) must not be damaged.

Replacement:
Remove cover (2) from retaining plate (3).
51 22 225 Removing and installing/replacing inside door opener of rear left
or right door

Necessary preliminary tasks:

Remove Bowden cable for door opener

Note:
Door opener is welded to door trim panel only on initial installation. The door
opener is screw-connected on second installation. If applicable, release
screws instead of welding spots.

Removal:

Important!

[Link]
Risk of damage!
To avoid damaging contact surface, only drill/grind to base area of door
trim panel.

Drill out/grind down welding spots.

Remove door opener from outside.
Remove welding remnants on door trim panel with a scalpel.

Installation:

Replacement:
Saw off weld pins (1) along moulding (2).
Insert door opener (2) in door trim [Link]:
Welding pins (1) must not protrude over door trim panel (2).

Secure armrest with the repair screws (1).

Tightening torque 51 42 4AZ.

[Link]
Required follow-up work:
Install Bowden cable for door opener
51 22 126 Removing and installing/replacing support for outer door handle
in left or right rear door

Necessary preliminary tasks:

Remove outer handle
Remove the sound insulation on the door

Removal:

Release screw (1).

Slide support (2) forwards and feed out inwards.
Detach wiring harness from support (2).
Feed out support (1) from door.

[Link]
Disengage the lever (1) and twist by 90°, then detach cable (2).
Attach it to the counter support (3) first, then to the Bowden cable nipple.

Installation:
Attach cable (2).
Attach it to Bowden cable nipple first, then to counter support (3).
Twist the lever (1) 90° and engage.

Feed in support (2) into door.

Feed in support (2) into mounting towards the rear.
Tighten screw (1).
Tightening torque 51 22 6AZ.

[Link]
Required reworking:
Install outer door handle
Install the sound insulation on the door
51 22 090 Removing and installing/replacing the door lock in the left or right
rear door

Necessary preliminary tasks:

Remove outer window cavity cover strip
Partially remove sound insulation at rear door

Removal:

Open side window completely.

Partly release rubber window seal for door window glass (1).
Release screws (2) and carefully feed out the triangular trim (3) upwards and
remove it.

[Link]
Close side window completely.

Important!
Do not damage door lock seal when removing.

Unclip locking rod (1).

Unfasten screws (2).
Disconnect plug connection on door lock (3).
Feed out door lock (3).

Installation:
Replacement:
Remount Bowden cable (1).

Insert door lock and screw in screws (3 and 4).

First tighten screws (3) and then tighten the screw (4) on the door lock (2).
Tightening torque 51 22 1AZ.
Connect plug connection on door lock (2).
Clip in locking rod (1).

[Link]
Required reworking:
Install outer weather strip
Mount sound insulation on rear door
51 22 280 Removing and installing/replacing the door stop in the left or right
rear door

Necessary preliminary tasks:

Partly remove sound insulation

Removal:

Attention!
After disengaging door stop, use suitable means of preventing door
from opening past its maximum permissible opening angle (risk of
damaging paintwork or bodywork).

Feed out gasket (1).

[Link]
Release screw (2).
Loosen screws (3).
Feed out door stop (1) from door and lay it aside.

Installation:

Feed in door stop (1) into the door.

Tighten down screws (3).
Tightening torque 51 22 5AZ.
Tighten screw (2).
Tightening torque 51 22 3AZ.
Install gasket (1).

Required follow-up work:

Mount sound insulation
51 22 330 Removing and installing/replacing the inner weather strip at rear
door

The Instructions on installation of rubber window seals serve as the basis for
these repair instructions and must be observed without fail.

Necessary preliminary tasks:

Remove rear door trim panel

Attention!
Risk of damage!
If weather strip is reused, make sure it is not bent.

[Link]
Removal:

Release weather strip (1) from brackets (2) and pull off upwards.

Installation:
If necessary, remove clamps (2) from weather strip and attach to door.
Replace faulty clamps.
Connect weather strip (1) to door and engage in brackets (2).

Required follow-up work:

Install rear door trim

[Link]
51 22 170 Removing and installing/replacing the outer door handle in the left
or right rear door

Operation is identical to:

Removing and installing or replacing outer door handle from left or right front
door

[Link]
51 22 300 Removing and installing/replacing weather strip on outside of rear
door

Operations identical to:

Removing and installing or replacing weather strip on outside of left or
right front door

[Link]
51 21 ... Removing weather strip with special tool 00 9 324 at front or rear

Special tools required:

00 9 318
00 9 324

Open side window completely.

Front door:
Insert special tool 00 9 324 at front (at A-pillar) in window cavity (1) (TOP
label pointing upwards).

Rear door:
Insert special tool 00 9 324 at rear (at C-pillar) in window cavity (2) (TOP
label pointing upwards).

[Link]
Note:
For purposes of clarity, graphic shows inner door panel and side window
removed.

Special tool 00 9 324 must be correctly guided under weather strip (1).
2 Short leg, bottom
3 Long leg, top (TOP)

Note:
Start at the front or rear, depending on the model.

Important!
Risk of damage!
Raise weather strip (3) no more than 5 mm in each levering operation,
otherwise the strip will be bent.

Position special tool 00 9 318 on door trim panel (1).

Push suitable tool (2) into the bore hole of special tool 00 9 324 and thus
lever out the weather strip (3) maximum 5 mm in upward direction.
Guide special tools 00 9 324 and 00 9 318 forward or backward step by step
until weather strip (3) is fully removed.
51 22 001 Replacing door detent (lock striker), rear left or right

Release screws (1).

Remove lock striker.
Tightening torque 51 22 2AZ.

After installation:
Adjust door detent.

[Link]
51 23 004 Adjusting engine compartment lid catch

Operation is described in:

Adjusting engine compartment lid.

[Link]
51 23 131 Adjusting left or right striker on engine compartment lid

Removal:

Unscrew nuts (1).

Remove striker (2).

[Link]
Installation:

Mount striker (2).

Tighten down nuts (1).
Tightening torque 51 23 1AZ.

Adjusting striker is described in:

Adjusting engine compartment lid
51 23 ... Adjusting/replacing bump stops

The illustrations are schematic representations and are to be applied to the

relevant vehicle type.

Version 1:
Following parts must not be damaged:
(1) Bump stop

[Link]
Adjust bump stop (1) to correct height by turning left or right.

Version 2:
Replace damaged bump stops (refer to EPC):
(1) Bump stop with ejector
Press ejector (1) into bump stop and, in this position, twist approx. 90°
counterclockwise with a Phillips screwdriver.
This locks the ejectors (1) in the bump stops.
Adjust bump stop (2) to correct height by turning left or right.
Unlock the ejector (1) again after completing adjustment.

Version 3:
Replace damaged bump stops (refer to EPC):
(1) Bump stop

[Link]
Turn lock (1) 45° counterclockwise.
Pull bump stop (2) upwards.
Close lid slowly until it is at the same height as the side panel.
Open lid and turn lock (1) clockwise.
Installation:
Press bump stop into panel and drive in expanding pins (3).
51 23 ... Adjusting/replacing bump stops

The graphics are schematic representations and are to be applied to the

relevant vehicle type.
Prerequisite: Lid must be correctly adjusted.

Version 1:
Following parts must not be damaged:
(1) Bump stop

[Link]
Adjust stop pad (1) to correct height by turning left or right.

Version 2:
Replace damaged stop pads (refer to EPC):
(1) Bump stop
Adjusting version 2:
Stop (1) 45° anticlockwise.
Pull stop pad (2) upwards.
Close lid slowly until it is at the same height as the side wall.
Open flap and turn stop (1) clockwise.
Installation note:
Press stop pad into panel and drive in expanding pins (3).

Version 3:
Lever out expanding rivets (1).
Remove stop pad (2).

[Link]
Adjusting version 3:
Checking correct adjustment:
Insert a strip of paper (normal writing paper) between stop pad and limit
position on body.
Close flap. Make sure that the paper strip remains between stop pad
and limit position.
The stop pad is correctly adjusted when the paper strip can be pulled
out ”with slight resistance”.

Adjustment procedures:
Screw in stop pad until the paper strip can be easily pulled out.
Then unscrew stop pad until the paper strip cannot be pulled out any more.
Screw in stop pad until the paper strip can be pulled out with "slight"
resistance.

Version 4:
Lever out expanding rivets (1).
Remove stop pad (2).

Adjusting version 4:
Set stop pad to the correct height by turning to the left or right.
Version 5:
Release screws (1) and remove stop pad (2).

Adjusting version 5:
Set stop pad to the correct height by turning to the left or right.

[Link]
51 23 ... Adjusting/replacing bump stops

The graphics are schematic representations and are to be applied to the

relevant vehicle type.
Prerequisite: Lid must be correctly adjusted.

Following parts must not be damaged:

(1) Bump stop
(2) Catches
Remove adjusting buffer by pressing latch mechanisms back.

[Link]
Screw adjusting buffer (1) until the pin (2) can be pulled out.
Slowly pull the pin (2) out approx. 15 mm.
Slowly close engine compartment lid.
The pin (2) is thus pushed into the adjusting buffer (1).

Raise engine compartment lid.

Unscrew the adjusting buffer (1) until it is flush with the upper edge of the
pin (2).
51 23 110 Removing and installing/replacing left engine compartment lid
lock.

Necessary preliminary tasks:

Remove cross connection

Removal:

Feed out engine compartment lock (1) upwards.

Detach Bowden cable (2) from the counter support (3) first and then from the
lock lever (4).
Unlock associated plug connection and disconnect.
Remove engine compartment lock (1).

[Link]
Installation:

Position engine compartment lock (1).

Attach Bowden cable (2) to lock lever (4) first and then to counter support (3).
Connect associated connector.
Feed in engine compartment lock (1).

Required follow-up work:

Install cross connection
51 23 400 Removing and installing/replacing left or right actuator (active
pedestrian protection)

Warning!
Adhere to the following safety information so as to avoid a danger of
injury by the actuator.
The battery negative lead must be clamped off prior to work on the
actuator or engine compartment lid!
Do not exert any force on the actuator.
Incorrect handling may result in triggering of the actuator and thereby
cause serious injury.

Necessary preliminary work

Disconnect battery earth lead
Remove cowl panel cover

[Link]
Removal

Unfasten plug connection (1) and disconnect.

Release bolt (2) and remove actuator (3).
Comply with notes regarding handling active pedestrian protection.

Installation
Install actuator (3) and tighten bolt (2).
Tightening torque 41 61 3AZ.
Connect the connector (1).

Required follow-up work:

Connect battery earth lead
Installing cowl panel cover

[Link]
51 23 265 Removing and installing/replacing left or right gas pressure spring
for engine compartment lid

Warning!
Danger of injury and damage!
For the following tasks, you must take the appropriate measures to
support the engine compartment lid.
As an alternative, you can enlist the help of a second person to hold the
engine compartment lid.

Removal:

Raise engine compartment lid.

Carry out ball socket removal at both ends (1) of gas pressure spring (2).

[Link]
Set down gas pressure spring (2).

Installation:

Mount gas pressure spring (2).

Carry out ball socket installation at both ends (1) of the gas pressure
spring (2).
Close the engine compartment lid.
51 23 211 Removing and installing/replacing pull cable for hood/bonnet
locks at front

Necessary preliminary tasks:

Remove left/right engine compartment lock

Removal:

Unclip the clutch housing for the Bowden cable (1) from the body in the
highlighted areas.

[Link]
Fold the cover (1) of the clutch housing for the Bowden cable (2) forwards.
Disconnect Bowden cable (3).

Loosen the clutch housing for the Bowden cable (1) from the body.
Feed out Bowden cable (2).
Installation:

Insert the Bowden cable (2).

Clip in the clutch housing for the Bowden cable (1) at the body.

Attach Bowden cable (3).

Fold the cover (1) of the clutch housing for the Bowden cable (2) backwards

[Link]
to close it.

Clip in the clutch housing for the Bowden cable (1) at the body in the
highlighted areas.

Required follow-up work:

Install left/right engine compartment lock
51 23 100 Removing and installing/replacing right engine compartment lid
lock.

Necessary preliminary tasks:

Remove cross connection

Removal:

Feed out engine compartment lock (1) upwards.

Unhook engine compartment lid cable (2) from counter support (3) first then
from lock lever (4).
Remove engine compartment lock (1).

[Link]
Installation:

Position engine compartment lock (1).

Hook engine compartment lid cable (2) into lock lever (4) first then into the
counter support (3).
Feed in engine compartment lock (1).

Required follow-up work:

Install cross connection
51 23 ... Removing/installing ball sockets with clip

Warning!
Danger of injury! When installed, the gas pressurised shock absorber is
under preload. Minimise preload as far as possible before removing.

Important!
Never lift off ball socket with engaged clamp.

Version A:
1. Push on clamp in direction of groove with screwdriver
2. Lift off ball socket from ball pin
3. Slide clamp back
4. Fit ball socket on ball stud and snap into place with force

[Link]
Installation note:
Pack grease into two opposite positions in socket. The grease spreads after
installation on the ball pin all round in the ball socket.

Version B:
Important!
Risk of damage!
If you are not careful, retaining spring (2) may be bent to such an extent
that the entire drive spindle will have to be replaced.

Press drive spindle (1) against ball pin in order to relieve strain on retaining
spring (2) at ball pin.
Pull out retaining spring (2) approx. 2-3 mm with screwdriver (3).
Pull off spindle foot.

Warning!
Observe warning notices on the damper.
Electrical spindle drive for tailgate is under mechanical spring load!
The component must be secured against falling down.
Attention!
Risk of damage!
Do not press on spindle drive at an angle or twisted.
Installation note:
Press ball socket (1) onto ball pin (2) until retaining spring (3) engages
correctly (clicking sound).

Important!
If retaining spring (4) is damaged!
Release pin (1).
Remove spindle drive (3).
Remove ball socket (2).
Remove retaining spring (4) and replace if necessary.

[Link]
51 24 ... Adjusting opening height of automatic luggage compartment lid
actuation (automatic tailgate activation)

Note:
For more information, see operating instructions.
Graphics may vary depending on the vehicle.

Select menu item "Settings - Tailgate" via controller.

[Link]
Use the controller to select "Opening Height Power tailgate".
51 24 004 Adjusting rear lid lock

Prerequisite:
Tailgate must be correctly adjusted, refer to body gap dimension.

Unclip cover (1).

[Link]
Slacken screws (1) until striker (2) can still just be moved and centres itself.
Close tailgate.
Adjust tailgate to nominal dimension.
Tighten down screws (1).
Tightening torque 51 24 2AZ.
Note:
When the tailgate is closed, the striker must not touch or scrape against the
rear lid lock. Look out for scratch marks.
51 23 ... Adjusting/replacing bump stops

The illustrations are schematic representations and are to be applied to the

relevant vehicle type.

Version 1:
Following parts must not be damaged:
(1) Bump stop

[Link]
Adjust bump stop (1) to correct height by turning left or right.

Version 2:
Replace damaged bump stops (refer to EPC):
(1) Bump stop with ejector
Press ejector (1) into bump stop and, in this position, twist approx. 90°
counterclockwise with a Phillips screwdriver.
This locks the ejectors (1) in the bump stops.
Adjust bump stop (2) to correct height by turning left or right.
Unlock the ejector (1) again after completing adjustment.

Version 3:
Replace damaged bump stops (refer to EPC):
(1) Bump stop

[Link]
Turn lock (1) 45° counterclockwise.
Pull bump stop (2) upwards.
Close lid slowly until it is at the same height as the side panel.
Open lid and turn lock (1) clockwise.
Installation:
Press bump stop into panel and drive in expanding pins (3).
51 24 351 Remove and install/replace spindle drive at right (automatic
tailgate operation)

Work is mirror-identical with:

Removing and installing/replacing left spindle drive

[Link]
51 24 300 Removing and installing or replacing left or right gas pressure
spring for tailgate

Warning!
Danger of injury!
Support tailgate in fully opened position with suitable device.

Make a written record of the alignment of gas strut (2) before removing.
Slide retaining spring (1) to end of gas pressure spring (2) and lever out gas
pressure spring (2).
Repeat the procedure at the other end of the gas pressure spring (2) and
remove.

[Link]
51 24 350 Removing and installing/replacing left spindle drive (automatic
luggage compartment lid actuation)

Warning!
Danger of injury!
Support rear lid in fully opened position with suitable apparatus.

Warning!
In the event of customer complaints:
Rattling when opening and closing
Drive not functioning
Drive is blocked or sluggish
No longer closes or opens
Or if incorrect operation is suspected:
Rear lid was closed with excessive exertion of force
Bent, broken piston rod
Broken ball head
The compression spring must be secured against unintentional

[Link]
sudden release.

Warning!
Observe warning notices on the damper.
Electric spindle drive for rear lid is under mechanical spring bias!
The component must be secured against falling down.

Attention!
Risk of damage to spindle drive!
If the spindle drive has been electrically disabled (e.g. connector
unplugged), the tailgate must only be moved slowly by hand.

These repair instructions are based on the disassembly and installation of

ball sockets with clamp.

Necessary preliminary tasks:

Determine and note down opening height of automatic luggage
compartment lid actuation
Set tailgate to the max. opening angle. The spindle drive may only
be removed or installed when the tailgate is open to the maximum.

Removal:
Feed the rubber grommet (1) including wiring harness out.
Disconnect plug connection (2).

Unclip spindle drive (2) from ball sockets (1) and remove.

[Link]
Installation:

Engage spindle drive (2) at ball sockets (1).

Connect plug connection (2).

Feed in rubber grommet (1) together with wiring harness.
Note:
The rubber hose with rubber grommet (1) of the spindle drive (2) must not be
damaged or missing. Install rubber grommet (1) correctly to prevent water
penetration.
Concluding tasks:
Initialise automatic operation of tailgate using the service function in the
diagnosis system.
Selection via:
Body
Automatic tailgate operation
Power tailgate initialisation
Check the opening angle setting of the tailgate and restore the customer
setting, if necessary.

[Link]
51 24 130 Removing and installing/replacing striker for tailgate lock

Necessary preliminary tasks:

Remove rear lid trim panel

Removal:

Loosen the screws (1) and remove the striker (2) including the associated
mounting plate.

[Link]
Installation:

Position the striker (2) and the associated mounting plate.

Tighten down screws (1).
Tightening torque 51 24 2AZ.

Required reworking:
Adjust rear lid lock
Installing the tailgate trim panel
51 24 105 Removing and installing/replacing tailgate lock

Necessary preliminary tasks:

Remove top cover from tail panel

Removal:

Release screws (1).

Disconnect plug connection (2).
Dismount tailgate lock (3).

[Link]
Installation:

Mount tailgate lock (3).

Connect plug connection (2).
Tighten down screws (1).
Tightening torque 51 24 1AZ.
Note:
Perform a function check of tailgate lock with the tailgate open.

Required follow-up work:

Mount top trim on tail panel
51 23 ... Removing/installing ball sockets with clip

Warning!
Danger of injury! When installed, the gas pressurised shock absorber is
under preload. Minimise preload as far as possible before removing.

Important!
Never lift off ball socket with engaged clamp.

Version A:
1. Push on clamp in direction of groove with screwdriver
2. Lift off ball socket from ball pin
3. Slide clamp back
4. Fit ball socket on ball stud and snap into place with force

[Link]
Installation note:
Pack grease into two opposite positions in socket. The grease spreads after
installation on the ball pin all round in the ball socket.

Version B:
Important!
Risk of damage!
If you are not careful, retaining spring (2) may be bent to such an extent
that the entire drive spindle will have to be replaced.

Press drive spindle (1) against ball pin in order to relieve strain on retaining
spring (2) at ball pin.
Pull out retaining spring (2) approx. 2-3 mm with screwdriver (3).
Pull off spindle foot.

Warning!
Observe warning notices on the damper.
Electrical spindle drive for tailgate is under mechanical spring load!
The component must be secured against falling down.
Attention!
Risk of damage!
Do not press on spindle drive at an angle or twisted.
Installation note:
Press ball socket (1) onto ball pin (2) until retaining spring (3) engages
correctly (clicking sound).

