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

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NOTE:

For Special Tool identification, see BODY EQUIPMENT - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required:

51 3 270

Windscreen Removal System "Roll Out 2000"

Fig 1: Identifying Windscreen Removal System Components

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Using the "Roll Out 2000" system 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). Refer to 51 00 ... SAFETY INSTRUCTIONS FOR WORKING ON CARS WITH AIRBAG SYSTEMS .

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: Identifying Taped Off Working Area
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.
Pull in both wires in succession crossways.

NOTE: Crossing the wires cuts through the adhesive bead completely.

Fig 3: Feeding Wire End Into Hole Of Wire Starter

Courtesy of BMW OF NORTH AMERICA, INC.

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: Pulling Excess Wire Into Car Interior

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: Inserting Cutting Wire Between Window And Body Cutout
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: Guiding Plastic Washer Between Wire And Panel
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: Fitting Reversible Ratchet On Coil And Tension Wire
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 Black Locking Button On Windlass
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: View Of Crossed Wires
Courtesy of BMW OF NORTH AMERICA, INC.