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"Roll Out 2000" has been replaced by the "SPIDER " removal system."Roll Out 2000" may still be used.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

Fig 1: Identifying "Roll Out 2000" Components

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NOTE: Both paint and ergonomic and health-endangering damage is minimized with the "Roll Out 2000" system.

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:

Fig 2: Mounting Suction Cup Lifters On Windscreen Or Rear Window

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Secure position of lifting jacks as shown (view from outside):

Suction cup lifter with double spool
Suction cup lifter with single spool (as deflecting point)
Window
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.

Fig 3: Mounting Suction Cup Lifters On Windscreen Or Rear Window

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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

Fig 4: Identifying Wire End And Adhesive Bead

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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.

Fig 5: Bending Wire End

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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

Fig 6: Laying Cutting Wire Around Window Glass

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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 molded-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)

Fig 7: Inserting Cutting Wire In Bend Between Window Glass And Body Aperture

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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

Fig 8: Identifying Plastic Washer, Wire And Dashboard Trim Panel

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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

Fig 9: Winding Cutting Wire Onto Spool

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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

Fig 10: Identifying Suction Cup Lifter Guide Channel And Top Spool Shaft
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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