Important!
If retaining spring (4) is damaged!
Release pin (1).
Remove spindle drive (3).
Remove ball socket (2).
Remove retaining spring (4) and replace if necessary.

[Link]
51 24 147 Replace button for tailgate activation

Special tools required:

00 9 327

Attention!
Disassembly of the button is not possible without destroying it.
To avoid water ingress, the button must be replaced every time after
disassembly.

Place special tool 00 9 327 at areas (A) between tailgate and button (1).
Destroy retaining tabs (2) in areas (A) by striking special tool 00 9 327 .
Pull out button (1) from latch mechanisms (2) in area (B).
Disconnect associated plug connections and remove button (1).
Installation note:
Check tailgate for damage, touch up if required.

[Link]
Perform function check with tailgate open.

Version with rear view camera:

Remount the rear view camera.
51 31 ... General procedure for the disassembly and installation of
bonded window glass
1 General information
Follow general instructions on window bonding.
Materials needed for window bonding.
The vehicle can be towed away or driven without a windscreen, rear window and side window.
When carrying out disassembly/installation work and during the hardening time, the vehicle must be standing on its
wheels on a level surface.
The windscreen, rear window and side windows are glued to the body. This bonding will increase the torsional
rigidity of the vehicle. To obtain perfect bonding, comply with the installation procedure described in the following.
2 Disassembly
2.1 Disassembly in general
The following dismantling methods are applied, according to the version:
Oscillating knife (not permissible for vehicles with window bonding on carbon body components)
Cutting wire with wire pull handles

[Link]
"Spider" window glass removal system (unsuitable for severely damaged window glass)

Note:
When cutting out the window glass with wire pull handles, there is a risk of damage to the window glass if the
wire is pulled over the window edge.
Unless otherwise described, only use this method when replacing the window glass.

Follow the vehicle-specific repair instructions!

2.2 Disassembly of damaged window glass
The disassembly method described in the REP may be unsuitable depending on the degree of damage.
e.g. suction cups cannot be attached to window glass around cracks
Damaged window glass may damage and tear the nylon string
Attention! Risk of damage!
Use one of the other disassembly methods at your own discretion in the event of severely damaged window glass.
Make sure adjacent components are adequately protected.
3 Installation
3.1 Preparation
Position the windscreen or rear window on a universal work top or secure the components on a tool trolley using
suction lifters.
Attach two suction lifters to the outsides of the window glass in the event of storage on a universal work top.
According to its size, fix side and door window glass onto the tool trolley using suction lifters or special tool 51 3 220
and set down on a suitable support.
Always keep the suction faces of the window glass suction lifters dry and clean.
Note:
If accessibility is restricted, insert the window glass on a trial basis.
 Bond two yellow plastic adhesive tapes (1) approx. 400 mm in
length to the roof.
(A) = 250 mm
Only the yellow plastic adhesive tape may be used to fix the window
glass.
The glass will slip down if other adhesive tapes are used.
Window glass slippage will result in leaks and wind noises.
After completing the paint work, the paint must be fully hardened
before the plastic adhesive tapes are applied.

3.2 Pre-treatment of bonding surfaces

Protect the vehicle interior against contamination, cover the Head‐Up Display.
Clean window glass and body aperture (with residual adhesive bead) with cleaning agent R2
Attention! Do not use Sika remover 208 for cleaning in the adhesive area.
Observe an air drying time of at least 5 minutes (at least 15 minutes when applied to residual adhesive bead)
Remove residual adhesive bead from body and window glass (see point 3.3)
Touch up paintwork damage to body aperture with BMW multibase filler (except for carbon body components)

[Link]
Pretreatment on new body component (no residual adhesive beads present):

Surface Pretreatment
Panel painted Wipe cleaning agent R1 dry with a paper towel or observe the air drying time of
at least 1 minute
Carbon Only cleaning agent R2
Carbon painted (e.g. roof outer Wipe cleaning agent R1 dry with a paper towel or observe the air drying time of
skin M3) at least 1 minute
Plastic (e.g. I01 A-pillar) Cleaning agent R2 and ScotchBrite Multiflex abrasive pad

3.3 Remove adhesive residue from the body and window glass

Do not remove residual adhesive bead (1) until shortly before

bonding.
Use the pitchweld scraper to remove the residual adhesive
bead (1) from the body aperture and window glass (3).
Position the pinchweld scraper (2) as shown and remove the
residual adhesive bead (1) up to a thickness of approx. 0.5 mm.
Attention!
Carbon body components are not to have scratches with a depth
greater than 0.2 mm.
Note, comply with life module check!

3.4 Installation of spacer (spacer buffer / dual-lock tapes)

Completely remove all residue of existing spacers before bonding new adhesive spacers.
The exact position of the spacers must be retained (see vehicle-specific repair instructions).
Incorrectly fitted spacers will result in:
Window glass breakage due to tension
leakage (if the spacer is in the adhesive area)
 Wind noises
3.5 Add-on part
Depending on the version, attach sealing, expanding foam tape, rain sensor, etc.
Observe Overview of additional work with rain sensor when working with versions including the rain sensor!
Follow the vehicle-specific repair instructions!
3.6 Pre-treatment of new window glass
Apply a thin coat of glass activator (yellow stick); a final wipe is not necessary.
Observe an air drying time of at least 2 minutes
The glass activator is used for adhesion between glass or ceramic glass and the adhesive. Therefore, a thin,
homogeneous and continuous line of glass activator must be applied. If the window glass is to be reused with a cut-
back adhesive bead, glass activator is not needed.
It must be guaranteed that a 1 to 2 mm wide line of glass activator is located on the ceramic glass next to the
squeezed adhesive bead.
The adhesive bead may become up to 15 mm wide in compressed condition. The width of the glass activator is
therefore normally a minimum of 17 mm for windscreens and rear windows and a minimum of 9 mm for side
windows.
The glass activator may not be applied in the field of view or the point grid. Fresh glass activator in the field of view

[Link]
must immediately be wiped off with cleaning agent R2 because hardened glass activator will leave a haze behind.
3.7 Version with inspection glass for vehicle identification number in windscreen

Foam tape (2) must be installed to protect the vehicle identification

number (1) against tampering. If necessary, install foam tape
07 14 7 222 909.
Close off the inspection glass on the windscreen (bottom left) with
Sika bonding base VP 206.
Except for:
All US/GB models
All models with a black dashboard cover, which means that
the vehicle colour cannot be seen through the inspection glass

3.8 Nozzle preparation

Use the standard nozzle C for windscreens, rear windows, and

body-specific fixed side window glass.

A 8 ±1 mm
B 12 ±1 mm

Prepare plastic nozzle for fixed door window glass.

A 8 ±1 mm
B 15 ±1 mm

Deviations are described in the vehicle-specific repair instructions.

Black ceramic glass impermeable to UV light is located on the peripheral zone of the inside of the window to protect
the adhesive bead.
Ceramic glass must not be damaged.
3.9 Apply adhesive
Adhesive is applied to the window glass using a cartridge gun.
Glue cartridge must be vertical to window glass.
The almost vertical part of the adhesive bead must be facing the outer window glass edge.
On window glass with guidelines, the adhesive bead must be applied centrally between the guidelines.
On window glass without guidelines, the position of the adhesive bead is specified in the vehicle-specific repair
instructions.
Coat bead joint.
Effect of differing adhesive quantities:

Too little adhesive: Too much adhesive:

Window glass rests too low in body Window glass rests too high in body aperture
aperture Wind noise may occur
Insufficient squeezing of adhesive Strains/tensions may occur (window glass breakage)
bead (leaking)
Dirt contamination of add-on parts by emerging adhesive
Adhesive on uninsulated strainer pressure lines of aerial(s)
(interference of reception)

[Link]
Note on bonding of windscreen:
The adhesive amount specified in the vehicle-specific repair instructions is sufficient if the specified adhesive bead
size is maintained.
If too much adhesive is applied due to application-related variations (manual application), the specified adhesive
amount may not be sufficient. To avoid interrupting adhesive application for longer than the permitted period, have
another glue cartridge ready.
Attention!
Once the adhesive bead has been applied, the window glass must be installed within 7 minutes (depending
on air humidity, temperature).
After 7 minutes the adhesive bead forms a skin which can no longer guarantee a perfect bond.

3.10 Mounting the window glass

To prevent a pressure build-up in the passenger compartment when the doors are closed:
Open a side window

Mount window glass (1) with suction lifter (51 3 010).

3.11 Adjusting the window glass

 To avoid wind noise, the front and rear windows (1) must be lower
than the roof outer skin (2).
Check ride height of the windscreen or rear window using special
tool 51 0 010.
Dimension (A) of window glass offset, refer to vehicle-specific
repair instructions.
X = measurement stages 1 ... 4 mm

3.12 Fixing the window glass

Fix the window glass with yellow plastic adhesive tapes (2).
Immediately remove dirt contamination with adhesive residue using
Sika remover 208. Do not press out the window glass again.
Hardened adhesive can only be removed mechanically.

[Link]
3.13 Label
Depending on version, apply label.
51 31 ... Materials for bonding window
Special tools required:
51 3 220

1 Tools

Type Type Order/part number

Electric special cutter SuperCut FSC 1.6Q 81 43 2 296 987
Knife set 81 43 9 428 596
Contains:
Knife (U-shape) 24 / 36 / 45 mm
Knife (L shape) 25,4 mm
Knife (straight with stop roller) 16 to 43 mm (adjustable)
14 mm (fixed)
”Roll Out 2000” Wire cutting system 81 62 0 301 768

[Link]
"Spider" Cutting system with nylon string 81 43 2 357 248
Wire pull handles 81 43 2 326 501
Cartridge gun 81 49 2 213 059
Pinchweld scraper set 81 62 0 410 436
Siphon 81 64 2 184 377
Single suction cup Special tool 51 3 220
Universal work table 81 49 0 151 675

2 Consumables:

Naming of Electronic Parts Designation, repair BMW part number

Catalogue instructions /addition
Window glass repair kit, cold, Small repair kit 83 19 2 289 285
1 hour
83 19 2 289 180 (US)
83 19 2 180 001 (China)
Window glass repair kit, cold, Large repair kit 83 19 2 360 680 (not available for
1 hour the US/China)
Like small repair kit,
plus 1x window glass adhesive 300 ml
Cutting wire for glass repair Cutting wire, square 83 19 2 150 267
Nylon string Nylon string 81 43 2 344 272
Multi-base filler BMW multibase filler
Cleaning agent R1 Cleaning agent R1 83 19 2 211 217
Cleaning agent R2 Cleaning agent R2 83 19 0 417 324
Adhesive tape Plastic adhesive tape, yellow 83 19 9 410 979
Adhesive cleaner 208 Sika remover 208 83 19 9 407 780
Aktivator 205 Sika Activator 205 83 19 0 030 155
(e.g. for rubber frame on windscreen)
Bonding base VP 206 Sika bonding base VP 206 83 19 9 407 777
(e.g. for inspection glass for vehicle
identification number)

Storage of all consumables

Dry at 15 ° - 25 °C.

[Link]
51 31 ... Notes on window bonding repair kit
Part number Part Part
number (US) number (China)
Small repair kit 83 19 2 289 285 83 19 2 289 180 83 19 2 180 001
- Window glass adhesive 300 ml 83 19 2 289 286 83 19 2 289 181 83 19 2 180 002
- Glass activator 83 19 0 444 142
- C nozzle 83 19 2 155 589
- Plastic nozzle and paper tissue
Large repair kit 83 19 2 360 680 Not available Not available
(Contains an additional window glass adhesive
300 ml)

Important!
Before working with the consumables, note the following information.
Country-specific safety and industrial safety regulations
Material safety data sheet of manufacturer
Processing instructions on the packaging

[Link]
1 Storage and processing of all consumables
Dry at 15 ° - 25 °C.
2 Expiry date of adhesive:
Repair kit and glue cartridges are marked with a date (expiry).
Date (1) refers to the calendar week and year (KW/JJJJ).
The adhesive cannot be used after this date (1).

3 Hardening of adhesive:
The adhesive hardens by reacting with air humidity at room temperature.
Important!
Once the adhesive bead has been applied, the window glass must be installed within 7 minutes (depending
on air humidity, temperature).
After 7 minutes the adhesive bead forms a skin which can no longer guarantee a perfect bond.

At ambient temperatures above 23 °C and 50 % relative air humidity (hot countries), the adhesive open time is
shortened to approx. 5 minutes (skin formation time).
A relative air humidity of < 30% significantly slows hardening.
The adhesive hardening process is interrupted completely at ambient temperatures below 5 °C. In this event, there
will be no increase in the strength of the bonded connection.
3.1 Minimum hardening time:
Minimum hardening time is reached beginning at 22 °C and 38 % relative air humidity.
1 hour, vehicles without front passenger airbag (after which vehicle can be moved)
2 hours, vehicles with front passenger airbag in countries without mandatory seat belt usage
Note:
In vehicles with front passenger airbag in countries without mandatory seat belt usage:
The vehicle can be transferred to the customer after a 1-hour hardening time with the following warning:
Once the windscreen glass has been bonded, all occupants must travel with their seat belts
attached for 1 hour.

Important!
If the minimum hardening time is not adhered to, an accident can cause the passenger together with the
windscreen to fall out of the vehicle after the front passenger airbag deploys.

[Link]
During the minimum hardening time of 1 hour, the vehicle must not be subjected to load on one side such as e.g.:
one wheel on kerb
vehicle hoist
etc.
Manoeuvring inside garage/workshop:
only permitted on level ground
do not under any circumstances drive over approach ramps, e.g. into multi-storey car parks
Do not remove adhesive tapes until after hardening time.
If the minimum hardening time of 1 hour is undercut, leaks and wind noises may occur at the window glass.
4 Disposal of adhesive:
Hardened adhesive is disposed of as normal waste.
Non-hardened adhesive, glue cartridge and mixtures of adhesive and solvents and the like must be disposed of as
hazardous waste.
The adhesive is disposed of in paper sacks so that it can react with moisture.
5 Glass activator:
Warning!
Wear cut resistant gloves when breaking the glass ampule.

Prepare glass activator for processing by shaking and snapping (breaking glass ampoule).
Apply glass activator by pressing gently. There is no need for final wiping. Air drying time approx. 2 minutes.
6 Expiry date of glass activator:
Repair kit and glass activator are marked with a date (best before date).
The glass activator may only be used up to this date (if not already opened previously).
After opening, keep only for one week even if the expiry date has not yet been reached.
7 Disposal of glass activator:
Glass activator must not be disposed of as part of household waste.
Glass activator must be disposed of as hazardous waste.

[Link]
61 35 ... Overview of additional work for the removal and installation
or replacement of electronic components in the body area/windscreen
Component Removal and Removal Replacement Replacement Remarks
installation and
installation Programming/encoding Use of the
Calibration/Initialisation
required Use of the Calibration/Initialisation Special tool
required
(diagnosis system Special tool necessary
must be connected) (diagnosis system
necessary must be connected)
Front section:
(including bumper
panel)
Park Distance No No No No
Control ultrasonic
sensor
Parking No No No No
Manoeuvring
Assistant
ultrasonic sensor

[Link]
Active pedestrian No No No No Must be
protection sensor replaced
after the
active
pedestrian
protection
has been
activated!
Impact
absorber
must also be
replaced!
Active pedestrian No No No No Must be
protection actuator replaced
after the
active
pedestrian
protection
has been
activated!
Rear area:
(including bumper
panel):
Rear view camera No No Yes No
Park Distance No No No No
Control ultrasonic
sensor
Windscreen:
KAFAS camera no* No no* No *Necessary
after
replacement
of the
windscreen
Camera-based no* No Yes No *Necessary
driver support after
systems camera replacement
of the
(F60 only) windscreen
Rain sensor
(separate
document)

[Link]
61 35 ... Overview, rain sensor (additional work when replacing the
windscreen / sensor replacement)
1-Series: E8x
3-Series: E9x
5-Series: E6x
6-Series: E6x
X1: E84
Z4: E89

Sensor type/ With windscreen When replacing When replacing Connecting the diagnosis
replacement system
Sensor shape the sensor/ the sensor/
replacement sensor required
Programming/encoding Initialisation
required required
necessary
Condensation Yes No No No
sensor
square
30 x 20 mm

[Link]
5-Series: E6x
6-Series: E6x
7-Series: E6x

Sensor type/ With windscreen When replacing When replacing When Connecting
replacement replacing the
Sensor shape the sensor substitute visuals diagnosis
replacement sensor the system
Programming/encoding Programming/encoding sensor/
required required
necessary necessary substitute
visuals
Initialisation
required
all types No Yes - Yes Yes
square
60 x 40 mm
RLS No - No Yes Yes
approximately (new substitute
ø 50 mm visuals required,
refer to Electronic
Parts Catalogue)

X5: E70
X6: E7x
Sensor type/ With When replacing When replacing When Connecting
windscreen replacing the
Sensor shape replacement the sensor substitute visuals diagnosis
the system
replacement Programming/encoding Programming/encoding sensor/
sensor required
required necessary necessary substitute
visuals
Initialisation
required

RLPSS (Rain, light Yes Yes - Yes Yes

and precipitation
solar sensor)
(Designation is
located on the back
of the sensor)
approximately ø
50 mm
RLS (vehicle with No - No Yes Yes
no HUD)
(new

[Link]
(Designation is substitute
located on the back visuals
of the sensor) required,
approximately ø refer to
50 mm Electronic
Parts
Catalogue)
RLSS (vehicle with Yes Yes - Yes Yes
HUD)
(Designation is
located on the back
of the sensor)
approximately ø
50 mm

1-Series: E8x
3-Series: E9x
X1: E84
X3: E83
Z4: E89

Sensor type/ With windscreen When replacing the When replacing the Connecting the
replacement sensor sensor diagnosis system
Sensor shape
replacement sensor Programming/encoding Initialisation required
required required
necessary
all types No Yes Yes Yes
square
60 x 40 mm

5-Series: F1x
5 Series GT: F07
6-Series: F06, F1x
7-Series: F0x
 X3: F25
X4: F26

Sensor type/ With windscreen When replacing the When replacing When Connecting
replacement sensor replacing the
Sensor shape substitute visuals diagnosis
replacement sensor Programming/encoding the system
required Programming/encoding sensor/
necessary required
necessary substitute
visuals
Initialisation
required
all types No No - Yes Yes
approximately
ø 35 mm
all types Yes Yes - Yes Yes
approximately
ø 50 mm
Only for F25 : No - No Yes Yes

[Link]
RLS (new substitute
visuals required,
approximately
ø 50 mm refer to Electronic
Parts Catalogue)

X5: F15, F85

X6: F16, F86

Sensor type/ With windscreen When replacing the When replacing the Connecting the
replacement sensor sensor diagnosis system
Sensor shape
replacement sensor Programming/encoding Initialisation required
required required
necessary
all types No No No No
approximately ø
35 mm

1-Series: F2x
2-Series: F2x
3-Series: F3x, F8x
3 Series GT: F34
4-Series: F3x, F8x

Sensor type/ With windscreen When replacing the When Connecting the
replacement sensor replacing the diagnosis system
Sensor shape sensor
replacement Programming/encoding required
sensor required Initialisation
necessary required
all up to 03/2014 except SBS No No Yes Yes
(01)
(Designation is located on the
back of the sensor)
approximately ø 35 mm
SBS (01) No No No No
(Designation is located on the
back of the sensor)
approximately ø 35 mm
All as from 03/2014 No No No No
approximately ø 35 mm

2-Series: F4x

Sensor With windscreen When replacing the When replacing the Connecting the diagnosis
type/ replacement sensor sensor system
Sensor replacement sensor Programming/encoding Initialisation required required
shape required
necessary
all types No No No No

BMW i:

Sensor type/ With windscreen When replacing the When replacing the Connecting the
replacement sensor sensor diagnosis system

[Link]
Sensor shape
replacement sensor Programming/encoding Initialisation required
required required
necessary
all types No No No No
approximately ø
35 mm

BMW from G series

Sensor With windscreen When replacing the When replacing the Connecting the diagnosis
type/ replacement sensor sensor system
Sensor replacement sensor Programming/encoding Initialisation required required
shape required
necessary
all types No No No No

MINI (all):

Sensor type/ With windscreen When replacing the When replacing the Connecting the
replacement sensor sensor diagnosis system
Sensor shape
replacement sensor Programming/encoding Initialisation required
required required
necessary
all types No Yes Yes Yes
square
60 x 40 mm
all types No No No No
approximately ø
35 mm

Rolls-Royce:
RR1
RR2
 RR3
RR4
RR5
RR6

Sensor type/ With windscreen When replacing the When replacing the Connecting the
replacement sensor sensor diagnosis system
Sensor shape
replacement sensor Programming/encoding Initialisation required
required required
necessary
all types No Yes Yes Yes
square
60 x 40 mm
all types No No Yes Yes
approximately ø
35 mm
all types Yes Yes Yes Yes
approximately ø
50 mm

[Link]
Rolls-Royce:
RR11
RR12

Sensor type/ With windscreen When replacing the When replacing the Connecting the
replacement sensor sensor diagnosis system
Sensor shape
replacement sensor Programming/encoding Initialisation required
required required
necessary
all types No No No No
approximately ø
35 mm
51 31 ... Remove windscreen with "Roll Out 2000"

Special tools required:

2 150 267

"Roll Out 2000" has been replaced by the "Spider" removal system."Roll Out
2000" may still be used. The "Spider" removal system is recommended for
removing window glass.

