Cut out windows with roll out - AR67.10-P-1000-11SX

Window removal tool, Roll out 2004 Scope of supply: 

Fig 1: Identifying Welding Equipment (209 589 05 23 00)

Courtesy of MERCEDES-BENZ USA

Work is shown on windshield.

1. Mask off puncture point at position (A) (arrow) from outside with suitable textile adhesive tape and punch from vehicle interior through adhesive seam of window (18) with awl (2).

   Except when removing rear window on model 216.

2. Cut cutting wire to correct length.

   The length of the cutting wire should be approx. 4 times the diagonal of the window.

   Fig 2: Identifying Vehicle Interior Window Puncture Point

   Courtesy of MERCEDES-BENZ USA

1. 3.1 Insert ends of cutting wire (17) through eye of awl (2) and bend over in direction of arrow.

   Except when removing rear window on model 216.

   Fig 3: Inserting End Of Cutting Wire

   Courtesy of MERCEDES-BENZ USA
2. 3.2 Insert ends of cutting wire (17) through eye of awl (2) and bend over opposite direction of arrow.

   When removing rear window on model 216.

3. 4.1 Cover areas adjacent to puncture point in vehicle interior with appropriate interior protection and pull cutting wire (17) approx. 70 cm into passenger compartment using awl (2).

   Except when removing rear window on model 216.

4. 4.2 Mask off puncture point in area of drip rail with suitable textile tape and punch with awl (2) together with cutting wire (17) from outside through adhesive seam on rear window, remove cutting wire (17) from eyelet of awl (2) and pull approx. 70 cm into passenger compartment. Then remove awl (2).

   When removing rear window on model 216.

5. 5 Bend cutting wire (17) straight and remove awl (2).

   Except when removing rear window on model 216.

6. 6 Insert guide needles (5) into adhesive seam at bottom edge of window (18).

   When removing windshield Ensures that cutting wire (17) makes contact to adhesive seam when tensioning.

   Fig 4: Identifying Guide Needles

   Courtesy of MERCEDES-BENZ USA
7. 7 Moisten sealing lip on window (18) with soapy water.

   On windows (18) with sealing lip to facilitate inserting cutting wire (17).

8. 8 Route the remaining outer wire loop between windshield (18) and body flange counterclockwise while pulling the excess cutting wire (17) into the inside of the vehicle.

   Ensure that cutting wire (17) is located below windshield (18) at all four corner points.

   Fig 5: Routing Outer Wire Loop Between Windshield And Body Flange

   Courtesy of MERCEDES-BENZ USA
9. 9 Install windlass (15) on opposite side of window (18) diagonal of puncture point.
10. 10 Insert end of cutting wire (17) into coil of windlass (15) with the shorter end toward the windlass (15).
    Fig 6: Installing Windlass On Opposite Side Of Window Diagonal Of Puncture Point

    Courtesy of MERCEDES-BENZ USA
11. 11 Position reversible ratchet (3) on windlass (15) and tension cutting wire (17). Then check from outside whether the cutting wire (17) makes contact to the adhesive seam on the window all-round.

    The coil of the windlass (15) can only be turned in one direction, therefore it is necessary to ensure that the cutting wire (17) is located in the guide groove (20) of the windlass (15).

12. 12 Insert suitable interior protection (10) between cutting wire (17) and inner paneling.

    Use parabolic chisel (1) at points not easy to reach.

    Fig 7: Positioning Reversible Ratchet On Windlass

    Courtesy of MERCEDES-BENZ USA
    Fig 8: Releasing Locking Knob

    Courtesy of MERCEDES-BENZ USA
13. 13 Slowly wrap cutting wire (17) onto coil of windlass (15) and cut out window up to marking (B).
14. 14 Remove reversible ratchet, parabolic chisel and interior protection and turn windlass (15) to next position.

    To move windlass (15), release locking knob (19) while retaining under tension the cutting wire (17) of the coil.

15. 15 Install reversible ratchet, parabolic chisel and appropriate interior protection.
16. 16 Install windlass (16) on inner side of window.
17. 17 Install second end of cutting wire (17) in coil of windlass (16).
18. 18 Install reversible ratchet on windlass (16) and tension cutting wire (17).

    The windlass coil (16) can only be turned in one direction. Ensure that the cutting wire (17) is located in the guide groove of the windlass (16).

19. 19 Insert suitable interior protection between cutting wire (17) and inner paneling.

    Use parabolic chisel at awkward locations.

20. 20 Slowly wrap cutting wire (17) onto coil of windlass (15) and cut out window up to marking (C).
    Fig 9: Identifying Window Cutting Markings

    Courtesy of MERCEDES-BENZ USA
21. 21 Slowly wrap cutting wire (17) onto coil of windlass (16) and cut out window up to marking (D).
22. 22 Move windlass (16) to next position.
23. 23 Slowly wrap cutting wire (17) onto coil of windlass (16) and cut out window up to marking (E).
24. 24 Move windlass (15) to next position.
25. 25 Slowly wrap cutting wire (17) onto coil of windlass (15) and cut out window up to marking (E).

    Secure window against falling down to prevent damage.

26. 26 Remove windlasses (15, 16) from window.
27. 27 Fasten cup suction tool at outside of window and remove window from body flange.

    Cup suction tool

    Aid of helper required.