Removing Glass With Cutting Wire Separator

Information 

• The following instructions describe the general procedure for removing glass from car windows. 
• Information on procedures relating to specific vehicles can be obtained from the instructions in the corresponding chapters in the Technical Information. 

Information 

• It is generally possible to remove the windscreen with the cutting wire and the optional cutting thread contained in the tool set. 
• In contrast to cutting threads, however, the cutting wire has the following disadvantages: 
• Danger of injury when tearing off the cutting wire. 
• Danger of damage to materials on paint surfaces and interior equipment parts. 
• For the reasons outlined above we recommend using the cutting thread. 

Information 

• In order to guarantee an optimum fastening intake grip, it is advisable to clean the inside of the glass before removal. 

1. Clean the inside of the glass.

   Information 

   • The film protects the dashboard from damage when removing the window glass. 
2. Select suitable protective film -1-  and insert it between the windscreen and damping mat.

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   Affix protective film

   Information 

   • To prevent damage, make sure that the vehicle identification number (VIN) is completely masked by the protective film when piercing the adhesive bead. 
3. Pull cutting thread into the passenger compartment.
   1. 3.1 Push through adhesive bead on the glass at the edge of the vehicle identification number -C -  using an awl -A4-  from the inside out.
   2. 3.2 Feed cutting thread -B -  through the eye on the awl -A4-  .
   3. 3.3 Pull cutting thread -B -  into the passenger compartment.
   4. 3.4 Pull cutting thread -B -  out of the awl -A4-  .
   5. 3.5 Pull cutting thread -B -  approx. 1 m into the passenger compartment.

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   Pulling cutting thread into passenger compartment

   Information 

   • The cutting thread should be positioned under the rim as far as possible. The sealing lip must be raised slightly in the upper part of the glass in order to pull the cutting thread through. 
4. Pull cutting thread -B -  in direction of arrow into the gap between the glass and body all the way around. Use filler if necessary.

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   Inserting cutting thread into gap in the glass

5. Clamp loose end of the cutting thread -B -  securely to a suitable point on the body using the screw -2-  for an add-on part (e.g. wiper motor mounting).

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   Securing cutting thread to body

6. Fit cutting thread to the spooling device.
   1. 6.1 Loosen clamping screw -3-  .
   2. 6.2 Insert cutting thread -B -  into the bore on the spooling device -A3-  .
   3. 6.3 Clamp cutting thread -B -  securely using a clamping screw -3-  .

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   Fitting cutting thread to the spooling device

   Information 

   • The fastening force can be increased by moistening the fastening intake. 
7. Fit spooling device and deflection rollers on the glass.
   1. 7.1 Position spooling device -A3-  diagonally in the centre of the glass.
   2. 7.2 Press spooling device -A3-  firmly against the glass using suction cups.
   3. 7.3 Secure suction cup to the glass by moving the actuating lever.

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   Fitting spooling device on the glass

8. Separate glass by spooling the cutting thread on the spooling device as far as -P1-  .
   1. 8.1

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   Separating glass

   Information 

   • The fastening force can be increased by moistening the fastening intake. 
9. Reposition spooling device.
   1. 9.1 Release spooling device.
   2. 9.2 Loosen the lower suction cup on the spooling device.
   3. 9.3 Pull cutting thread through onto the other side of the suction cup.
   4. 9.4 Secure suction cup to the glass by moving the actuating lever.

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   Reposition spooling device

   Information 

   • The fastening force can be increased by moistening the fastening intake. 
10. Separate glass as far as -P2-  .
    1. 10.1 Position deflection roller in the lower right corner.
    2. 10.2 Press deflection roller with suction cup firmly against the glass.
    3. 10.3 Secure suction cup to the glass by moving the actuating lever.
    4. 10.4 Guide cutting thread over the deflection roller to the spooling device.
    5. 10.5 Separate glass by spooling the cutting thread on the spooling device as far as -P2-  .

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    Separating glass

    Information 

    • The fastening force can be increased by moistening the fastening intake. 
11. Separate glass as far as -P3-  .
    1. 11.1 Release spooling device.
    2. 11.2 Position deflection roller in the upper right corner.
    3. 11.3 Press deflection roller with suction cup firmly against the glass.
    4. 11.4 Secure suction cup to the glass by moving the actuating lever.
    5. 11.5 Guide cutting thread over the deflection roller to the spooling device.
    6. 11.6 Separate glass by spooling the cutting thread on the spooling device as far as -P3-  .

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    Separating glass

    Information 

    • The fastening force can be increased by moistening the fastening intake. 
12. Reposition spooling device.
    1. 12.1 Release spooling device.
    2. 12.2 Loosen the upper suction cup on the spooling device.
    3. 12.3 Pull cutting thread through onto the other side of the suction cup.
    4. 12.4 Secure suction cup to the glass by moving the actuating lever.

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    Reposition spooling device

    Information 

    • The fastening force can be increased by moistening the fastening intake. 
13. Separate glass as far as -P4-  .
    1. 13.1 Position deflection roller in the upper left corner.
    2. 13.2 Press deflection roller with suction cup firmly against the glass.
    3. 13.3 Secure suction cup to the glass by moving the actuating lever.
    4. 13.4 Guide cutting thread over the deflection roller to the spooling device.
    5. 13.5 Separate glass by spooling the cutting thread on the spooling device as far as -P4-  .

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    Separating glass

    Information 

    • The fastening force can be increased by moistening the fastening intake. 
14. Separate glass as far as -P5-  .
    1. 14.1 Release spooling device.
    2. 14.2 Position deflection roller in the lower left corner.
    3. 14.3 Press deflection roller with suction cup firmly against the glass.
    4. 14.4 Secure suction cup to the glass by moving the actuating lever.
    5. 14.5 Guide cutting thread over the deflection roller to the spooling device.
    6. 14.6 Separate glass by spooling the cutting thread on the spooling device as far as -P5-  .

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    Separating glass

15. Separate glass by spooling the cutting thread on the spooling device as far as -P6-  .

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    Separating glass

16. Remove glass.