"Roll Out 2000" window glass removal system

[Link]
1 Wire starter 8 Extension (short)
2 Parabolic tool 9 Extension (long)
3 Plastic washer 10 Reversible ratchet
4 Wire cutting roller 11 Plastic wedge
5 Suction cup lifters 12 Guide needles
6 Protective gloves 13 Suction cup lifter with double spool
7 Safety goggles

Note:
Both paint and ergonomic and health-endangering damage is minimised with
the "Roll Out 2000" system.
Sourcing reference:
See Aftersales Assistance Portal (ASAP) - Service/Technical - Workshop
Equipment (Start BMW) - Shop Workshop Equipment or at
[Link]
 Warning!
Follow safety instructions for working on vehicles with airbag systems
(risk of injury).

Important!
Take care when handling sharp-edged tools and cutting wire (risk of
damage to head airbag and window glass).

Important!
Always keep both suction cups dry and clean to ensure their optimum
adhesion on the windscreen.
Suction cup may not be applied at the damaged point (crack in window
glass).
Lubricate spool if lock rattling becomes too loud.
Always wear safety goggles and protective gloves for your own safety.

Mounting suction cup lifters on windscreen or rear window:

[Link]
Secure position of lifting jacks as shown (view from outside):
1. Suction cup lifter with double spool
2. Suction cup lifter with single spool (as deflecting point)
3. Window
4. Cutting wire
Note:
Optimum cutting is guaranteed when the cutting wire is at an acute angle to the adhesive bead. There is a risk of the cutting wire
breaking if the angle is too obtuse.
The suction cup lifter (2) is used as the deflection point to achieve the corresponding angle.
Depending on the window glass version and the effort applied during cutting, it may be necessary to change the deflection point
during cutting.
The suction cups without a spool can even be used as the deflection point.
 [Link]
Preparatory work:
Cut off required cutting wire length:
Length approximately = 6 x window glass diagonal
The cutting wire loops must lie on top of each other in area (B).
They must not get caught up in each other. (Otherwise no possibility of cutting the adhesive bead/wire will break.)
Overlapping of cutting wire loops approx. 10 cm.
Distance from right window edge approx. 30 cm.

Pulling cutting wire into vehicle:

Grip wire with pliers
(If accessibility is bad, stick wire with wire starter 2 150 267 through
adhesive bead.)
Wire end (1) must be bent towards window glass.
Heat wire end (1) and use it to pierce adhesive bead (2).
Pull the wire approximately 1.5 m into the passenger compartment

Using wire starter:

Bend wire end approx. 10 mm and insert in notched tip.
Pierce wire starter with uniform pressure through adhesive bead, wire end
(bent part) must be positioned on window glass.
Laying cutting wire around window glass:
Starting from pull-in point, lay wire eyelet created on the outside around
the window glass
Pull excess wire into passenger compartment
Important!
Make sure the cutting wire is located at all four corner points below the
window glass.
Check that the cutting wire is not caught on clamps or body.
Secure window glass on outside with adhesive tape against sliding.

Note:
Window glass (1) with installed seals (3) or moulded-on surrounds:
Moisten cutting wire (4) and seals (3) on window glass (1) with water
Insert cutting wire (4) in bend (without kinking) between window glass(1)
and body aperture (2)

[Link]
Protect the passenger compartment:
To avoid damage and possible dirt contamination, protect A-pillars,
roof and dashboard trim panel (3) by means of plastic washer (1)
Always carry plastic washer (1) between respective wire (2) being
tightened and trim panels

Attaching wire in hoisting winch with double coil:

Bend over cutting wire end (1) approximately 10 mm and insert into slot
of spool (2)
Repeat process with other end of wire (1) and second spool (2)
Wind cutting wire (1) onto spools by hand until cutting wire (1) is under
slight tension
Starting the dismantling: Note:
Spools can only be rotated in one direction.

Make sure the wire is always situated in the guide channel of the suction
cup lifter (1)
Fit reversible ratchet onto top spool shaft (2) and tighten wire
Start by cutting lower adhesive bead
At the end of the cutting process, the two wire loops join up at the lifting
winch (1)
Remove "Roll Out 2000"
Remove window glass

[Link]
51 31 030 Removing and installing or replacing left or right gutter strip along
windscreen

Removal:

Unclip the gutter strip (1) upward from the clips (2) beginning with the roof.
Feed gutter strip (1) out of the guide (3).
Important!
Replace gutter strip (1) after each dismantling.
Exception: New gutter strips (1) may only be removed once for
correcting the position.

[Link]
Installation:

Note:
Replace faulty clamps (2).

Feed in the gutter strip (1) correctly with guide (3).

First, align gutter strip (1) with the roof, then clip it in.
51 31 000 Removing and installing windscreen

Up until this point, the work is identical to "Replace windscreen" .

Rain/light/solar sensor and/or camera remain on the windscreen; only
disconnect the plug connections
Replace the cover / windscreen rubber surround only in the event of
damage.
Replace expanding foam tape only if damaged.

[Link]
51 31 200 Removing and installing/replacing rear window

Attention!
The following notes form the basis for these repair instructions and must
be adhered to at all times:
Notes on window bonding
General procedure for dismantling/installation of affixed window
glass

When reusing the rear window:

Avoid damaging lines for heated rear window / -aerial.
Note:
Removal is carried out with Spider.

The following new parts / consumables are required (sourcing reference

BMW Parts Department).

Material Quantity

[Link]
Rear window (with replacement) 1
Spacer buffer 5x5x20 mm 6
Dual Lock/Velcro fastener on rear window 4
Dual Lock/Velcro fastener on tailgate 4
Small repair kit 1

Necessary preliminary tasks:

Remove wiper arm for rear wiper
Remove trim for rear lid

Removal:

Unlock the plugs (1 and 2) and disconnect them.

Release screws (3) and fix all cables to the rear window using adhesive tape.
 Attention!
Tape off body in area of piercing point with fabric adhesive tape (risk of
damage).

Slide string out of Spider at line (1) through the adhesive bead.
Cut out rear window.

Installation:

Installation of spacer buffers/Dual Locks (spacers): Attention!

Spacer buffers and Dual Locks are installed to avoid rear window
breakage.

[Link]
Completely remove remains of faulty spacer buffers (1) and dual
locks (2).
Bond new spacer buffer (1) and dual locks (2) within the marks.
Position of new Dual Locks (2) must be matched to position of Dual
Locks on rear window.
Check water drain (3) for damage and replace if necessary.

Overview of rear window bonding:

a [mm] = Position adhesive bead centrally between the tolerance band

b [mm] = Width adhesive bead 7 ±1
h [mm] = Height adhesive bead 12 ±1

Replace faulty dual locks (1).

Apply bead joint in area (2).
A tolerance band is printed on the ceramic (two dashed lines) that marks the position of the adhesive bead. Place the adhesive
bead centrally on the tolerance band.

Installation note:
Carefully working on rear window with siphon:
install at top
Align sides evenly
align bottom left and right to dimension (A and B)

A (short length) 5 ±1.5 mm

B (distance between rear window and tailgate) 3.5 ±1 mm

[Link]
Connect connectors (1 and 2).
Secure ground cable with screws (3).

Necessary preliminary tasks:

Remove wiper arm for rear wiper
Remove trim for rear lid
51 31 021 Removing and installing/replacing windscreen rubber surround

Special tools required:

51 3 320

Necessary preliminary work:

Remove windscreen

Attention!
The glass activator to pre-treat the area of the windscreen adhesive
bead may not come in contact with the adhesive area of the cover.
The bonding result of the cover is otherwise compromised.
Therefore, the cover must be installed prior to application of the glass
activator.
Following instructions for bonding components with double-sided

[Link]
adhesive tape.

Detach cover (1).

Remove remnants of adhesive tape (2).
Clean bonding surface.
Air drying time: ≥ 1 minute
Attention!
Adhesive area must be dry and free from dust and grease.
Once it has been cleaned, do not touch the adhesive area with bare
hands.

Installation note:
Pre-treat adhesive area with Sika-Aktivator205.
Air drying time: ≥ 1 minute
Sika Activator 205 must not get onto adhesive area of adhesive bead.

Reposition lever (1) and open special tool 51 3 320 .

Pull off protective film (2) in stages from adhesive tape.
Insert cover (1) in guide pulleys (3).

Place special tool with contact rollers (1) up against window edge.
Align cover to window outer edge.
Fit cover and visually check for perfect fit.

[Link]
Reposition lever (1) and close special tool.
Make cover (3) is correctly seated in guide pulleys (2).

Continue to pull off protective film (1) in stages from adhesive tape.
Run special tool with adjuster knob over entire upper window edge.
51 31 ... Removing windows with a "Spider"
Windscreen removal system "Spider"

[Link]
1 "Spider" separation device 6 Line threader
2 Bit holder 7 Line routing tool
3 Operating instructions 8 Suction anchor
4 Dashboard protection 9 Cord for separating adhesive strips
5 Angular transmission

Accessories required for operation (not included):

Cordless screwdriver/drill with at least a 10.8 V Li-ion battery or a 18 V Ni-Cd battery and variable speed.
Note: Always use a low gear setting.

Note:
Damage as well as ergonomic and health-endangering damage are minimised with the "Spider" disassembly
system.
Sourcing reference:
See Aftersales Assistance Portal (ASAP) - Service/Technical - Workshop Equipment (Start BMW) - Shop
Workshop Equipment or at [Link]

Warning!
Follow safety instructions for working on vehicles with airbag systems (risk of injury).

Important!
Handle sharp-edged tools with care (risk of damage to the head airbag and the window glass).
 Important!
Always keep both suction cups dry and clean to ensure their optimum adhesion on the windscreen.
Suction cup may not be applied at the damaged point (crack in window glass).
The bearing bushes of the shaft (spindle) must always be lubricated.
Always wear safety goggles and protective gloves for your own safety.

The procedure for disassembly of the windscreen is described below as an example.

Deviations in the work procedure can be found in the vehicle-specific repair instructions.

General
A cord approx. 6.8 m long is used to cut through the adhesive bead.
The cord length to be used is identified by a short red mark (A) approx. 5 cm.
The part of the cord laid outside around the window glass (approx. 5 m) is
identified with a long red mark (B) (approx. 18 cm).
The marks are applied so that the cord has to be pulled from the inside to the
outside.

[Link]
Preparation

A. Pierce cord from the roller (1) or separation device (2) with cord threader (3) through the adhesive bead from the inside,
protect the area from the inside as required.
B. Pull out cord up to the first red mark (approx. 18 cm long).
C. Lay cord around the window glass, use pulling aid (4) if required.
D. Secure suction anchor (5) outside on window glass, secure cord to suction anchor (5).
If required, unwind cord from roller (1) up to the second red mark (approx. 5 cm long) and cut off.
 Make sure the cord lies below the window glass at all four corners.
Check that the cord is not caught on clamps or body.
Secure window glass on outside with adhesive tape against sliding.

Feeding in the cord on the separation device

[Link]
Normally, the adhesive bead is cut through anticlockwise seen from the passenger compartment.
This means the cord must be fed into the separation device as shown in graphic A.
When accessibility is not optimal, the opposite cutting direction may be required (comply with vehicle-specific repair instructions).
This means the cord must be fed into the separation device as shown in graphic B.
Feed cord into coil and wind it on, at the same time trapping the end of the cord.
When winding the cord, the correct direction of rotation on the separation device must be observed.

Cutting out procedure

 [Link]
Optimum cutting is guaranteed when the cord is at an acute angle to the adhesive bead. There is a risk of the cord ripping
if the angle is too obtuse.
The separation device must be positioned correspondingly to achieve the appropriate angle.

A. Fix separation device (1) on window glass at bottom right.

B. Depending on accessibility, attach bit holder (2) or angle gear (3) to cordless screwdriver (4).
C. Place cordless screwdriver (4) on separation device (1) and start winding cord, observe direction of rotation on separation
device.
If required, over trim panel components with plastic protection.
Guide cord with plastic protection around sharp-edged positions.
Cut through adhesive bead up to bottom area of A-pillar.
Turn back cordless screwdriver (4) approx. 2 rotations and remove.

Cutting out procedure

 [Link]
A. Discharge vacuum on windscreen removal tool (1) by pressing the tab, remove windscreen removal tool (1) from window
glass.
B. Reset removal tool (1) at illustrated and wind up cord up to the position of windscreen removal tool (1).
C./D. Repeat further resetting, work sequence as given at B.

Additional resetting may be required for very curved window glass.

It is possible to reuse the cord. When a cord is used many times the risk of ripping increases.
Dirt contamination must be avoided when a cord is reused.
51 31 ... Removing windows with an oscillating knife

Warning!
Follow safety instructions for working on vehicles with airbag systems
(risk of injury).

Important!
Handle sharp-edged tools with care (risk of damage to the head airbag
and the window glass).

Important!
Follow the vehicle-specific repair instructions!
Always wear safety goggles and protective gloves for your own safety.
Cover the working area (side walls, roof-mounted aerial and if
necessary interior equipment) with protective covers.
Tape off body with fabric adhesive tape (e.g. Tesa) in areas where the
oscillating knife could damage the window glass or the paint.

[Link]
Use suction cups (51 3 010) to lift out the window glass.
Always keep both suction cups dry and clean to ensure their optimum
adhesion on the windscreen.
Secure window glass against falling out.

Depending on the area of application, knife 1 or 2 is used.

(1) Straight knife with adjustable thrust roller
(2) U-shaped knife
Dimension (X) on the knife (1) can be adjusted individually, see vehicle-
specific repair instructions.
Note:
Sharpen knife blade before every use on a running machine with a grinding
stone (even with new knife blade).
Removing from the inside:
Guide knife carefully between body and window glass.
Run blade of knife parallel to glass.
Take care not to damage paintwork.
Cut through adhesive bead all the way around.
Pull window glass outwards to remove.

Removal from outside:

Guide knife carefully between body and window glass.
Run blade of knife parallel to glass.
Take care not to damage paintwork.
Cut through adhesive bead all the way around.
Pull window glass outwards to remove.

[Link]
Cut through adhesive bead as closely as possible to window glass.
(1) Body opening
(2) Adhesive bead
(3) Knife
(4) Window
51 31 011 Replace windscreen

Special tools required:

51 0 010

Attention!
The following notes form the basis for these repair instructions and must be adhered to at all times:
Notes on window bonding
General procedure for dismantling/installing bonded window glass

Removal is carried out with Spider.

The following new parts/consumables are required (sourcing reference BMW Group Parts).

Material Quantity

[Link]
Windscreen 1
Cover, windscreen 1
Gutter strip, left and right 1
Spacer buffer 5x5x20 mm 6
Large repair kit 1
Sika Activator 205 (for windscreen cover) 1
Expanding foam tape 1

Necessary preliminary tasks:

Remove left/right gutter strips
Removing the rear cowl panel cover
Remove inside mirror
Remove trim panel for roof pillar (A‐pillar) left/right

Removal:
Depending on version:
Unplug plug connections (1 to 3).
Remount the rain-light-solar and condensation sensor after having
disassembled the windscreen.
Remove camera.
Note:
Cables torn from the windscreen must not be soldered back in place. The
windscreen must be replaced.

Attention!
Pay attention to cable when cutting in this area.

Attention!
Tape off body in area of piercing point with fabric adhesive tape.

Slide wire along line (1) from the inside through the adhesive bead (2).
Cut out windscreen.

[Link]
Remove the rain/light/solar and condensation sensor and immediately install
on a new windscreen.

Installation:

Fitting spacer buffers (spacers): Attention!

Spacer buffers are installed to avoid windscreen breakage and wind
noises.
Completely remove remnants of removed spacer buffers and maintain
installation location exactly.
Position new spacer buffer centrally on the embossed marks and bond.
 Observe notes on component-bonding with adhesive tape!
Bond expanding foam tape (1) above the inspection glass for the vehicle
identification number (2) parallel to the strip (3) on the windscreen.

Install the cover / rubber frame (1) for the windscreen.

Pre-treat adhesive area with Sika-Aktivator205.

[Link]
Overview of windscreen bonding:

Cut A-A B -B C -C
a [mm] = Position adhesive bead 2 ±2 3 ±1 32 ±2
b [mm] = Width adhesive bead 8 ±1
h [mm] = Height adhesive bead 12 ±1

Apply bead joint in area (1).

Prepare the body and windscreen.
Perform the following steps carefully on the windscreen (1) using suction
cup (51 3 010):
Feed in at bottom of front of engine compartment lid
Position at top
Align sides evenly
press upwards until sealing rests evenly on roof and apply pressure
secure in terms of height in this position at top with two yellow plastic
adhesive tapes (2)

Windscreen gap dimensions:

To avoid wind noises, the windscreen (1) must be lower than the roof outer
skin (2).
Measure the short length (A) on the left and right using special tool 51 0 010 .
Rubber frame (3) must be even and in parallel to roof outer skin (2).
(A) = 3 ± 1 mm

[Link]
Only with camera-based driver support systems:
Carry out camera calibration via diagnosis system.
Under Service Functions menu:
Driver assistance
Camera-based driver assistance systems
Calibration of camera-based driver support systems

Depending on version:
Connect connectors (1 to 3).
Install camera .

Necessary preliminary tasks:

Install left/right gutter strips
Installing the rear cowl panel cover
Install interior mirror
Install left/right trim panel for roof pillar (A-pillar)
51 31 ... Window glass removal with wire pull handle

Special tools required:

2 150 267

Warning!
Follow safety instructions for working on vehicles with airbag systems (risk of injury).
Always wear safety goggles and protective gloves for your own safety.
Attention!
Handle sharp-edged tools with care (risk of damage to the head airbag and the window glass).

Attention!
Follow the vehicle-specific repair instructions!
Protect inner and outer working area (body, trim panels, cables etc.) against damage.

Depending on the area of application, a separating cord can also be used as an alternative to wire.
Using the separating cord prevents any damage to the body.

[Link]
Do not pull the separating cord over any sharp edges (risk of tearing)!

Used tool:
Wire pull handles
Dashboard protection
Wire starter (special tool 2 150 267 )

Use suction cups (51 3 010) to lift out the window glass.
Always keep both suction cups dry and clean to ensure their optimum
adhesion on the windscreen.
Secure window glass (if necessary with adhesive tape) against falling out.
Pulling cutting wire into vehicle:
Grip wire with pliers
(If access is difficult: using wire starter 2 150 267 , feed wire through
adhesive bead.)
Wire end (1) must be bent towards window glass.
Heat wire end (1) and use it to pierce adhesive bead (2).
Pull approximately half of the wire into the passenger compartment

Note:
When using the separating cord, always pull it in using the wire
starter 2 150 267 .

