Removal Procedure
Refer to Cracked Window Warning .
Refer to Glass and Sheet Metal Handling Warning .
- Position the vehicle on level ground and move the front wheels to the straight-ahead position.
- Disconnect the battery negative connection. Refer to Battery Negative Cable Disconnection and Connection (without Start/Stop System)
- Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement .
- Remove the inside rearview mirror. Refer to Inside Rearview Mirror Replacement .
- Remove the remote control door lock receiver. Refer to Remote Control Door Lock Receiver Replacement .
- Remove the windshield outside moisture sensor. Refer to Windshield Outside Moisture Sensor Replacement .
- Use BO-46974 removal system.
- Take the diagonal measurement (1) of the windshield.
- Cut cutting wire into four times lengths.
Approx. 6400 mm (251.9677 in), the circumference of the corresponding roll of wire is approximately 1000 mm (39.369 in).
- Heat the awl with a suitable tool.
- Stick the awl (1) with adhesive bed in the area of the front wall.
- Pull the wire through.
- Thread the cutting wire into the hole of the awl and bend it over.
- Pull the cutting wire with the awl to the middle of the steering wheel in the interior.
- Lay the wire under the windshield all the way round.
- Pull the second wire end through.
- Stick awl approx. 1 cm (0.393 in) overlapping the first entry place with adhesive bed.
- Thread the cutting wire into the hole of the awl and bend it over.
- Pull the rest of the wire into the interior with the awl.
- Place the winch with two winding heads (2) on windshield inside.
- Position winch in right-hand area of the windshield.
- Attach the cutting wire to the winch.
- Cut out windshield.
- Use the plastic sheet for the protection of the armature board.
- Arrow shows the path taken by the cutting wire (1).
- Insert transfer ratchet and pre-tension cutting wire.
- Cut out the windshield until the cutting wire is level with the winch.
- Place the winch with two winding heads (2) in the vehicle.
- Position the winch near to the interior rear view mirror.
- Insert transfer ratchet and pre-tension cutting wire.
- Cut out windshield.
- Use the hold-down positioner and the plastic sheet to protect the sunroof.
- Arrow shows the path taken by the cutting wire (1).
- Cut out the windshield until the cutting wire is level with the winch.
- Place the winch with one winding head in the vehicle.
- Position the winch with one winding head on the A-pillar on the driver's side (2).
- Attach the cutting wire (1) to the winch.
- Insert transfer ratchet and pre-tension cutting wire.
- Cut out windshield.
- Cut out the windshield until the cutting wire is level with the winch.
- Use the plastic sheet for the protection of the armature board.
- Place the winch with one winding head in the vehicle.
- Position the winch with one winding head in the area of the roof frame (1).
- Insert transfer ratchet and pre-tension cutting wire (2).
- Cut out windshield.
- Cut out the windshield until the cutting wire is level with the winch.
- Use the plastic sheet for the protection of the ceiling.
- Position both cutting tools.
- Shift winch with two winding heads downwards (1).
- Shift the winch with one winding head (2) in the ceiling area so that the cutting wire (3) is crossed.
- Insert transfer ratchet and pre-tension cutting wire.
- Cut out windshield.
- Cut out windscreen until the cutting wire has cut through the adhesive bed completely.
- Use the plastic sheet for the protection of the ceiling.
- Remove glass removal system.
- Fit and lock BO-641 holder to windshield.
- Remove windshield.
- Remove the windshield upper reveal molding. Refer to Windshield Upper Reveal Molding Replacement .
- Cut out the adhesive tape with the knife provided (1) to within 1 mm (0.039 in).
- Repair any paint damage.
Using a touch-up pen to match the color of the vehicle, repair any paint damage.
- Cut off the adhesive bead on the glass pane
Cut out the adhesive tape with the knife provided (1) to within 1 mm (0.039 in).
Refer to Defroster Outlet Warning .
Ensure that the windshield is not damaged in the process, otherwise stress cracks in the windshield may occur.
The cutting wire (1) should be rolled in beneath the rubber window seal (2) at the windscreen.
Ensure that the cutting wire is fitted correctly to the winch deflection roller.
In the area of the A-pillar/front wall, increased cutting effort must be made.
Ensure that the cutting wire is fitted correctly to the winch deflection roller.
In the area of the A-pillar/roof frame, increased cutting effort must be made.
Ensure that the cutting wire is fitted correctly to the winch deflection roller.
Use lubricant on the winch deflection roller. More pulling force is required to cut the area around the A-pillar/bulkhead.
Arrow shows the path taken by the cutting wire.
Ensure that the cutting wire is fitted correctly to the winch deflection roller.
Use lubricant on the winch deflection roller. More pulling force is required to cut the area around the A-pillar/roof frame.
Arrow shows the path taken by the cutting wire.
Arrow shows the path taken by the cutting wire.
Second mechanic required.