Windshield Removal System "Roll Out 2000"

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2003 BMW 540i, 2002 BMW 540i, 2001 BMW 540i, 2000 BMW 540i, and 1999 BMW 540i. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Windshield Removal System Special Tools

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).

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 windshield.
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: Checking Whether Wire Can Get Caught On Rivets Or Retainers
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

Fig 3: Feeding Wire End Into Hole Of Wire Starter And Bend Back
Courtesy of BMW OF NORTH AMERICA, INC.

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

Laying cutting wire around windshield:

Starting from pull-in point, lay wire eyelet created on the outside counterclockwise around the windshield
Pull excess wire into car interior

IMPORTANT: Make sure the cutting wire is located at all four corner points below the windshield.
Check that the cutting wire is not caught on retainers or body.
Secure window on outside with adhesive tape against slipping

Fig 4: Checking Cutting Wire Is Not Caught On Retainers Or Body

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 In Bend 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: Moving Parabolic Tool During Removal So That Wire Cannot Get Caught
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Starting removal:

Place windlass (1) on windshield
Feed wire end into coil of windlass (1)

NOTE: Coil can only be turned in one direction.

Fig 7: Feeding Wire End Into Coil Of Windlass

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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

Moving windlass:

Before moving windlass, remove reversible ratchet, extension and parabolic tool
Release sucker on windlass
Pull and hold black locking button (1)

Fig 8: Pulling And Holding Black Locking Button
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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

Installing second windlass:

Secure second windlass by suction on windshield
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: Cutting Left Side And Top Left Corner Point
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: Feeding Upper Wire End Into Lower Coil Or Lower Wire End Into Upper Cut
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: Feeding Other Wire End Into Free Coil So Wires Cross
Courtesy of BMW OF NORTH AMERICA, INC.