Using wire starter:

Bend wire end approx. 10 mm and insert in notched tip.
Pierce wire starter with uniform pressure through adhesive bead, wire end
(bent part) must be positioned on window glass.

[Link]
Attach wire pull handles:
Feed in cutting wire (1) in cutting handle (2) and clamping element (3) as
illustrated.
Move back cutting handle (2) over clamping element (3) and trap wire
end (4).

Danger of injury!
Wire end (4) must not protrude out of cutting handle (2).

Cutting handle (2) can be secured with suction cup (5) to the vehicle window
or body during each of the work operations. This prevents damage to the
paint.
Fit second wire pull handle to other wire end.

Perform repair work with the aid of a second person.

Cutting wire (4) must be guided in cutting direction at an acute as possible
angle (>45°) to adhesive bead (1).
Cut through adhesive bead (1) by pulling cutting handle (2) and at the same
time providing counter support with cutting handle (3).
Pull back cutting wire (4) with cutting handle (3) and make sure that cutting
wire (4) is always held under tension.
Cut through remaining adhesive bead in the same way.
51 34 211 Remove and install/replace rubber window seal for rear left or
right door window glass

The Instructions on installation of rubber window seals serve as the basis for
these repair instructions and must be observed without fail.

Necessary preliminary tasks:

Remove outer weather strip at rear door
Completely lower fixed side window glass

Removal:

[Link]
Loosen rubber window seal (1) from bracket (2).

Remove rubber window seal (1) sideways from door window frame.
Pull out rubber window seal (1) from window guide rails and remove it.

Installation:
Insert rubber window seal (1) into the guide rail.
Mount rubber window seal (1) on door window frame.

Engage rubber window seal (1) to bracket (2).Note:

Make sure rubber window seals (1) are correctly seated on the door window
frame.

[Link]
Required reworking:
Install outer weather strip at rear door
Close side window completely
51 32 420 Remove and install/replace trim on window frame of front left or
right door

The Instructions on installation of rubber window seals serve as the basis for
these repair instructions and must be observed without fail.

Necessary preliminary tasks:

Open side window
Detach window shaft cover strip from rear area

Removal:

[Link]
Pull rubber window seal (1) out of rear window guide.
Unfasten screws (2).
Feed out cover (3) in upward direction.

Installation:

Feed in cover (3).

Tighten down screws (2).
Mount rubber window seal (1) into rear window guide.
Required follow-up work:
Close door windows
Fasten window shaft cover strip in rear area

[Link]
51 32 170 Removing and installing/replacing door window glass, front left or
right

Necessary preliminary tasks:

Remove sound insulation in front door
Remove weather strip on outside of front door

Removal:

Move door window glass (1) until stop of fixture (2) can be operated.
Push stop of fixture (2) back using a screwdriver and disengage door window
glass (1) upwards.
Rotate door window glass slightly and lift out.

[Link]
Installation:

Rotate door window glass slightly and install.

Engage door window glass (1) in stop of fixture (2).
Note:
Make sure door window (1) is correctly seated on rubber window seal at front
and rear.

Required follow-up work:

Install sound insulation in front door
Mount weather strip on outside of front door
51 32 211 Replace front left or right rubber window seal for left or right side
window

Necessary preliminary tasks:

Remove exterior mirror on front door
Remove front door window glass

Important!
Instructions for installation of rubber window seal are fundamental to this
repair instructions and must absolutely be complied with.

Removal:

Remove sound insulation (1).

[Link]
Completely pull off rubber window seal (2) from door window frame (3).
Feed out rubber window seal (2) from window guide rail and remove.

Installation:
Note:
Coat rubber seal before installation with approved lubricant.

Feed in rubber window seal (2) into window guide rail.

Completely connect rubber window seal (2) to door window frame (3).
Note:
Make sure rubber window seal is correctly seated.

Install sound insulation (1).

[Link]
Required follow-up work:
Install exterior mirror on front door
Install front door window glass
51 33 000 Removing and installing (replacing) power window regulator in
left or right front door

Necessary preliminary tasks:

Remove sound insulation
Release door window at front

Note:
Disengage (but do not remove) door window glass and secure in door
window frame.

Removal:

Unfasten plug connection (1) and disconnect.

Release nuts (2) and feed out power window regulator (3).

[Link]
Installation:
Replacement
Remount flat motor for power window regulator.

Feed in power window regulator (3) and tighten nuts (2).

Tightening torque 51 33 2AZ.
Connect and lock plug connection (1).

Required follow-up work:

Engage front door window glass
Install sound insulation
67 62 000 Removing and installing or replacing flat motor for front left or
right power window regulator

Necessary preliminary tasks:

Remove front power windows

REMOVAL:

Release screws (1).

Detach flat motor (2) from power window regulator (3).

[Link]
INSTALLATION:

Note:
Diagram similar.
Make sure drive shaft (2) is correctly seated in mounting (1) at power window
regulator (3)!
Ensure that the flat motor (2) is assembled without tension.
Position flat motor (2) correctly on power window regulator (3).
Tighten down screws (1).
Tightening torque 51 33 4AZ.

Required reworking:
Install front power window regulator

An initialisation must be carried out in order to activate anti-trap mechanism.

Read and comply with notes on initialisation of power window regulator.

[Link]
51 34 211 Remove and install/replace rubber window seal for rear left or
right door window glass

The Instructions on installation of rubber window seals serve as the basis for
these repair instructions and must be observed without fail.

Necessary preliminary tasks:

Remove outer weather strip at rear door
Completely lower fixed side window glass

Removal:

[Link]
Loosen rubber window seal (1) from bracket (2).

Remove rubber window seal (1) sideways from door window frame.
Pull out rubber window seal (1) from window guide rails and remove it.

Installation:
Insert rubber window seal (1) into the guide rail.
Mount rubber window seal (1) on door window frame.

Engage rubber window seal (1) to bracket (2).Note:

Make sure rubber window seals (1) are correctly seated on the door window
frame.

[Link]
Required reworking:
Install outer weather strip at rear door
Close side window completely
51 34 420 Removing and installing/replacing cover on window frame of rear
door (front), left or right

The Instructions on installation of rubber window seals serve as the basis for
these repair instructions and must be observed without fail.

Necessary preliminary tasks:

Open rear side window
Remove weather strip from rear door

Removal:

[Link]
Pull off rubber seal (1) and rubber window seal (2) from trim (3).
Release screws (4).
Feed out trim (3).

Installation:

Feed in cover (3).

Tighten down screws (4).
Fit rubber seal (1) and rubber window seal (2) onto trim (3).
Note:
Make sure rubber window seal (2) is correctly seated on cover (3).
Required follow-up work:
Close rear side window
Install weather strip onto rear door

[Link]
51 34 425 Removing and installing/replacing trim on window frame of rear
left or right door

Necessary preliminary tasks:

Remove window cavity weather strip
Open side window completely.

Removal:

Partly loosen rubber window seal for door window glass (1) and pull out of
window guide rail.
Unfasten screws (2).
Move fixed side window glass upwards by approx. 3 centimetres.

[Link]
Carefully feed out triangular trim (3) towards the top and remove it.

Installation:

Carefully feed in triangular trim (3) and tighten screws (2).

Tightening torque 51 42 5AZ.
Feed in rubber window seal for door window glass (1) at the window guide
rail.
Reinstall rubber window seal for door window glass (1) onto door window
frame.

Required follow-up work:

Install the weather strip
Close side window completely.
51 34 171 Replacing rear left or right door window

Warning!
Danger of injury!
Carry out work on the electric power windows only when the power
window motor is de-energized (unplug connector).

Necessary preliminary tasks:

Remove sound insulation on rear door
Remove window frame trim of the rear door

Removal:

[Link]
Move door window glass (1) until the stop of the fixture (2) can be operated.
Press the stop of the fixture (2) outwards using a screwdriver and feed out the
door window glass (1) towards the top.

Installation:

Feed in door window glass (1).

Engage door window glass (1) in the stop of the fixture (2).
Note:
Door window glass (1) must engage properly.
Required follow-up work:
Install window frame trim of the rear door
Install sound insulation on rear door

[Link]
51 37 000 Removing and installing/replacing complete rear left or right
power window regulator

Necessary preliminary tasks:

Loosen door window glass

Note:
Exclusively disengage (but do not remove) door window glass and secure in
window frame.

Removal:

Unfasten plug connection (1) and disconnect.

Loosen nuts (2) and feed out window crank (3) from door.

[Link]
Installation:

Replacement:
Remount flat motor for power window regulator.

Feed in window crank (3) at the door and tighten nuts (2).
Tightening torque 51 35 2AZ.
Connect the connector (1).
Required follow-up work:
Install door window glass.

[Link]
51 34 171 Replacing rear left or right door window

Warning!
Danger of injury!
Carry out work on the electric power windows only when the power
window motor is de-energized (unplug connector).

Necessary preliminary tasks:

Remove sound insulation on rear door
Remove window frame trim of the rear door

Removal:

[Link]
Move door window glass (1) until the stop of the fixture (2) can be operated.
Press the stop of the fixture (2) outwards using a screwdriver and feed out the
door window glass (1) towards the top.

Installation:

Feed in door window glass (1).

Engage door window glass (1) in the stop of the fixture (2).
Note:
Door window glass (1) must engage properly.
Required follow-up work:
Install window frame trim of the rear door
Install sound insulation on rear door

[Link]
51 36 190 Removing and installing (replacing) front left or right side window

Necessary preliminary tasks:

Remove the triangle window trim

Removal:

Secure the side window (1) against falling off.

Unscrew nuts.
Remove side window (1).

[Link]
Installation:

Note:
The circumferential gasket (1) on the side window (2) must not be damaged.

Insert the side window (1) and secure it against falling off.
Tighten nuts.
Tightening torque 51 33 5AZ.
Required follow-up work:
Installing the triangle window trim

[Link]
51 36 070 Removing and installing / replacing left or right rear side window
Attention!
Notes on window bonding
General procedure for dismantling/installation of affixed window glass

Removal is carried out with an oscillating knife and wire pull handles.

The following new parts / consumables are required (sourcing reference BMW Parts Department).

Material Quantity
Small repair kit 1
Cutting wire (square) 1
Velcro fastener (Dual Lock tape) 2
Side window (with replacement) 1

[Link]
Necessary preliminary tasks:
Remove C/D pillar cover

Removal:

Secure the side window on the body with adhesive tape.

Cut through guide pins (1) with a straight knife without thrust roller.
Cut through adhesive bead in area (B) from inside using an L-shaped knife
with blade length 19 mm.
Place wire around the adhesive bead from outside in the area of the C-pillar
and feed through to the inside.
Secure wire pull handle (1) on the wire.
Cut through adhesive bead completely and remove side window.

Touch up any paint damage following the side window disassembly.

Installation:

Remove the remaining guide pins (1) and Dual Lock tape (2) and clean the
bonding surface.

[Link]
Apply new Dual Lock tape (2) between the marks on the body area.

Overview for side window bonding:

a [mm] = Position adhesive bead 2 ±0,5

b [mm] = Width adhesive bead 8 ±1
h [mm] = Height adhesive bead 15 ±1

Apply bead joint in area (1).

Follow the adhesive bead around the circumference of the PVC coating (2).

For reusing the side window:

Place side window (1) at side panel.
Align side window (1) at the side panel (2) and rear door (3) and engage in
the Dual Lock tape.
Fix side window (1) in position with yellow plastic adhesive tape (sourcing
reference: BMW Parts Department).
Replacement:
Mount side window (1) on side panel and feed in with guide pins (2).
Align the side window (1) at the side panel and engage in the Dual Lock
tape.
Fix side window (1) in position with yellow plastic adhesive tape (sourcing
reference: BMW Parts Department).

Required follow-up work:

Install C/D pillar cover

[Link]
51 37 000 Removing and installing/replacing complete rear left or right
power window regulator

Necessary preliminary tasks:

Loosen door window glass

Note:
Exclusively disengage (but do not remove) door window glass and secure in
window frame.

Removal:

Unfasten plug connection (1) and disconnect.

Loosen nuts (2) and feed out window crank (3) from door.

[Link]
Installation:

Replacement:
Remount flat motor for power window regulator.

Feed in window crank (3) at the door and tighten nuts (2).
Tightening torque 51 35 2AZ.
Connect the connector (1).
Required follow-up work:
Install door window glass.

[Link]
67 62 020 Removing and installing/replacing flat motor for rear left or right
power window regulator

Necessary preliminary tasks:

Remove rear power window regulator

Release screw connections (1).

Remove flat motor (2) from power window regulator.
Cable must not come loose from power window.
Installation note:
Simultaneously tighten both screw connections (1).
The shaft of the flat motor (2) must be pulled into the holder of the power
window regulator under slight tension.
Tightening torque 51 35 1AZ.

[Link]
Flat motor (2) must engage exactly at the marked points of the power window
regulator (1).Important!
Ensure that the flat motor (2) is assembled without tension.

After installation:
An initialisation must be carried out in order to activate anti-trap mechanism.
Read and comply with notes on initialisation of power window regulator.
51 48 ... Notes for bonding sound insulation (SI), doors
Special tools required:
51 0 300

Attention!
Do not yank at the sound insulation (risk of damage).

General:
Sound insulation is bonded to the inner door panel.
Bonded sound insulation must not be subjected to load (e.g. leak test) before 5 hours have elapsed.
On-the-job safety:
When working with bonding products (adhesive, cleaning agent, etc.):
Wear safety goggles, protective gloves and if necessary an apron.
Ensure the area is well ventilated.

[Link]
Change work clothing contaminated with adhesive immediately.
Change work clothing contaminated with solvents and swelling agents immediately (keep spare work clothing
on hand).
Take skin protection measures, provide washing facilities including hot water, use silicone-free skin creams.
Always keep an eye douche on hand, change the water regularly (once a month).
Comply with the relevant safety regulations.
Handling adhesive area on inner door panel:

Adhesive Cleaning

a. Cleaning agentR2
a. Butyl bead applied to sound Under no circumstances: paint thinning
insulation with protective b. Carry out bonding only after an air drying time ≥ 1 min. Air drying time
film may be omitted if the entire bonding surface is wiped with a dry cloth
b. Butyl mini-round profile c. After cleaning, the bonding surface may not be touched with hands or
∅ 4 mm from the roller fouled again
c. Butyl round profile ∅ 6 mm
from the roller

Repair in area of sound insulation, door:

Repair
Cut the butyl rope between the sound insulation and the inner door panel with a sharp
knife
After the repair is finished, position a new butyl rope ∅ 4 mm directly on the original
adhesive bead
Heat the butyl bead with a standard hot air blower until the butyl rope strings when
touched slightly. Do not damage the sound insulation in the process
Press on with special tool 51 0 300. Perform this work extremely carefully because the
increased amount of adhesive requires contact pressure of ≥ 20 N/cm2 (compared to
firm thumb pressure ~ 30 N/cm2)
Visually check the adhesive bead and its compression (no capillaries or broken
adhesive bead permitted)
in the event of
damaged sound In the cases mentioned, the complete sound insulation must be replaced. After
insulation or leakage removing the sound insulation, removal all butyl remnants from the inner door panel.
Apply 6 mm ∅ butyl rope to new sound insulation
Press on with special tool 51 0 300. Contact pressure ≥ 20 N/cm2 (compare to firm
thumb pressure ~ 30 N/cm2)

The sound insulation must be bonded watertight below the door lock:
Flat bonding surface required all round.
No bonding in the event of moisture (e.g. condensation, etc.).
Bonding area must not show any traces of adhesion-reducing residues (e.g. separating agents, greases, oils,
paraffins, plastisols, cavity wax, polishing dust residues, etc.).
Remove the protective film directly before joining (under no circumstances remove earlier, since the butyl,
because of its stickiness, will very quickly pick up adhesion-reducing dirt contaminants).
The sound insulation must be attached with positional accuracy to the inner door panel because it will no longer
be possible to change the position without damaging the butyl bead.
With repainted areas, the maximum permitted temperature of 90°C may not be exceeded in the area of the
sound insulation. Otherwise, the sound insulation must be removed (and replaced, if necessary).
Expiry date of adhesive:

[Link]
24 months, see label on packaging.
Disposal of the cleaning cloth:
Cleaning cloths and cleaning agent residues are hazardous waste (see also safety data sheet).
Disposal of adhesive:
Hazardous waste (see also safety data sheet).
51 41 000 Removing and installing (replacing) front left or right door trim
panel

Special tools required:

00 9 325

Necessary preliminary tasks:

Remove power window regulator switch

Removal:

[Link]
Release screws (1).

Release screws (1).

Unclip door trim panel at clips (1) using special tool 00 9 325 (starting in area
of A-pillar).
Unclip door trim panel from clips (2) at top.

Disengage Bowden cable (1) from door lock (2).

Disconnect all plug connections and remove door trim panel.

[Link]
Installation:

Hold door trim panel in position and connect all plug connections.
Attach Bowden cable (1) to door lock (2).

Note:
Replace faulty clips (1).
Fit all clips with sealing ring.

Clip door trim panel at top into clamps (2).

Clip door trim panel into clips (1).
Tighten down screws (1).
Tightening torque 51 41 1AZ.

Tighten down screws (1).

Tightening torque 51 41 1AZ.

[Link]
Note:
After assembling the door trim panel proceed as follows:
Open side window
Lock with vehicle key
Check for ease of movement on locking button linkage
If necessary, align linkage

Required follow-up work:

Install power window regulator switch
51 41 060 Removing and installing or replacing armrest on door trim panel,
front left or right

Necessary preliminary tasks:

Remove front door trim panel

Note:
Armrest is welded to door trim panel only on initial installation. The armrest is
screw-connected on second installation. If necessary, release screws instead
of welding spots.

Removal:

Important!

[Link]
Risk of damage!
To avoid damaging the contact surface, only drill down to door trim
panel area (2)

Drill out/grind all welding spots in the marked area (1) on the door trim
panel (2).
Remove armrest from the door trim panel (2).
Remove welding residues on the door trim panel (2) with a scalpel.

Installation:

Replacement:
Saw off all welding pins (1) along the moulding (2).
Insert armrest in door trim [Link]:
Welding pins (1) must not protrude over door trim panel (2).

Note:
Secure armrest with the repair screws (1).
Tightening torque 51 41 2AZ.

[Link]
Required follow-up work:
Mount door trim panel
51 41 030 Removing and installing/replacing decorative strip on front left or
right door trim panel
When working on trim panel components, make sure that visible surfaces are not scratched or damaged (e.g. by
sharp-edged tools).

Necessary preliminary tasks:

Remove front door trim panel

Note:
The decorative strip is welded to door trim panel only on initial installation.
The decorative strip is screw-connected on second installation. If necessary,
release screws instead of welding spots.

Removal:

[Link]
Depending on version:
Remove LED module (1).
Unfasten cable strap (2).
Unfasten plug connection (3) and disconnect.

Release screw (1).

Important!
Risk of damage!
To avoid damaging the contact surface, only drill/grind down to door
trim panel area (3).

Drill out/grind all welding spots in the marked area (2) at the door trim
panel (3).
Feed out decorative strip from the door trim panel (3).
Remove welding residues on the door trim panel (3) with a scalpel.

Installation:
Replacement:
Rear welding pin (1) may not be shortened.
Saw off welding pins (1) along the moulding (2).

Equipment specification with two fibre-optic conductors.

Release LED module (1) from holder.
Release fibre-optic conductor (2) on latch mechanism by using a screwdriver
(3 mm blade).
Important!
Do not damage fibre-optic conductor (2).

Install LED module (1) into new decorative strip.

[Link]
Insert the armrest with fibre-optic conductor and retaining hook in the door
trim panel (2).Note:
Welding pins (1) must not protrude over door trim panel (2).

Note:
Insert the screw (1) with a length of 20 mm only at the rear welding pin.
The other welding pins are fixed with repair screws (2) with a length
of 10 mm.

Attach the armrest with the screw (1) and the repair screws (2).
Tightening torque 51 41 3AZ.
Depending on version:
Install the LED module (1).
Secure cable clip (2).
Connect connector (3).

