51 31 ... Removing windscreen with "Roll Out 2000"

WARNING: This page is about a different car, the 2005 BMW 645Ci and 2004 BMW 645Ci. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required

NOTE: For special tools, refer to BODY EQUIPMENT - SPECIAL TOOLS - 645CI (E63) .

51 3 270

Windscreen removal system "Roll Out 2000"

Fig 1: Identifying Windscreen Removal System "Roll Out 2000"

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Using the "Roll Out 2000" system: Workshop Equipment and Planning Documentation) minimizes paintwork and ergonomic damage as well as damage that is hazardous to health.

WARNING: Follow safety instructions for working on cars with airbag systems (risk of injury).

IMPORTANT: Take care when handling sharp-edged tools and cutting wire (risk of damage to head airbag).

IMPORTANT: Always keep both suckers dry and clean to ensure their optimum adhesion on the windscreen. Lubricate coil if interlock rattling becomes too loud. Always wear protective goggles and gloves for your own safety.

Preparatory work:

To avoid paintwork damage, tape off working area over large area at outlet of wire starter (2) with fabric adhesive tape (1)
Cut off required length (A) from cutting wire
(A) = Window diagonal x 4
Check whether wire can get caught on rivets or retainers; if necessary, insert guide needles in bonding joint and guide cutting wire past

Fig 2: Protecting Working Area With Tape
Courtesy of BMW OF NORTH AMERICA, INC.

Pulling cutting wire into car:

Push wire starter (2) from inside at a suitable point through adhesive bead
Feed wire end (1) into hole of wire starter (2) and bend back

Fig 3: Feeding Wire End (1) Into Hole Of Wire Starter (2) And Bending Back

Courtesy of BMW OF NORTH AMERICA, INC.

Pull in both wires in succession crossways
NOTE: Crossing the wires cuts through the adhesive bead completely.

Laying cutting wire around windscreen:

Starting from pull-in point, lay wire eyelet created on the outside counterclockwise around the windscreen
Pull excess wire into car interior
IMPORTANT: Make sure the cutting wire is located at all four corner points below the windscreen.
Check that the cutting wire is not caught on retainers or body.
Secure window on outside with adhesive tape against slipping

Fig 4: Laying Cutting Wire Around Windscreen
Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Windows (1) with fitted seals (3) or sprayed-on surrounds:

Moisten cutting wire (4) and seals (3) on window (1) with water
Insert cutting wire (4) in bend (without kinking) between window (1) and body cutout (2)

Fig 5: Moistening Cutting Wire And Seals On Window With Water

Courtesy of BMW OF NORTH AMERICA, INC.

Protecting car interior:

To avoid damage and if necessary dirt, protect A-pillars, roof and instrument panel by means of parabolic tool (1) or plastic washer (2)
Move parabolic tool (1) during removal so that wire cannot get caught
Always guide plastic washer (2) between wire and panel

Fig 6: Identifying Parabolic Tool (1) And Plastic Washer (2)
Courtesy of BMW OF NORTH AMERICA, INC.

Starting removal:

Place windlass (1) on windscreen
Feed wire end into coil of windlass (1)
NOTE: Coil can only be turned in one direction.
Make sure the wire is always situated in the guide channel of the windlass (1)
Fit reversible ratchet (2) on coil and tension wire
Start by cutting lower adhesive bead
Grip second wire end in special tool 51 3 270

Fig 7: Identifying Windlass (1) And Reversible Ratchet (2)
Courtesy of BMW OF NORTH AMERICA, INC.

Moving windlass:

Before moving windlass, remove reversible ratchet, extension and parabolic tool
Release sucker on windlass
Pull and hold black locking button (1)
Turn windlass and move with sucker
Refit reversible ratchet, parabolic tool and if necessary extension
When cutting the corner points, make sure the wire is situated in the guide channel of the windlass; this makes the cutting job easier

Fig 8: Identifying Windlass Locking Button
Courtesy of BMW OF NORTH AMERICA, INC.

Installing second windlass:

Secure second windlass by suction on windscreen
Feed second wire end into coil
Cut left side and top left corner point, as described above
Finish removal
Remove "Roll Out 2000"

Fig 9: Installing Second Windlass
Courtesy of BMW OF NORTH AMERICA, INC.

Windlass with double coil:

For use with small windows.

Attach windlass firmly to window so that both coils are turned away from application point of wire
Feed either the upper wire end into the lower coil or the lower wire end into the upper coil
Fit reversible ratchet on coil and tension wire
Cut through approx. 10 cm of bonding joint

Fig 10: Identifying Windlass With Double Coil
Courtesy of BMW OF NORTH AMERICA, INC.
Feed other wire end into free coil so that the wires cross
Continue cutting bonding joint by alternately using the coils
Both wires meet ahead of both coils when removal is completed
Remove "Roll Out 2000"

Fig 11: Identifying Wires Meeting Point
Courtesy of BMW OF NORTH AMERICA, INC.