Required follow-up work:

Install door trim panel

[Link]
51 48 060 Removing and installing/replacing sound insulation in left or right
front door

Necessary preliminary tasks:

Remove front door trim panel

Attention!
Instructions for sound insulation are an essential part of these repair
instructions and must be followed without fail.
Do not detach sound insulation in jerks (risk of damage).
Ensure watertightness of sound insulation after every repair (water
ingress).

Note:
Position of sealing bead (1).
Pay attention to the cable (2) when removing the sound insulation (3).

[Link]
Attention!
When cutting through sealing bead (1), do not damage sound
insulation (2) and if necessary cable.
With a suitable sharp cutting tool (3) cut through sealing bead (1) of
sound insulation (2) in the area to be detached.
When refitting:
Damaged sound insulation must be replaced.
Lay butyl rope with ∅ 4 mm (sourcing reference: BMW Parts Department)
onto the original butyl rope.

Replacement:
Remove residual butyl at the door and clean the adhesive area.
Air drying time: 1 minute
Attention!
Bonding surfaces must be dry and free of dust and grease.
Once it has been cleaned, do not touch the adhesive area with bare
hands.

Lay 6 mm dia. butyl rope (sourcing reference: BMW Parts Department) in

specified adhesive area onto the sound insulation.

Note:
Position of butyl rope (1) on sound insulation (2).

[Link]
Note:
A mark (2) is provided all round on the sound insulation (1).
Butyl rope (3) rests on or inside the marking (2).
Heat butyl rope (3) (hot air blower) and press sound insulation (1) on firmly all-
round.
Contact pressure with hand roller: approx. 20 N/cm2
Manual contact pressure: approx. 10 N/cm2
Note:
Firm thumb pressure has approx. 30 N/cm2
51 41 018 Replacing speaker cover on left or right front door trim panel

Special tools required:

00 9 327

Unclip speaker cover (1) from door trim panel with special tool 00 9 327 .

[Link]
Installation note:
Catches (1) and guides (2) must not be damaged or missing.
Guides (2) are used for correct positioning of speaker cover on door trim
panel.
51 48 ... Notes for bonding sound insulation (SI), doors
Special tools required:
51 0 300

Attention!
Do not yank at the sound insulation (risk of damage).

General:
Sound insulation is bonded to the inner door panel.
Bonded sound insulation must not be subjected to load (e.g. leak test) before 5 hours have elapsed.
On-the-job safety:
When working with bonding products (adhesive, cleaning agent, etc.):
Wear safety goggles, protective gloves and if necessary an apron.
Ensure the area is well ventilated.

[Link]
Change work clothing contaminated with adhesive immediately.
Change work clothing contaminated with solvents and swelling agents immediately (keep spare work clothing
on hand).
Take skin protection measures, provide washing facilities including hot water, use silicone-free skin creams.
Always keep an eye douche on hand, change the water regularly (once a month).
Comply with the relevant safety regulations.
Handling adhesive area on inner door panel:

Adhesive Cleaning

a. Cleaning agentR2
a. Butyl bead applied to sound Under no circumstances: paint thinning
insulation with protective b. Carry out bonding only after an air drying time ≥ 1 min. Air drying time
film may be omitted if the entire bonding surface is wiped with a dry cloth
b. Butyl mini-round profile c. After cleaning, the bonding surface may not be touched with hands or
∅ 4 mm from the roller fouled again
c. Butyl round profile ∅ 6 mm
from the roller

Repair in area of sound insulation, door:

Repair
Cut the butyl rope between the sound insulation and the inner door panel with a sharp
knife
After the repair is finished, position a new butyl rope ∅ 4 mm directly on the original
adhesive bead
Heat the butyl bead with a standard hot air blower until the butyl rope strings when
touched slightly. Do not damage the sound insulation in the process
Press on with special tool 51 0 300. Perform this work extremely carefully because the
increased amount of adhesive requires contact pressure of ≥ 20 N/cm2 (compared to
firm thumb pressure ~ 30 N/cm2)
Visually check the adhesive bead and its compression (no capillaries or broken
adhesive bead permitted)
in the event of
damaged sound In the cases mentioned, the complete sound insulation must be replaced. After
insulation or leakage removing the sound insulation, removal all butyl remnants from the inner door panel.
Apply 6 mm ∅ butyl rope to new sound insulation
Press on with special tool 51 0 300. Contact pressure ≥ 20 N/cm2 (compare to firm
thumb pressure ~ 30 N/cm2)

The sound insulation must be bonded watertight below the door lock:
Flat bonding surface required all round.
No bonding in the event of moisture (e.g. condensation, etc.).
Bonding area must not show any traces of adhesion-reducing residues (e.g. separating agents, greases, oils,
paraffins, plastisols, cavity wax, polishing dust residues, etc.).
Remove the protective film directly before joining (under no circumstances remove earlier, since the butyl,
because of its stickiness, will very quickly pick up adhesion-reducing dirt contaminants).
The sound insulation must be attached with positional accuracy to the inner door panel because it will no longer
be possible to change the position without damaging the butyl bead.
With repainted areas, the maximum permitted temperature of 90°C may not be exceeded in the area of the
sound insulation. Otherwise, the sound insulation must be removed (and replaced, if necessary).
Expiry date of adhesive:

[Link]
24 months, see label on packaging.
Disposal of the cleaning cloth:
Cleaning cloths and cleaning agent residues are hazardous waste (see also safety data sheet).
Disposal of adhesive:
Hazardous waste (see also safety data sheet).
51 42 000 Remove and install left or right rear door trim panel

Special tools required:

00 9 325

When working on trim panel components, make sure that visible surfaces are
not scratched or damaged (e.g. by sharp-edged tools).

Necessary preliminary tasks:

Remove rocker switch for power window regulator

Removal:

[Link]
Important!
Do not under any circumstances pull on map pocket.

Release screws (1).

Release door trim panel (2) from clips (3) with special tool 00 9 325 , starting
at bottom.
Release door trim panel (2) from clamps at top and remove.

Disengage Bowden cable (1) for release lever first at counter support (2) and
then at door lock (3).
Feed out door wiring harness from all brackets.
Unlock and disconnect all plug connections, then remove door trim panel.
Installation: Note:
Replace faulty clips.
Replace faulty clamps.

Feed in door wiring harness in all mountings.

Connect and lock all plug connections.
Attach bowden cable (1) for release lever first to door lock (3) and then to
counter support (2).

Engage door trim panel (2) in clamps at top.

Engage door trim panel (2) into clips (3).

[Link]
Tighten down screws (1).

Note:
After assembling the door trim panel proceed as follows:
Open side window
Lock with ignition key
Check for ease of movement on locking button linkage
If necessary, align linkage

Required follow-up work:

Install rocker switch for power window regulator
51 42 060 Removing and installing/replacing armrest on left or right rear
door trim

Necessary preliminary tasks:

Remove rear door trim panel

Note:
Armrest is welded to door trim panel only on initial installation. The armrest is
screw-connected on second installation. If necessary, release screws instead
of welding spots.

Removal:

Important!

[Link]
Risk of damage!
To avoid damaging the contact surface, only drill down to door trim
panel area (2)

Drill out/grind all welding spots in the marked area (1) on the door trim
panel (2).
Remove armrest from the door trim panel (2).
Remove welding residues on the door trim panel (2) with a scalpel.

Installation:

Replacement:
Saw off all welding pins (1) along the moulding (2).
Insert armrest in door trim [Link]:
Welding pins (1) must not protrude over door trim panel (2).

Note:
Secure armrest with the repair screws (1).
Tightening torque 51 42 2AZ.

[Link]
Required follow-up work:
Install rear door trim
51 42 030 Removing and installing/replacing decorative strip on left or right
rear door trim panel
When working on trim panel components, make sure that visible surfaces are not scratched or damaged (e.g. by
sharp-edged tools).

Necessary preliminary tasks:

Remove rear door trim panel

Note:
The decorative strip is welded to door trim panel only on initial installation.
The decorative strip is screw-connected on second installation. If necessary,
release screws instead of welding spots.

Removal:

[Link]
Depending on version:
Remove LED module (1).
Unfasten cable strap (2).
Unfasten plug connection (3) and disconnect.

Important!
Risk of damage!
To avoid damaging the contact surface, only drill/grind down to door
trim panel area (2).

Drill out/grind all welding spots in the marked area (1) on the door trim
panel (2).
Feed out decorative strip from the door trim panel (2).
Remove welding residues on the door trim panel (2) with a scalpel.

Installation:
Replacement:
Saw off weld pins (1) along moulding (2).

Equipment specification with two fibre-optic conductors.

Release LED module (1) from holder.
Release fibre-optic conductor (2) on latch mechanism by using a screwdriver
(3 mm blade).
Attention, do not damage the fibre-optic conductor (2) when doing
this.
Install LED module (1) into new decorative strip.

[Link]
Insert the armrest with fibre-optic conductor and retaining hook in the door
trim panel (2).Note:
Welding pins (1) must not protrude over door trim panel (2).

Secure armrest with the repair screws (1).

Tightening torque 51 42 3AZ.
Depending on version:
Install the LED module (1).
Secure cable clip (2).
Connect connector (3).

Required follow-up work:

Install rear door trim

[Link]
51 48 070 Removing and installing/replacing sound insulation in left or right
rear door

Attention!
Instructions for sound insulation are an essential part of these repair
instructions and must be followed without fail.
Do not detach sound insulation in jerks (risk of damage).
Ensure watertightness of sound insulation after every repair (water
ingress).

Necessary preliminary tasks:

Remove door trim panel

Removal:

[Link]
Note:
Position of sealing bead (1).

Feed out line (2) from sound insulation (3).

Attention!
When cutting through sealing bead (1), do not damage sound
insulation (2) and if necessary cable.

With a suitable sharp cutting tool (3) cut through sealing bead (1) of sound
insulation (2) in the area to be detached.
When refitting:
Damaged sound insulation must be replaced.
Lay butyl rope with ∅ 4 mm (sourcing reference: BMW Parts Department)
onto the original butyl rope.

Replacement:
Remove residual butyl at the door and clean the adhesive area.
Air drying time: 1 minute
Attention!
Bonding surfaces must be dry and free of dust and grease.
Once it has been cleaned, do not touch the adhesive area with bare
hands.

Lay 6 mm dia. butyl rope (sourcing reference: BMW Parts Department) in

specified adhesive area onto the sound insulation.

Note:
Position of butyl rope (1) on sound insulation (2).

[Link]
Note:
A mark (2) is provided all round on the sound insulation (1).
Butyl rope (3) rests on or inside the marking (2).
Heat butyl rope (3) (hot air blower) and press sound insulation (1) on firmly all-
round.
Contact pressure with hand roller: approx. 20 N/cm2
Manual contact pressure: approx. 10 N/cm2
Note:
Firm thumb pressure has approx. 30 N/cm2

Feed in line (2) at sound insulation (3).

Press sealing bead (1) onto door with your thumb.
Required follow-up work:
Mount door trim panel

[Link]
51 42 018 Replacing speaker cover on rear left or right door trim panel

Special tools required:

00 9 327

Unclip speaker cover (1) with special tool 00 9 327 from door trim panel.

[Link]
Installation note:
Catches (1) and guides (2) must not be damaged or missing.
Guides (2) are used for the correct positioning of the speaker cover on the
door trim panel.
51 43 150 Removing and installing or replacing trim for left or right door
pillar (bottom)

Necessary preliminary tasks:

Remove front door sill cover strip
Remove rear door sill cover strip

Removal:

Detach trim panel (1) from clips (2).

Feed out trim panel (2) downwards.

[Link]
Installation:

Feed in trim panel (2) upwards.

Engage trim panel (1) in the clips (2).
Note:
Replace faulty clips (1).
Ensure edge protection is correctly positioned.

Required follow-up work:

Install front door sill cover strip
Install rear door sill cover strip
51 43 201 Removing and installing or replacing trim panel for roof pillar at
front (A-pillar), left or right

Warning!
Follow safety information for working on vehicles with airbag systems.

Important!
Do not use a sharp-edged removal tool on the trim panel (risk of
damage to head airbag).

Removal:

Detach trim panel (1) from the first detent position of the clamp (2) toward the
inside.
Loosen the trim panel (1) toward the top and thereby detach it from the
clips (3).

[Link]
Feed out trim panel (1) from dashboard and remove.

Installation:

Note:
Always replace clamps (2).
Pry out any clips (1) remaining in the body and insert in cover
Replace faulty clips (1).
Make sure guides (3) is correctly seated in associated mounts.
Feed trim panel (1) into instrument panel.
Clip trim panel (1) into the clamp (2) and clips (3).
Note:
Make sure edge protection on trim panel (1) fits correctly.

[Link]
51 43 148 Removing and installing or replacing trim panel on left or right
door post (top)

Necessary preliminary tasks:

Remove trim panel for rear door post

Removal:

Release trim panel (1) at clips (2) and feed out downwards out of headlining.
Complete removal only:
Remove end fitting from front seat.
Feed out seat belt strap (3) from trim panel (1).

[Link]
Installation:

Only after complete removal:

Feed seat belt strap (3) into trim panel (1).
Attach end fitting to front seat.
Feed trim panel (1) into headlining and engage with clips (2) at bottom.
Note:
Make sure edge protection on trim panel (1) fits correctly.
Make sure the trim panel is correctly seated on the roofliner.
Clips (2) on the trim panel (1) must not be damaged or missing.

Required follow-up work:

Install bottom trim panel for door post
51 43 070 Removing and installing/replacing side trim panel, footwell, on A-
pillar, left

Necessary preliminary tasks:

Remove front door sill cover strip (inside)

Removal:

Release screw (1).

Remove engine compartment lid release lever (2).

[Link]
Release screw (1).
Release clips (3) and remove trim panel (2).

Installation:
Note:
Make sure edge protection on trim panel (2) fits correctly.

Install trim panel (2) and clip into clips (3).

Tighten screw (1).

Install engine compartment lid release lever (2).

Tighten screw (1).

[Link]
Required follow-up work:
Install front door sill cover strip (inner)
51 43 075 Removing and installing/replacing side trim panel, footwell, on A-
pillar, right

Necessary preliminary tasks:

Remove front door sill cover strip (inner), right
Remove dashboard trim at bottom right

Removal:

Pull off trim panel (1) from clips (2) and remove.

[Link]
Installation:

Note:
Clips (2) must not be missing or damaged.
Make sure trim panel (1) is correctly seated against the edge protection.

Install trim panel (1) and engage in clips (2).

Required follow-up work:

Install right door sill cover strip (interior)
Install bottom instrument panel trim on the right
51 43 ... Removing and installing/replacing the front triangle window trim (A-
pillar), left or right

Necessary preliminary tasks:

Remove A-pillar cover

Removal:

Release screw (1).

Release expanding rivet (2).
Feed out trim panel (3) and remove.

[Link]
Installation:

Feed in trim panel (3).

Mount expanding rivets (2).
Tighten screw (1).

Required follow-up work:

Install A-pillar trim
51 43 150 Removing and installing/replacing the trim panel for the left or
right door post
(bottom) \PREMIUM

PRELIMINARY WORK

1 – Remove front entrance cover strip

NOTICE
Description is for left component only. Procedure on the right side is identical.

RISK OF DAMAGE
Bending of plastic parts.

Application of too much force can lead to bending of plastic parts.

Place special tool directly beside the mounting clip.

[Link]
Continue unclipping the part without using the tool if possible.

Unclip the front door sill cover strip (1) at the clips (2) using the special tool
0 496 569 (00 9 325) in the direction of arrow starting from the rear.
If applicable, unclip the clips (1) from the floor panel (2).

2 – Remove rear entrance cover strip

RISK OF DAMAGE
Bending of plastic parts.

Application of too much force can lead to bending of plastic parts.

Place special tool directly beside the mounting clip.
Continue unclipping the part without using the tool if possible.

NOTICE
Description is for left component only. Procedure on the right side is identical.
 Lever out and remove the rear door sill cover strip (1) with the special tool
0 496 569 (00 9 325) from the clips (2).
If applicable, unclip the clips (2) from the floor panel.

MAIN WORK

3 – Remove the lower B‐pillar trim panel

NOTICE
Description is for left component only. Procedure on the right side is identical.

Release the B-pillar trim panel (1) at bottom starting from the clips (2).

[Link]
Feed out and remove the B-pillar trim panel (1) inwards.

4 – Install the lower B‐pillar trim panel

NOTICE
Description is for left component only. Procedure on the right side is identical.

Renew damaged clips (2).

Parts: Clips
Feed in the B-pillar trim panel (1) at the top and position correctly.
Clip in the B-pillar trim panel (1) at the clips (2).
Make sure the B-pillar trim panel (1) is correctly positioned on the edge
protection.
POSTPROCESSES

5 – Install the rear door sill cover strip

NOTICE
Description is for left component only. Procedure on the right side is identical.

Renew damaged clips (2).

Parts: Clips
Engage the rear door sill cover strip (1) with the clips (2).

6 – Install the front door sill cover strip

[Link]
NOTICE
Description is for left component only. Procedure on the right side is identical.

Renew faulty clips (1) on the front door sill cover strip (2).
Parts: Clips

Install and engage the front door sill cover strip (1) with the clips (2) in the
direction of the arrow.

Additional Information

Overview of Special Tools

0 496 569 (00 9 325) Wedge
Common Used in step 1 2

Usage (Panel wedge) From 11/2008 this special tool replaces

panel wedge 00 9 317 (different material)
Included in the tool or 0 490 527
work
Storage location Individual
Replaced by
In connection with
SI-Number 41 01 09 (507)

[Link]
51 43 148 Removing and installing/replacing trim panel on left or right door
post
(top) \PREMIUM

PRELIMINARY WORK

1 – Remove front entrance cover strip

NOTICE
Description is for left component only. Procedure on the right side is identical.

RISK OF DAMAGE
Bending of plastic parts.

Application of too much force can lead to bending of plastic parts.

Place special tool directly beside the mounting clip.

[Link]
Continue unclipping the part without using the tool if possible.

Unclip the front door sill cover strip (1) at the clips (2) using the special tool
0 496 569 (00 9 325) in the direction of arrow starting from the rear.
If applicable, unclip the clips (1) from the floor panel (2).

2 – Remove rear entrance cover strip

RISK OF DAMAGE
Bending of plastic parts.

Application of too much force can lead to bending of plastic parts.

Place special tool directly beside the mounting clip.
Continue unclipping the part without using the tool if possible.

NOTICE
Description is for left component only. Procedure on the right side is identical.
 Lever out and remove the rear door sill cover strip (1) with the special tool
0 496 569 (00 9 325) from the clips (2).
If applicable, unclip the clips (2) from the floor panel.

3 – Remove the lower B‐pillar trim panel

NOTICE
Description is for left component only. Procedure on the right side is identical.

Release the B-pillar trim panel (1) at bottom starting from the clips (2).
Feed out and remove the B-pillar trim panel (1) inwards.

[Link]
MAIN WORK

4 – Remove the upper B‐pillar trim panel

NOTICE
Description is for left component only. Procedure on the right side is identical.

Release the B-pillar trim panel (1) from the clips (2).
Guide the B-pillar trim panel (1) out of the headlining inwards towards the bottom
and remove.
If removing completely:
- Remove end fitting from front seat.
- Guide out the seat belt strap (3) and remove the B-pillar trim panel.

5 – Install upper B-pillar trim panel

[Link]
NOTICE
Description is for left component only. Procedure on the right side is identical.

After complete removal:

- Thread seat belt strap (3) into B-pillar trim panel.
- Install the end fitting on the front seat.
Renew faulty clips (2).
Parts: Clips
Thread B-pillar trim panel (1) upwards into headlining.
Engage B-pillar trim panel (1) on clips (2).
Check for correct seating of B-pillar trim panel (1) on edge protection.

POSTPROCESSES

6 – Install the lower B‐pillar trim panel

NOTICE
Description is for left component only. Procedure on the right side is identical.
 Renew damaged clips (2).
Parts: Clips
Feed in the B-pillar trim panel (1) at the top and position correctly.
Clip in the B-pillar trim panel (1) at the clips (2).
Make sure the B-pillar trim panel (1) is correctly positioned on the edge
protection.

7 – Install the rear door sill cover strip

NOTICE
Description is for left component only. Procedure on the right side is identical.

Renew damaged clips (2).

Parts: Clips

[Link]
Engage the rear door sill cover strip (1) with the clips (2).

8 – Install the front door sill cover strip

NOTICE
Description is for left component only. Procedure on the right side is identical.

Renew faulty clips (1) on the front door sill cover strip (2).
Parts: Clips
 Install and engage the front door sill cover strip (1) with the clips (2) in the
direction of the arrow.

Additional Information

Overview of Special Tools

0 496 569 (00 9 325) Wedge
Common Used in step 1 2

Usage (Panel wedge) From 11/2008 this special tool replaces

panel wedge 00 9 317 (different material)
Included in the tool or 0 490 527

[Link]
work
Storage location Individual
Replaced by
In connection with
SI-Number 41 01 09 (507)
51 44 011 Removing and installing/replacing headlining (version with
slide/tilt sunroof)

Necessary preliminary tasks:

Open slide/tilt sunroof panel at front
Remove both trim panels for roof pillar at front (A-pillar)
Remove hands-free microphone
Remove both trim panels for door post at top (B-pillar)
Remove both trim panels for rear roof pillar (C-pillar)
Remove interior roof light
Remove vanity mirror lights
Remove both sun visors and counter supports
Remove roof switch cluster
Remove all grab handles
Remove front head restraints

Removal:

[Link]
Release screws (1).

Unclip cover (1) from clip (2) and feed out towards the front.
Feed seat belt out of cover (1).
Release clamps (1).

Move seat back of driver's seat to max. rear position.

Move seat surface of driver's seat to the lowest position.
Move seat back of passenger seat to max. rear position.
Move seat surface of front passenger seat to the lowest position.
Important!
The following tasks must be carried out with a second person assisting:

[Link]
Support headlining (1) at front.
Unclip headlining (1) in marked side area in downward direction (2).
Carefully pull headlining (1) downward until headlining (1) is released from
remaining clips (2).
Feed headlining (1) out through tailgate.

Installation:

Feed headlining (1) in through tailgate.

Clip in headlining (1) at front and rear.
Clip in headlining (1) in marked side area (2).
Secure headlining (1) on edge protection at front and rear.
Feed belt into cover (1).
Feed in cover (1) and clip into clip (2).

Tighten down screws (1).

[Link]
Required follow-up work:
Mount both trim panels for roof pillar at front (A-pillar)
Install microphone
Mount both trim panels for door post at top (B-pillar)
Mount both trim panels for rear roof pillar (C-pillar)
Install interior roof light
Install vanity mirror lights.
Mount both sun visors and counter supports
Install roof switch cluster
Mount all grab handles
Mount front head restraints
Close glass slide/tilt sunroof cover at front
51 44 001 Removing and refitting/replacing roofliner (version without
sliding/tilting sunroof)
Except for the steps relating to the slide/tilt sunroof, the work is identical to:
Removing and installing/replacing headlining (version with slide/tilt sunroof).

[Link]
51 45 ... Removing and installing (replacing) side centre console trim panel

Necessary preliminary tasks:

Right side only:
Remove bottom right dashboard trim panel

Removal:

Release screw (1).

Release side centre console trim panel (2) from the retaining clips (3).
Feed out side centre console trim panel (2) from the guides (4) and remove.

[Link]
Installation:

Feed in trim panel (2) into the guides (4) and lock in the clamps (3).
Tighten screw (1).

Required reworking:
Right side only:
Install bottom right instrument panel trim panel
51 45 475 Removing and installing (replacing) trim for light operating facility

Operation is described in:

Removing and installing/replacing light operating facility

[Link]
51 45 370 Removing and installing decorative strip on left dashboard

Special tools required:

00 9 325

When working on trim panel components, make sure that the sensitive surfaces are not scratched or damaged.

Removal:

Pry out decorative strip (1) at attachment points (2) using special tool
00 9 325 and remove.

[Link]
Installation:

Engage decorative strip (1) at attachment points (2).

51 45 380 Removing and installing decorative strip on right dashboard

Special tools required:

00 9 325

When working on trim panel components, make sure that the sensitive
surfaces are not scratched or damaged.

Necessary preliminary tasks:

Remove the audio operating unit

Removal:

[Link]
Carefully unclip sides of decorative strip (1) with special tool 00 9 325 .
Then carefully unclip middle.
Lift decorative strip (1) and disconnect plug connections located beneath.
Remove decorative strip (1).

Installation:

Replacement:
Remount middle fresh air grille.
Note:
Replace any faulty clamps on back of decorative strip.

Mount decorative strip (1).

Connect plug connections.
Engage decorative strip (1) in clamps.
Required follow-up work:
Install the audio operating unit

[Link]
51 45 ... Removing and installing glove box trim panel at bottom right

Removal:

Unclip trim panel (1) from clamps (2) and remove.

[Link]
Installation:

Clip trim panel (1) into clamps (2).

51 45 030 Removing and installing instrument panel trim

When working on trim panel components, make sure that visible surfaces are
not scratched or damaged (e.g. by sharp-edged tools).

For version with Head-Up Display, make sure that Head-Up Display is
retracted.

Necessary preliminary tasks:

Remove trim for head‐up display
Remove side trim panel from footwell on A-pillar, left/right
Remove speaker in instrument panel
Remove Central Information Display
Remove Car Information Computer

[Link]
The following parts must be removed as preliminary work.

1 Centre console, complete

2 Airbag and steering wheel
3 Triangular window cover at front (A-pillar), left/right
4 Light operating unit
5 Side panel on instrument panel, left/right
6 Footwell trim panel at bottom left
 [Link]
7 Steering column switch cluster
8 Fresh-air grille, left
9 Instrument cluster
10 Start/stop switch
11 Ventilation grille on instrument panel, left/right
12 Trim panel on glove box, bottom
13 Glovebox

Removal:

Release expanding rivets (1) and remove defroster channel (2) on left and
right.
 [Link]
Unscrew all bolts.
Disconnect plug connection from front passenger airbag.
(Observe notes regarding Airbag plug connections).
Remove instrument panel with assistant and feed out all electrical lines.

Installation:

Install instrument panel with assistant and feed in all electrical lines.
Connect plug connection of front passenger airbag.
(Observe notes regarding Airbag plug connections).
Tighten down all bolts.
Tightening torque 51 45 4AZ.
Note:
Make sure guides on instrument panel are correctly seated in respective mountings of bulkhead.
Make sure gaskets are correctly seated on air ducts.
Make sure all electrical lines (2) are correctly routed.

Install defroster channel (2) on left and right and mount expanding rivet (1).

Required follow-up work:

[Link]

The following parts must be installed as follow-up work.

1 Centre console, complete

2 Airbag and steering wheel
3 Triangular window cover at front (A-pillar), left/right
4 Light operating unit
5 Side panel on instrument panel, left/right
6 Footwell trim panel at bottom left
 [Link]
7 Steering column switch cluster
8 Fresh-air grille, left
9 Instrument cluster
10 Start/stop switch
11 Ventilation grille on instrument panel, left/right
12 Trim panel on glove box, bottom
13 Glovebox

Install Car Information Computer

Installing the trim for the Head‐Up Display
Install side trim panel in footwell at A-pillar, left/right
Install speaker in instrument panel
Install central information display
51 45 ... Removing and installing trim panel in footwell at bottom left

Necessary preliminary tasks:

Release centre console

Removal:

Release trim panel (1) from clamps (2).

Raise centre console at rear until trim panel (1) can be fed out.

[Link]
Release trim panel (1) from clamps (2) and remove.

Installation:

Engage trim panel (1) in clamps (2).

Raise centre console at rear until trim panel (1) can be fed in.
Engage trim panel (1) in clamps (2).

Required follow-up work:

Secure centre console

[Link]
51 45 ... Removing and installing ventilation grille of instrument panel, left
and right

Special tools required:

64 1 020

Removal:

Pry out ventilation grille (1) with special tool 64 1 020 and remove.

[Link]
Installation:

Install ventilation grille (1).

51 45 075 Removing and installing/replacing carrier for instrument panel

Necessary preliminary tasks:

Remove instrument panel trim
Depending on equipment specification:
Disconnect plug connection on knee protection airbag module

Removal:

Release screw (1) on bulkhead.

[Link]
Release clamping bolt (1) of steering shaft at steering column.
Release steering shaft from steering column.

Unfasten screws (1) and nuts (2).

Remove retaining bracket (3).
Unscrew marked nuts.

Release screws (1) and remove air duct (2).

[Link]
Release screw (1) and remove air duct (2).

Disconnect plug connection (1).

Release screws (1).
Raise heating and air-conditioning unit (2) slightly and feed out support (3)
towards rear.
If necessary, remove further cables and cable clips and remove support (3).

Installation:

Replacement:
Remount Head‐Up Display

[Link]
Swap over wiring loom
Depending on equipment specification:
Remount airbag module for driver- and passenger knee protection

Insert support (3).

Position heating and air-conditioning unit (2) in area of screw connection (1)
correctly on support (3).
Tighten down screws (1).
Tightening torque 51 45 5AZ.
Make sure cable routing is correct and clip in cable clip into support.

Connect plug connections (1).

Fit air duct (2) and tighten screw (1).

Fit air duct (2) and tighten screws (1).

[Link]
Tighten marked nuts.
Tightening torque 51 45 1AZ.

Tighten down screws (1).

Tightening torque 51 45 2AZ.
Insert retaining bracket (3).
Tighten down nuts (2).
Tightening torque 51 45 2AZ.
Install steering shaft.
Tighten clamping bolt (1) of steering shaft.
Tightening torque 32 31 3AZ.

Tighten screw (1) on bulkhead.

Tightening torque 51 45 3AZ.

[Link]
Required follow-up work:
Install instrument panel trim
Depending on equipment specification:
Connect plug connection on knee protection airbag module
51 45 195 Removing and installing/replacing instrument panel trim, bottom
right

Removal:

Unscrew nuts (1).

Lower trim panel (2) slightly and disconnect plug connections behind it.
Feed the trim panel (2) out of the guides and remove.

[Link]
Installation:

Hold on to the trim panel (2) and connect the plug connection.
Feed in the trim panel (2) into the guides at the front.
Note:
Feed the guides of the trim panel (2) correctly into the corresponding holders
on the vehicle.

Tighten down nuts (1).

51 45 ... Removing and installing/replacing side panel on dashboard on left
or right

Special tools required:

00 9 327

When working on trim panel components, make sure that visible surfaces are
not scratched or damaged (e.g. by sharp-edged tools).

Removal:

[Link]
Unclip the side panel (1) in the highlighted areas using special tool 00 9 327
and remove it at an angle towards the rear.
If necessary, unlock and disconnect the plug connection on the switch for the
front passenger airbag deactivation.

Installation:

Note:
The latch mechanisms (1) and guide tab (2) on the side panel (3) must not be
damaged or missing.
If necessary, connect the plug connection on the switch for front passenger
airbag deactivation.
Insert and clip in the side panel (1) towards the front at an angle.

For replacement on passenger's side:

Remount switch for front passenger airbag deactivation.

[Link]
51 45 031 Replacing instrument panel trim

Necessary preliminary tasks:

Remove instrument panel trim
Remove airbag module on passenger's side
Remove decorative strip on dashboard on left
Remove speaker (tweeter)

Removal:

Remove air ducts (1).

If necessary, remove other mounting elements that are not included with the
new part.

[Link]
Installation:

Install air ducts (1).

If necessary, install other mounting elements that are not included with the
new part.

Required follow-up work:

Install airbag module on passenger's side
Install decorative strip on instrument panel, left
Install speaker (tweeter)
Install instrument panel trim
51 46 050 Removing and installing/replacing top cover on tail panel

Necessary preliminary tasks:

Removing luggage compartment well

Removal:

Release expanding rivets (1) from tail panel trim (2).

Lift off trim on tail panel (2).

[Link]
Installation:

Install trim on tail panel (2).

Mount expanding rivets (1) on tail panel trim (2).

Required follow-up work:

Install luggage compartment well
51 46 003 Removing and installing/replacing trim panel for storage shelf

Open tailgate.
Release holding straps (1) on left and right.
Pull storage shelf (3) out of guides (2).

[Link]
51 47 370 Detaching and attaching/replacing the C/D pillar trim

Necessary preliminary tasks:

Remove luggage compartment wheel arch panel
Remove C-pillar cover at bottom.

Removal:

Release screws (1).

[Link]
Undo and remove screw (1) from end fitting (2).

Remove cover (1) and release screw underneath.

Unclip trim (2) out of the clips (3).
Feed seat belt strap out of the trim (2).
Remove cover (2).
Installation:

Feed seat belt strap into the trim (2).

Attach trim (2) and clip into clips (3).
Tighten bolt and mount cover (1).
Tightening torque 54 43 1AZ.

Install end fitting (2) and tighten screw (1).

Tightening torque 72 11 21AZ.

[Link]
Tighten down screws (1).
Tightening torque 51 43 2AZ.

Required follow-up work:

Install luggage compartment wheel arch panel
Install trim of bottom C-pillar
51 47 000 Remove and install/replace the front left or right door sill cover
strip
(inner)
1 – Remove front entrance cover strip

NOTICE
Description is for left component only. Procedure on the right side is identical.

RISK OF DAMAGE
Bending of plastic parts.

Application of too much force can lead to bending of plastic parts.

Place special tool directly beside the mounting clip.
Continue unclipping the part without using the tool if possible.

[Link]
Unclip the front door sill cover strip (1) at the clips (2) using the special tool
0 496 569 (00 9 325) in the direction of arrow starting from the rear.
If applicable, unclip the clips (1) from the floor panel (2).

2 – Install the front door sill cover strip

NOTICE
Description is for left component only. Procedure on the right side is identical.

Renew faulty clips (1) on the front door sill cover strip (2).
Parts: Clips
 Install and engage the front door sill cover strip (1) with the clips (2) in the
direction of the arrow.

Additional Information

Overview of Special Tools

0 496 569 (00 9 325) Wedge
Common Used in step 1

Usage (Panel wedge) From 11/2008 this special tool replaces

panel wedge 00 9 317 (different material)
Included in the tool or 0 490 527

[Link]
work
Storage location Individual
Replaced by
In connection with
SI-Number 41 01 09 (507)
51 47 440 Removing and installing or replacing rear carpet on seat pan

Necessary preliminary tasks:

Remove both front seats
Remove seat bench
Remove bottom B-pillar trim panel on the left/right
Remove complete centre console
Remove bass speaker cover on the left/right

Removal:

Lift off carpet (1) towards the top and remove it from the vehicle.

[Link]
Installation:

Replacement:
Lay removed carpet over new one and transfer cuts to new carpet (if
necessary).
Install the carpet (1).
Note:
Make sure carpet (1) is correctly positioned compared with adjacent parts.
Required follow-up work:
Install both front seats
Install rear seat bench
Install door post trim panel at the bottom on left and right
Install centre console, complete
Install bass speaker cover on the left/right

[Link]
51 47 315 Removing and installing/replacing carpet for vehicle interior

Necessary preliminary tasks:

Disconnect battery earth lead
Remove centre console.
Remove footwell side trim panel on A-pillar on front left/right
Remove complete accelerator pedal module
Remove left and right cover for bass speaker
Remove door post trim panel on left and right
Remove centre console cover on the side on the left/right

Removal:

[Link]
Important!
Risk of damage!
Pay attention to cables when cutting.
Start cuts towards centre of vehicle as far as is possible. This
guarantees that cutting edges are covered by storage compartment
and/or dashboard.

Remove carpet (1) along lines, cut on the right and left.

Remove carpet (1) along lines, cut on the right and left.
Remove carpet (1) toward rear/top and if necessary feed out cable.
Installation:

Replacement:
Lay removed carpet over new one and transfer cuts to new carpet.
Install the carpet (1).
Note:
Make sure carpet (1) is correctly positioned compared with adjacent parts.

Required follow-up work:

Connect battery earth lead

[Link]
Install centre console
Install footwell side trim panel on A-pillar on front left/right
Install complete accelerator pedal module
Install left and right cover for bass speaker
Install door post trim panel on left and right
Install centre console cover on the side on the left/right
51 47 072 Removing and installing/replacing finishing strip on rear left or
right entrance (outer)

Special tools required:

00 9 325

Removal:

Lever out and remove trim (1) from the clips (2) using special tool 00 9 325 .

[Link]
Installation:

Note:
Clips (2) must not be missing or damaged.

Engage trim (1) in clips (2).

51 47 000 Removing and installing/replacing front (inside) left or right door
sill cover strip

Special tools required:

00 9 325

Attention!
Do not raise door sill cover strip (1) over entire length simultaneously.

Unclip rear door sill cover strip (1) from clips (2) starting from the rear with
special tool 00 9 325 .

[Link]
If necessary lift clip (1) from floor panel (2) and clip on door sill cover strip.

Installation note:
Replace defective clips (1) on door sill cover strip (2).
51 47 151 Removing and installing/replacing left luggage compartment
wheel arch trim

Necessary preliminary tasks:

Remove cover from tail panel

Removal:

For equipment specification with seat adjustment for rear seat:

Fold the backrest towards the front.
Move rear seat assembly forward.
Press latch mechanism (1) inward and detach holder (2) upwards.
Remove cover (3).

[Link]
Lift out storage compartment (1) upwards.
Lever out lashing eye covers (2) and release screws underneath.
Remove the lashing eyes.

Pull lower trim panel (1) inwards, feed out by lifting up and forwards, and
remove.
Installation:

Feed in trim panel (1) forwards and upwards, then install by pressing down
and [Link]:
Make sure trim panel (1) is correctly seated against the edge protection.

Install lashing eyes and tighten screws.

Tightening torque 51 47 1AZ.

[Link]
Install lashing eye covers (2).
Install storage compartment (1).

For equipment specification with seat adjustment for rear seat:

Clip in cover (3) from above with holder (2).
Note:
Ensure catches (1) are correctly seated.

Required follow-up work:

Install cover on tail panel
51 75 001 Removing and installing/replacing left or right underbody cover

Removal:

Release plastic nuts (1).

Release screws.
Feed out cover (2).

[Link]
Installation:

Note:
Ensure cover (2) is correctly seated.

Feed in cover (2).

Tighten plastic nuts (1).
Tighten down screws.
51 47 101 Removing and installing/replacing luggage compartment floor trim
panel

Removal:

Lift luggage compartment floor trim panel (1) at rear and remove.

[Link]
Installation:

Attach luggage compartment floor trim panel (1) at front in hooks and lay
down at rear.
51 47 ... Removing and installing/replacing luggage compartment well

Necessary preliminary tasks:

Remove luggage compartment floor trim panel

Removal:

Release and remove Mobility Set (1).

Lift up luggage compartment well (2) at front and feed out to rear.

[Link]
Installation:

Feed in luggage compartment well (2).

Insert Mobility Set (1) and secure.

Required follow-up work:

Install luggage compartment floor trim panel
51 47 030 Removing and installing/replacing rear left or right door sill cover
strip (inside)

Special tools required:

00 9 325

Removal:

Lever the rocker panel trim (1) out of the clips (2) using special tool 00 9 325
and remove.

[Link]
Installation:

Note:
Replace faulty clips (2).

Replacement
Remount clips (2).
Engage rocker panel trim (1) in clips (2).
51 47 161 Removing and installing/replacing right luggage compartment
wheel arch panel

Necessary preliminary tasks:

Remove cover from tail panel
Remove luggage compartment light

Removal:

For equipment specification with seat adjustment for rear seat:

Fold the backrest towards the front.
Move rear seat assembly forward.
Press latch mechanism (1) inward and detach holder (2) upwards.

[Link]
Remove cover (3).

Lift out storage compartment (1) upwards.

Lever out lashing eye covers (2) and loosen screws underneath.
Remove the lashing eyes.

Pull lower trim panel (1) inwards, feed out by lifting up and forwards, and
remove.
Installation:

Feed in trim panel (1) forwards and upwards, then install by pressing down
and [Link]:
Make sure trim panel (1) is correctly seated against the edge protection.

Install lashing eyes and tighten screws.

Tightening torque 51 47 1AZ.

[Link]
Install lashing eye covers (2).
Install storage compartment (1).

For equipment specification with seat adjustment for rear seat:

Clip in cover (3) from above with holder (2).
Note:
Ensure catches (1) are correctly seated.

Required follow-up work:

Install cover on tail panel
Install luggage compartment light
51 47 065 Removing and installing/replacing rocker panel trim on front left or
right entrance (outer)

Special tools required:

00 9 325

Removal:

Pry trim (1) out of clips (2) with special tool 00 9 325 and remove.

[Link]
Installation:

Note:
Clips (2) must not be missing or damaged.

Engage trim (1) in clips (2).

51 75 ... Removing and installing/replacing tank cover on left or right

Necessary preliminary work:

Remove torsion strut

Removal:

Unscrew all bolts.

Remove tank cover (1).

[Link]
Installation:

Install tank cover (1).

Tighten down all screws.
Tightening torque 51 75 1AZ.

Required follow-up work:

Install torsion strut
51 47 030 Removing and installing/replacing the rear left or right door sill
cover strip
(inner)
1 – Remove rear entrance cover strip

RISK OF DAMAGE
Bending of plastic parts.

Application of too much force can lead to bending of plastic parts.

Place special tool directly beside the mounting clip.
Continue unclipping the part without using the tool if possible.

NOTICE
Description is for left component only. Procedure on the right side is identical.

[Link]
Lever out and remove the rear door sill cover strip (1) with the special tool
0 496 569 (00 9 325) from the clips (2).
If applicable, unclip the clips (2) from the floor panel.

2 – Install the rear door sill cover strip

NOTICE
Description is for left component only. Procedure on the right side is identical.

Renew damaged clips (2).

Parts: Clips
Engage the rear door sill cover strip (1) with the clips (2).

Additional Information

Overview of Special Tools

0 496 569 (00 9 325) Wedge
Common Used in step 1

(Panel wedge) From 11/2008 this special tool replaces

Usage
panel wedge 00 9 317 (different material)
Included in the tool or
0 490 527
work
Storage location Individual
Replaced by
In connection with
SI-Number 41 01 09 (507)

[Link]
51 47 098 Removing and installing/replacing trim on C-pillar at bottom left or
right

Necessary preliminary tasks:

Remove door sill cover strip at rear
Release rear end fitting

Removal:

Unclip the trim panel (1) from the clips (2) and the clamps (3).
Feed out seat belt and remove trim panel (1).

[Link]
Installation:

Feed in seat belt and install trim panel (1).

Clip trim panel (1) in clips (2) and clamps (3).

Required follow-up work:

Install rear door sill cover strip
Mount rear end fitting
51 47 490 Removing and installing/replacing underbody protection
(front)
1 – Removing the front underbody protection
Remove screws (arrows).
Pull the front underbody protection (1) from underneath the bumper panel (2).

2 – Installing the front underbody protection

Position the front underbody protection (1) under the bumper panel (2).
Tighten screws (arrows).
Underbody protection to body

[Link]
Screw Tightening torque 2.5 Nm

Additional Information

Overview of Tightening Torques

Underbody protection to body Used in step 2

Screw Tightening torque 2.5 Nm

51 47 490 Removing and installing/replacing underbody protection (front)

Note:
Picture for example purposes. There may be differences in detail in the case
of other models.

Removal:

Loosen screws.
Pull forward underbody protection (1) below bumper panel (2) and remove.

[Link]
Installation:

Feed in underbody protection (1) below bumper panel (2) and position at
screw points.
Secure underbody protection (1) with bolts.
Tightening torque 51 71 5AZ.
51 47 491 Removing refitting/replacing rear engine undercover

NOTICE
Schematic diagram is for example purposes. Some parts may differ in certain details.

1 – Removing rear underbody protection

Loosen screws (1) and (2).
Remove underbody protection (3).

[Link]
2 – Installing underbody protection at rear
Install the underbody protection (3).
Tighten down screws (1) and (2).
Underbody protection to body
Screw Tightening torque 3 Nm

Additional Information

Overview of Tightening Torques

Underbody protection to body Used in step 2

Screw Tightening torque 3 Nm

51 47 491 Removing refitting/replacing rear engine undercover

Note:
Picture for example purposes. Some parts may differ in certain details.

Removal:

Release screws (1 and 2).

Remove underbody protection (3).

[Link]
Installation:

Install underbody protection (3).

Tighten down screws (1 and 2).
Tightening torque 51 71 5AZ
51 48 ... Notes for bonding sound insulation (SI), doors
Special tools required:
51 0 300

Attention!
Do not yank at the sound insulation (risk of damage).

General:
Sound insulation is bonded to the inner door panel.
Bonded sound insulation must not be subjected to load (e.g. leak test) before 5 hours have elapsed.
On-the-job safety:
When working with bonding products (adhesive, cleaning agent, etc.):
Wear safety goggles, protective gloves and if necessary an apron.
Ensure the area is well ventilated.

[Link]
Change work clothing contaminated with adhesive immediately.
Change work clothing contaminated with solvents and swelling agents immediately (keep spare work clothing
on hand).
Take skin protection measures, provide washing facilities including hot water, use silicone-free skin creams.
Always keep an eye douche on hand, change the water regularly (once a month).
Comply with the relevant safety regulations.
Handling adhesive area on inner door panel:

Adhesive Cleaning

a. Cleaning agentR2
a. Butyl bead applied to sound Under no circumstances: paint thinning
insulation with protective b. Carry out bonding only after an air drying time ≥ 1 min. Air drying time
film may be omitted if the entire bonding surface is wiped with a dry cloth
b. Butyl mini-round profile c. After cleaning, the bonding surface may not be touched with hands or
∅ 4 mm from the roller fouled again
c. Butyl round profile ∅ 6 mm
from the roller

Repair in area of sound insulation, door:

Repair
Cut the butyl rope between the sound insulation and the inner door panel with a sharp
knife
After the repair is finished, position a new butyl rope ∅ 4 mm directly on the original
adhesive bead
Heat the butyl bead with a standard hot air blower until the butyl rope strings when
touched slightly. Do not damage the sound insulation in the process
Press on with special tool 51 0 300. Perform this work extremely carefully because the
increased amount of adhesive requires contact pressure of ≥ 20 N/cm2 (compared to
firm thumb pressure ~ 30 N/cm2)
Visually check the adhesive bead and its compression (no capillaries or broken
adhesive bead permitted)
in the event of
damaged sound In the cases mentioned, the complete sound insulation must be replaced. After
insulation or leakage removing the sound insulation, removal all butyl remnants from the inner door panel.
Apply 6 mm ∅ butyl rope to new sound insulation
Press on with special tool 51 0 300. Contact pressure ≥ 20 N/cm2 (compare to firm
thumb pressure ~ 30 N/cm2)

The sound insulation must be bonded watertight below the door lock:
Flat bonding surface required all round.
No bonding in the event of moisture (e.g. condensation, etc.).
Bonding area must not show any traces of adhesion-reducing residues (e.g. separating agents, greases, oils,
paraffins, plastisols, cavity wax, polishing dust residues, etc.).
Remove the protective film directly before joining (under no circumstances remove earlier, since the butyl,
because of its stickiness, will very quickly pick up adhesion-reducing dirt contaminants).
The sound insulation must be attached with positional accuracy to the inner door panel because it will no longer
be possible to change the position without damaging the butyl bead.
With repainted areas, the maximum permitted temperature of 90°C may not be exceeded in the area of the
sound insulation. Otherwise, the sound insulation must be removed (and replaced, if necessary).
Expiry date of adhesive:

[Link]
24 months, see label on packaging.
Disposal of the cleaning cloth:
Cleaning cloths and cleaning agent residues are hazardous waste (see also safety data sheet).
Disposal of adhesive:
Hazardous waste (see also safety data sheet).
51 48 001 Removing and installing/replacing insulation lining on engine
hood/bonnet

Removal:

Remove clips from damping material.

Remove insulation lining.

[Link]
Installation:

Position damping material and secure with clips.

51 48 060 Removing and installing/replacing sound insulation in left or right
front door

Necessary preliminary tasks:

Remove front door trim panel

Attention!
Instructions for sound insulation are an essential part of these repair
instructions and must be followed without fail.
Do not detach sound insulation in jerks (risk of damage).
Ensure watertightness of sound insulation after every repair (water
ingress).

Note:
Position of sealing bead (1).
Pay attention to the cable (2) when removing the sound insulation (3).

[Link]
Attention!
When cutting through sealing bead (1), do not damage sound
insulation (2) and if necessary cable.
With a suitable sharp cutting tool (3) cut through sealing bead (1) of
sound insulation (2) in the area to be detached.
When refitting:
Damaged sound insulation must be replaced.
Lay butyl rope with ∅ 4 mm (sourcing reference: BMW Parts Department)
onto the original butyl rope.

Replacement:
Remove residual butyl at the door and clean the adhesive area.
Air drying time: 1 minute
Attention!
Bonding surfaces must be dry and free of dust and grease.
Once it has been cleaned, do not touch the adhesive area with bare
hands.

Lay 6 mm dia. butyl rope (sourcing reference: BMW Parts Department) in

specified adhesive area onto the sound insulation.

Note:
Position of butyl rope (1) on sound insulation (2).

[Link]
Note:
A mark (2) is provided all round on the sound insulation (1).
Butyl rope (3) rests on or inside the marking (2).
Heat butyl rope (3) (hot air blower) and press sound insulation (1) on firmly all-
round.
Contact pressure with hand roller: approx. 20 N/cm2
Manual contact pressure: approx. 10 N/cm2
Note:
Firm thumb pressure has approx. 30 N/cm2
51 48 070 Removing and installing/replacing sound insulation in left or right
rear door

Attention!
Instructions for sound insulation are an essential part of these repair
instructions and must be followed without fail.
Do not detach sound insulation in jerks (risk of damage).
Ensure watertightness of sound insulation after every repair (water
ingress).

Necessary preliminary tasks:

Remove door trim panel

Removal:

[Link]
Note:
Position of sealing bead (1).

Feed out line (2) from sound insulation (3).

Attention!
When cutting through sealing bead (1), do not damage sound
insulation (2) and if necessary cable.

With a suitable sharp cutting tool (3) cut through sealing bead (1) of sound
insulation (2) in the area to be detached.
When refitting:
Damaged sound insulation must be replaced.
Lay butyl rope with ∅ 4 mm (sourcing reference: BMW Parts Department)
onto the original butyl rope.

Replacement:
Remove residual butyl at the door and clean the adhesive area.
Air drying time: 1 minute
Attention!
Bonding surfaces must be dry and free of dust and grease.
Once it has been cleaned, do not touch the adhesive area with bare
hands.

Lay 6 mm dia. butyl rope (sourcing reference: BMW Parts Department) in

specified adhesive area onto the sound insulation.

Note:
Position of butyl rope (1) on sound insulation (2).

[Link]
Note:
A mark (2) is provided all round on the sound insulation (1).
Butyl rope (3) rests on or inside the marking (2).
Heat butyl rope (3) (hot air blower) and press sound insulation (1) on firmly all-
round.
Contact pressure with hand roller: approx. 20 N/cm2
Manual contact pressure: approx. 10 N/cm2
Note:
Firm thumb pressure has approx. 30 N/cm2

Feed in line (2) at sound insulation (3).

Press sealing bead (1) onto door with your thumb.
Required follow-up work:
Mount door trim panel

[Link]
51 49 000 Removing and installing or replacing trim for rear lid

When working on trim panel components, make sure that the sensitive
surfaces are not scratched or damaged.

Necessary preliminary tasks:

Remove warning triangle.
Remove the covers of the rear lights on the side.
Remove trim panel for storage shelf
Remove cover for side rear window frame

Removal:

[Link]
Release screws (1).
Unclip trim panel (2) at the clips and remove downwards.

Installation:

Note:
Clips and guides on the tailgate trim panel must not be damaged or missing.
Replacement:
Remount clips.

Attach trim panel (2) and clip into place at the clips.
Tighten down screws (1).
Required follow-up work:
Install trim for rear window frame on side
Install trim panel for storage shelf
Install the covers of the rear lights.
Install warning triangle.

[Link]
51 49 015 Removing and installing/replacing cover for rear window frame at
top

Removal:

Unclip trim (1) from clips (2) and remove downwards.

[Link]
Installation:

Note:
The clips (1) and the guides must not be damaged or missing.

Install trim (1) and attach to clips (2).

51 49 003 Removing and installing/replacing left or right rear window frame
cover

When working on trim panel components, make sure that the sensitive
surfaces are not scratched or damaged.

Necessary preliminary tasks:

Remove cover for rear window frame at top.

Removal:

[Link]
Release cover (1) at clips (2) and remove.

Installation:

Note:
Clips (1) and guides (2) on trim (3) must not be damaged or missing.
Attach trim (1) and engage at clips (2).

Required follow-up work:

Install trim for rear window frame at top.

[Link]
51 71 ... Remove and install/replace left or right lower front brake air duct

Necessary preliminary tasks:

Remove front bumper panel
Right side only:
Release fluid fuel tank for windscreen washer system

Removal:

Undo expander rivet or screws (1).

Release screw (2).
Feed out air duct (3) from guide (4) and remove.

[Link]
Installation:

Feed in air duct (3) with guide (4) into holder.

Secure air duct (3) with screw (2).
Secure expanding rivet or screws (1).

Required follow-up work:

Secure washer fluid reservoir for window washer system
Install front bumper panel
51 34 211 Remove and install/replace rubber window seal for rear left or
right door window glass

The Instructions on installation of rubber window seals serve as the basis for
these repair instructions and must be observed without fail.

Necessary preliminary tasks:

Remove outer weather strip at rear door
Completely lower fixed side window glass

Removal:

[Link]
Loosen rubber window seal (1) from bracket (2).

Remove rubber window seal (1) sideways from door window frame.
Pull out rubber window seal (1) from window guide rails and remove it.

Installation:
Insert rubber window seal (1) into the guide rail.
Mount rubber window seal (1) on door window frame.

Engage rubber window seal (1) to bracket (2).Note:

Make sure rubber window seals (1) are correctly seated on the door window
frame.

[Link]
Required reworking:
Install outer weather strip at rear door
Close side window completely
51 71 360 Remove and install/replace sealing for tailgate

Removal:

Detach gasket (1) starting at sealing joint (2), to the rear.

[Link]
Installation:

Mount gasket (1). Make sure that the sealing joint (2) is at the indicated
position.
Make sure that the gasket lies correctly on the adjacent trim panel
components.
51 13 115 Remove and install/replace the cowl panel cover (front)

Necessary preliminary tasks:

Remove rear bonnet seal

Note:
Bonnet shown removed for purposes of clarity.

Removal:

Lift off cowl panel cover (1).

[Link]
Installation:

Feed in cowl panel cover (1) towards [Link]:

Check front cover is correctly seated relative to rear cover.

Required follow-up work:

Install rear bonnet seal
51 71 345 Removing and installing / replacing left (rear) suspension cross-
brace

Important!
Driving without the strut brace is not permitted! (risk of damage to the
body).

Necessary preliminary tasks:

Remove upper bulkhead cover (front part)

Removal:

[Link]
Release screw (1).
Slacken nut (2).
Remove suspension cross-brace (3).

Installation:

Install strut brace (3).

Tighten nut (2).
Tightening torque 51 61 2AZ.
Tighten screw (1).
Tightening torque 51 61 3AZ.
Note:
Make sure suspension cross-brace (3) is in correct installation position.
Required follow-up work:
Install cover for bulkhead at top (front section)

[Link]
51 71 346 Removing and installing / replacing right (rear) suspension cross-
brace.

Important!
Driving without the suspension cross-brace is not permitted! (risk of
damage to the body).

Necessary preliminary tasks:

Remove upper bulkhead cover (front part)

Removal:

[Link]
Release screw (1).
Slacken nut (2).
Remove suspension cross-brace (3).

Installation:

Install strut brace (3).

Tighten nut (2).
Tightening torque 51 61 2AZ.
Tighten screw (1).
Tightening torque 51 61 3AZ.
Note:
Make sure suspension cross-brace (3) is in correct installation position.
Required follow-up work:
Install upper bulkhead cover (front part)

[Link]
51 13 116 Removing and installing cowl panel cover (rear)

Necessary preliminary tasks:

Remove front cowl panel cover
Removing the wiper arm on the left or right
Removing the gutter strip on the windscreen on the left and right

Note:
Bonnet shown removed for purposes of clarity.

Removal:

[Link]
Disengage cover (1) upwards and feed out.

Installation:

Feed in cover (1) and engage.

Required follow-up work:
Mount left or right wiper arm
Install front cowl panel cover
Installing the gutter strip on the windscreen on the left and right

[Link]
51 71 447 Removing and installing left or right side sill trim panel

Necessary preliminary tasks:

Remove rear door
Remove tank cover
For F48/49 only
Partially release front wheel arch trim
Partially loosen the rear wheel arch trim

Removal:

Release expanding rivets (1) on bottom of trim panel (2).

[Link]
Unclip the trim panel (2) along the mark (3) to the outside.

Installation:

Note:
If necessary, replace faulty screws and corresponding mountings (1).
Latch mechanisms on holder (1) and the side sill trim panel must not be
damaged.
Clip in trim panel (2) along marking (3).
Mount expanding rivets (1) on bottom of trim panel (2).

Required follow-up work:

Install rear door
Install tank cover
For F48/49 only
Install front wheel arch trim
Mount trim on rear wheel arch

[Link]
51 71 415 Removing and installing rear spoiler

Necessary preliminary tasks:

Remove rear spoiler

Removal:

Open tailgate.
Release left and right screws (1).

[Link]
Release screw (1).

Disconnect plug connection for additional brake light and expose wiring.
Disconnect coolant hose from washer jet and expose.
Release screws (1).
Release rear spoiler lower section (2) from clips (3) and remove.
Installation: Note:
Replacement:
Remount additional brake light

Mount rear spoiler lower section (2) and engage in clips (3).
Secure coolant hose and connect to washer jet.
Install wiring for additional brake light and connect plug connection.
Tighten down screws (1).
Tightening torque 51 71 15AZ.

Tighten screw (1).

[Link]
Tightening torque 51 71 15AZ.

Tighten screws (1) on left and right.

Tightening torque 51 71 16AZ.

Required follow-up work:

Attach rear spoiler
51 76 031 Removing and installing/replacing bonnet gasket at the front

Removal:

Pull off gasket (1) towards the top.

[Link]
Loosen gasket (1) at clips (2) and remove it.

Detach gasket (1) with clamps (2) from the headlight moving inwards.

Installation:
Attach gasket (1) with clamps (2) to headlights.

Engage gasket (1) in clips (2).

[Link]
Press in gasket (1) at groove on the bumper.
51 71 040 Removing and installing/replacing front left or right wheel arch
cover

Necessary preliminary tasks:

Remove front wheel

Note:
For purposes of clarity, shown with removed front axle.

REMOVAL:

Release expanding rivet (1).

Release all screws and nuts.
Feed out wheel arch cover (2).

[Link]
INSTALLATION:

Feed in wheel arch cover (2).

Tighten all screws and nuts.
Fasten the expanding rivet (1).

Required follow-up work:

Install front wheel
51 71 482 Removing and installing/replacing left or right tension strut

Important!
Observe safety informations for raising the vehicle
Driving without the trailing link is not permitted!

Removal:

Release screws (1).

Remove tension strut (2).

[Link]
Installation:

Install tension strut (2).

Tighten down screws (1).
Tightening torque 51 61 1AZ.
51 71 ... Removing and installing/replacing left or right torsion strut

Important!
Observe safety informations for raising the vehicle
Driving without the trailing link is not permitted!

Removal:

Release screws (1).

Remove tension strut (2).

[Link]
Installation:

Install tension strut (2).

Tighten down screws (1).
Tightening torque 51 61 1AZ.
51 71 099 Removing and installing/replacing radiator air duct

Necessary preliminary tasks:

Remove front bumper panel
Remove intake filter housing
Remove pressure hose from charge air cooler
Release washer fluid reservoir

Removal:

Release screws (1 and 2).

[Link]
Release screws (1 to 3) on left and right.

Note:
Some components are not shown for purposes of clarity.
For the removal of the screws (1), use a long extension and a joint if
necessary.

Release left and right screws (1).

Feed out air duct (1) with holder towards the front, disconnecting the
associated plug connections.

Release screws (1 and 2).

Remove air duct (3) from support.

[Link]
Installation:

Mount air duct (3) on support.

Tighten down screws (1 and 2).
Tightening torque:

Screws (1) 51 71 12AZ

Screws (2) 51 71 13AZ

Feed in air duct (1) with holder, connecting the associated plug connections.
Tighten screws (1) on left and right.
Tightening torque: 51 71 14AZ

Tighten screws (1 to 3) on left and right.

Screws (1) 51 71 14AZ

Screws (2) 51 11 3AZ
Screws (3) 51 11 6AZ

[Link]
Tighten down screws (1).
Tightening torque: 51 71 12AZ
Tighten down screws (2).
Tightening torque: 51 71 13AZ

Required follow-up work:

Install front bumper panel
Install intake silencer housing
Install pressure hose of charge air cooler
Mount washer fluid reservoir
51 76 030 Removing and installing/replacing rear engine hood/bonnet seal

Note:
For purposes of clarity, engine compartment lid shown removed.

Removal:

Pull off gasket (1) towards the top.

[Link]
Installation:

Press gasket (1) towards the [Link]:

Ensure gasket (1) is seated correctly.
51 71 041 Removing and installing/replacing rear left or right wheel arch
cover

Necessary preliminary tasks:

Remove rear wheel

Removal:

Release all screws and nuts.

Carefully feed out wheel arch cover (1) towards bottom.

[Link]
Installation:

Feed in wheel arch cover (1).

Tighten all screws and nuts.
Note:
Make sure wheel arch cover (1) is correctly seated.

Required follow-up work:

Install rear wheel
51 71 412 Removing and installing/replacing rear spoiler

Necessary preliminary tasks:

Remove trim for rear window frame, top

Removal:

Lift out the sealing cap and loosen screws (1) underneath.

[Link]
Unclip the trim (1) from the clips (2).
Remove trim (1) towards the front.

Installation:

Note:
Check sealing rings on clips (2).
If sealing rings are damaged, replace clips (2).

Feed in trim (1) towards the rear.

Clip in the trim (1) into the clips (2).
Tighten the screws (1) and install the sealing caps.
Tightening torque 51 71 1AZ.

Required follow-up work:

Install trim for rear window frame, top

[Link]
51 71 099 Removing and installing/replacing the air duct for the coolant
radiator

RISK OF DAMAGE
Scratches.

Tools and sharp-edged components can cause scratches.

Protect working area.
Handle tools and components carefully.

PRELIMINARY WORK

1 – Disconnecting all battery earth leads

See additional information.

[Link]
2 – Remove the intake neck for intake silencer housing
Loosen nuts (1).
Loosen the lock (2).
Guide the intake neck (3) out and remove it.

3 – Removing intake silencer housing

Loosen the holder (1).
Loosen screw (2).
Unlock and loosen connector (3).
Unfasten clamp (4).
Pull out and remove the intake silencer housing (5) from the rubber mounts
towards the top.

4 – Removing the front underbody protection

 Remove screws (arrows).
Pull out and remove front underbody protection (1) under the bumper panel (2).

5 – Remove the pressure pipe between the throttle body and the charge air cooler

WARNING
Hot surfaces.

Risk of burning!
Perform all work only on components that have cooled down.

[Link]
Unlock the lock (1).
The lock (1) must engage in the bracket (arrow).

Unlock and detach the locks (1) on both sides.

Guide out the pressure pipe (2) in the direction of the arrow and set it aside.

Unlock and detach the locks (1) on both sides.

Guide out the pressure pipe (2) in the direction of the arrow and set it aside.
 Remove the pressure pipe (1) in the direction of the arrow.

6 – Remove front bumper panel

Remove seal (1) upwards.
Loosen screws (2).

[Link]
Loosen the bottom screws on the bumper panel (1).

NOTICE
To provide a better overview: Schematic diagram with partially hidden
components.

Release screws (1) on the wheel arch trim panel (2).

Partially fold the wheel arch trim panel (2) back.

NOTICE
To provide a better overview: Schematic diagram with partially hidden
components.

Release screws (1) on the bumper panel (2).

Detach the bumper panel (2) on the side.
 TECHNICAL INFORMATION
Conduct the following operation with the assistance of a second person.

Tilt top of bumper panel (1) down.

Unlock all plug connections and disconnect.
Remove bumper panel (1) towards front.

7 – Removing the pedestrian protection sensor on the impact absorber

Unlock and disconnect connector (1).
Remove the impact absorber (2).

[Link]
Remove pedestrian protection sensor (1) from impact absorber (2).
Dispose of the impact absorber (2).
Impact absorber (2) must not be reused.

8 – Remove the washer fluid reservoir from the fixture

Loosen screws (1).
Guide the washer fluid reservoir (2) up and out of the fixture (3) and set it aside.

MAIN WORK

9 – Removing air duct for the radiator

 Loosen screws (1) and (2).

Loosen screws (1) to (3) on left and right.

[Link]
For the removal of the screws (1), use a long extension and a joint if necessary.
Loosen screws (1) on left and right.

Feed out air duct (1) completely with the support towards the front,
disconnecting the associated plug connections.

Loosen screws (1) and (2).

Remove air duct (3) from support.

10 – Installing the air duct for the radiator

 Install the air duct (3) on the support.
Tighten the screws (1).
Air duct to deformation element top/bottom
Screw Tightening torque 6 Nm

Tighten down screws (2).

Vertical strut to deformation element/connection at top
Screw Tightening torque 11,8 Nm

Guide in the air duct (1) together with the support, connecting and locking the
associated connectors in the process.

[Link]
Tighten screws (1) on left and right.
Lock support to deformation element
Screw Tightening torque 11,8 Nm

Tighten screws (1) on left and right.

Lock support to deformation element
Screw Tightening torque 11,8 Nm

Tighten screws (2) on left and right.

Deformation element, top, to engine carrier
M12 screw Replace screws Jointing torque 100 Nm
Angle of rotation 180 °

Tighten screws (3) on left and right.

Deformation element, bottom, to adapter plate, front axle carrier
Tightening torque 11,8 Nm

Tighten the screws (1).

Air duct on top cross connection
Screw Tightening torque 6 Nm

Tighten down screws (2).

Vertical strut on upper connection
Oval-head Tightening torque 25 Nm
screw with
positioning tip
POSTPROCESSES

11 – Install the washer fluid reservoir in the fixture

Feed washer fluid reservoir (2) into the mounting (3) and install.
Tighten the screws (1).
Washer fluid reservoir to body
M6x20 Tightening torque 8 Nm

12 – Installing pedestrian protection sensor on the impact absorber

TECHNICAL INFORMATION
Notes on active pedestrian protection are a fundamental requirement for these repair instructions and must be complied with
at all times.

[Link]
For additional information see: 41 00 ... Procedure for vehicles with active pedestrian protection after an accident

Renew the impact absorber (2).

Parts: Impact absorber
Check the impact absorber (2) for damage to the retaining lugs.
If necessary, replace pedestrian protection sensor.
After an accident, the pedestrian protection sensor (1) must always be
replaced.
Insert the pedestrian protection sensor (1) into the impact absorber (2).
The pedestrian protection sensor must be routed correctly.

Carefully attach the impact absorber (2) at the bottom and then press it in at the
top.
Connect connectors (1) and lock.

13 – Install bumper panel, front

Attach the bumper panel (1) in the support at the bottom.

TECHNICAL INFORMATION
Conduct the following operation with the assistance of a second person.

Connect all connectors and lock.

Tilt bumper panel (1) up and position it.
 Attach bumper panel (2) on the side.

NOTICE
To provide a better overview: Schematic diagram with partially hidden
components.

Tighten screws (1) on the bumper panel (2).

Bumper panel on side wall
Screw Tightening torque 3 Nm

NOTICE
To provide a better overview: Schematic diagram with partially hidden
components.

Correctly position the wheel arch trim panel (2).

Tighten screws (1) on the wheel arch trim panel (2).

[Link]
Wheel arch cover
Screw Tightening torque 3 Nm

Tighten bottom screws on the bumper panel (1).

Bumper trim, lower
Screw Tightening torque 2,5 Nm

Tighten down screws (2).

Bumper panel on air duct, top
Screw Tightening torque 4,6 Nm

Install new gasket (1).

14 – Installing pressure pipe between throttle body and charge air cooler

RISK OF DAMAGE
Damage to the exhaust turbocharger.

A leak at the pressure pipe can damage the exhaust turbocharger.

Replace the gaskets and pressure pipe if necessary.
 Check seal (1) for damage and renew seal (1) as needed.
Parts: Gasket

▶ Replace damaged gasket

TECHNICAL INFORMATION
Do not use pointed or sharp-edged tools for the installation and/or removal.

Remove damaged seal.

Clean gasket groove (1) with a dry towel.

[Link]
The gasket groove (1) must be clean.

Renew gasket.
Parts: Gasket
Install seal dry without lubricant or mounting agent.

TECHNICAL INFORMATION
Incorrect assembly is possible. Ensure correct installation position.

Feed in and install the seal.

Make sure the seal is correctly installed in the gasket groove (1).
Make sure that the sealing lip (2) is pointing downwards (see figure).
Detach the locks (1) in the direction of the arrow from the brackets.
 Insert and install the pressure pipe (1) in the direction of the arrow.

Insert and install the pressure pipe (1) in the direction of the arrow.
Ensure that the locks (1) engage audibly.

[Link]
Insert and install the pressure pipe (1) in the direction of the arrow.
Ensure that the locks (2)engage audibly.

15 – Installing the front underbody protection

Guide the front underbody protection (1) in under the bumper panel (2) and
position it at the screw points.
Tighten screws (arrows).
Underbody protection front
3 Nm

16 – Installing intake silencer housing

 Insert the intake silencer housing (5) into the rubber mounts and install it.
Intake filter housing (5) must engage audibly.
Tighten down screw (2).
Intake silencer housing to lock bridge
M6X30 Tightening torque 8 Nm

Tighten clamp (4).

Clean air pipe to intake silencer housing
Clamp Tightening torque 3 Nm

Connect and lock the connector (3).

The connector (3) must engage audibly.
Insert and install the holder (1).

17 – Install the intake neck for the intake filter housing

Insert and install the intake neck (3).
The lock (2) must audibly engage.
Tighten nuts (1).

[Link]
Intake neck to cross connection
M6 Tightening torque 8 Nm

18 – Disconnecting all battery earth leads

See additional information.

Additional Information

Overview of Tightening Torques

Air duct to deformation element top/bottom Used in step 10

Screw Tightening torque 6 Nm

Vertical strut to deformation element/connection at top Used in step 10

Screw Tightening torque 11,8 Nm

Lock support to deformation element Used in step 10

Screw Tightening torque 11,8 Nm

Deformation element, top, to engine carrier Used in step 10

M12 screw Replace screws Jointing torque 100 Nm

Angle of rotation 180 °

Deformation element, bottom, to adapter plate, front axle carrier Used in step 10

Tightening torque 11,8 Nm

Air duct on top cross connection Used in step 10

Screw Tightening torque 6 Nm

Vertical strut on upper connection Used in step 10

Oval-head screw with Tightening torque 25 Nm

positioning tip

Washer fluid reservoir to body Used in step 11

M6x20 Tightening torque 8 Nm

Bumper panel on side wall Used in step 13

Screw Tightening torque 3 Nm

[Link]
Wheel arch cover Used in step 13

Screw Tightening torque 3 Nm

Bumper trim, lower Used in step 13

Screw Tightening torque 2,5 Nm

Bumper panel on air duct, top Used in step 13

Screw Tightening torque 4,6 Nm

Underbody protection front Used in step 15

3 Nm

Intake silencer housing to lock bridge Used in step 16

M6X30 Tightening torque 8 Nm

Clean air pipe to intake silencer housing Used in step 16

Clamp Tightening torque 3 Nm

Intake neck to cross connection Used in step 17

M6 Tightening torque 8 Nm

Links
General repair instructions Used in step
72 Safety information and general information 12
41 00 ... Procedure for vehicles with active pedestrian protection after an accident 12

Repair instructions Used in step

61 20 900 Disconnecting and connecting battery earth lead 1 18
61 20 900 Disconnecting and connecting battery earth lead 1 18
61 20 900 Disconnecting and connecting battery earth lead 1 18
61 20 900 Disconnecting and connecting battery earth lead 1 18
61 20 900 Disconnecting and connecting battery earth lead 1 18
61 20 900 Disconnecting and connecting battery earth lead 1 18
61 20 900 Disconnecting and connecting the battery earth lead (all battery earth leads) 1 18
61 20 900 Disconnecting and connecting the battery earth lead (all battery earth leads) 1 18
61 20 900 Disconnecting and connecting battery earth lead 1 18
61 20 900 Disconnecting and connecting the battery earth lead (all battery earth leads) 1 18
61 20 900 Disconnect and connect battery earth lead (Plug-in Hybrid Electric Vehicle) 1 18
61 20 900 Disconnecting and connecting battery earth lead 1 18
61 20 900 Disconnecting and connecting battery earth lead 1 18
61 20 900 Disconnecting and connecting battery earth lead 1 18
61 20 900 Disconnecting and connecting battery earth lead 1 18
61 20 900 Disconnecting and connecting battery earth lead 1 18
61 20 900 Disconnecting and connecting battery earth lead 1 18
61 20 900 Disconnecting and connecting battery earth lead 1 18
61 20 900 Disconnecting and connecting battery earth lead 1 18
61 20 900 Disconnecting and connecting battery earth lead 1 18

[Link]
61 20 900 Disconnecting and connecting battery earth lead 1 18
61 20 900 Disconnecting and connecting the battery earth lead (all battery earth leads) 1 18
61 20 900 Disconnecting and connecting battery earth lead 1 18
61 20 900 Disconnecting and connecting battery earth lead 1 18
61 20 900 Disconnecting and connecting battery earth lead 1 18
61 20 900 Disconnecting and connecting battery earth lead 1 18
61 20 900 Disconnecting and connecting battery earth lead 1 18
61 20 900 Disconnecting and connecting battery earth lead 1 18
61 20 900 Disconnecting and connecting battery earth lead 1 18
51 71 071 Removing and installing/replacing upper bulkhead cover

Necessary preliminary tasks:

Remove cowl panel cover (front section)

Removal:

Release screws (1).

[Link]
Release screws (1).

Release screws (1).

Feed out cover (2) and remove.

Installation:
Feed in cover (2).
Tighten down screws (1).
Tightening torque 51 71 17AZ.

Tighten down screws (1).

Tightening torque 51 71 17AZ.

[Link]
Tighten down screws (1).
Tightening torque 51 71 17AZ.

Required follow-up work:

Install cowl panel cover (front section)
51 72 ... Sealing installation

Note:
The utmost care must be taken when removing all sealings on the vehicle.
Incorrect fitting can lead to wind noise and water ingress among other things
and can affect the ease of closing and opening.

The following instructions only apply to sealing without sealant.

Sealings with sealant must be replaced each time they are disassembled.
Sealing surfaces must be cleaned.

In general, the following applies:

Sealings on the side frame can be fitted and removed any number of
times.
Sealings must not be damaged or torn.
The clamping surface must be compressed by hand far enough to
ensure that a tight connection on the side flange is still possible. The

[Link]
sealing shanks may touch each other slightly. A completely compressed
sealing is not permitted.

It is not necessary to use special tools to compress the clamping

surface. This can be done carefully by hand.
The sealings must always be fitted except in the case of blockages.
There is no defined contact pressure.
A new gasket must be fitted if sealings in the tailgate area are
repeatedly fitted and removed (water ingress due to cracked sheet
metal).
Sealings must be checked for correct fit after installation. If necessary,
sealings should be lifted over the adjacent components using the
appropriate tool. Neighbouring components must not be damaged.
Sealings must be replaced if the metal inlay of the sealing is visible
(corrosion).

Ensure the clamping surface is even all round.

Sealings that are installed with plastic clips fit tightly against the body. If
this is not the case, replace the clips or sealings.

[Link]
51 72 010 Replace edge protection for left or right rear door

When working on trim panel components, make sure that the sensitive
surfaces are not scratched or damaged.

Necessary preliminary tasks:

Remove rear door sill cover strip (inner)

Removal:

Detach edge protection (1).

[Link]
Installation:

Follow the notes on fitting seals.

Mount edge protection (1) starting at the top [Link]:

When installed, the location of edge protection contact point (1) must be in
area "A".
Make sure edge protection (1) is correctly fitted on body and all trim panel
components.

Required follow-up work:

Install rear door sill cover strip (inner)
51 72 000 Replacing edge protection for left or right front door

When working on trim panel components, make sure that the sensitive
surfaces are not scratched or damaged.

Necessary preliminary tasks:

Remove front door sill cover strip (inner)

Removal:

Detach edge protection (1).

[Link]
Installation:

Follow the notes on fitting seals.

Mount edge protection (1) starting at the top on the [Link]:

When installed, the location of edge protection contact point (1) must be in
area "A".
Make sure edge protection (1) is correctly fitted on body and all trim panel
components.

Required follow-up work:

Install front door sill cover strip (interior)
51 72 ... Sealing installation

Note:
The utmost care must be taken when removing all sealings on the vehicle.
Incorrect fitting can lead to wind noise and water ingress among other things
and can affect the ease of closing and opening.

The following instructions only apply to sealing without sealant.

Sealings with sealant must be replaced each time they are disassembled.
Sealing surfaces must be cleaned.

In general, the following applies:

Sealings on the side frame can be fitted and removed any number of
times.
Sealings must not be damaged or torn.
The clamping surface must be compressed by hand far enough to
ensure that a tight connection on the side flange is still possible. The

[Link]
sealing shanks may touch each other slightly. A completely compressed
sealing is not permitted.

It is not necessary to use special tools to compress the clamping

surface. This can be done carefully by hand.
The sealings must always be fitted except in the case of blockages.
There is no defined contact pressure.
A new gasket must be fitted if sealings in the tailgate area are
repeatedly fitted and removed (water ingress due to cracked sheet
metal).
Sealings must be checked for correct fit after installation. If necessary,
sealings should be lifted over the adjacent components using the
appropriate tool. Neighbouring components must not be damaged.
Sealings must be replaced if the metal inlay of the sealing is visible
(corrosion).

Ensure the clamping surface is even all round.

Sealings that are installed with plastic clips fit tightly against the body. If
this is not the case, replace the clips or sealings.

[Link]
51 75 001 Removing and installing/replacing left or right underbody cover

Removal:

Release plastic nuts (1).

Release screws.
Feed out cover (2).

[Link]
Installation:

Note:
Ensure cover (2) is correctly seated.

Feed in cover (2).

Tighten plastic nuts (1).
Tighten down screws.
51 75 ... Removing and installing/replacing tank cover on left or right

Necessary preliminary work:

Remove torsion strut

Removal:

Unscrew all bolts.

Remove tank cover (1).

[Link]
Installation:

Install tank cover (1).

Tighten down all screws.
Tightening torque 51 75 1AZ.

Required follow-up work:

Install torsion strut
51 76 031 Removing and installing/replacing bonnet gasket at the front

Removal:

Pull off gasket (1) towards the top.

[Link]
Loosen gasket (1) at clips (2) and remove it.

Detach gasket (1) with clamps (2) from the headlight moving inwards.

Installation:
Attach gasket (1) with clamps (2) to headlights.

Engage gasket (1) in clips (2).

[Link]
Press in gasket (1) at groove on the bumper.
51 76 030 Removing and installing/replacing rear engine hood/bonnet seal

Note:
For purposes of clarity, engine compartment lid shown removed.

Removal:

Pull off gasket (1) towards the top.

[Link]
Installation:

Press gasket (1) towards the [Link]:

Ensure gasket (1) is seated correctly.