54 37 160 Removing rear module

Special tools required:

Necessary preliminary tasks

Connect battery charger
Removing LUGGAGE COMPARTMENT PARTITION .
Remove COVER FROM TAIL PANEL .

Installation note:

Microencapsulated screws (Loctite) must be replaced and may not be reused
Screw connection must be completed within 20 mins. (start of curing)
Microencapsulated screws must not be retightened
Thread of nut must be cleaned beforehand in event of repeated use

Open soft top compartment cover.

Open tailgate mechanically.

Fig 1: Opening Soft Top Compartment Cover

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IMPORTANT: Soft top compartment lid can tilt forwards when hydraulic cylinders are removed and must be supported with suitable apparatus.

Fig 2: Supporting Soft Top With Suitable Apparatus

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Measure distance A between rear module kinematics.

Installation note:

Adjust distance A.

Basic adjustment dimension e.g. for replacement:

A = 770.3 mm.

Fig 3: Measuring Distance Between Rear Module Kinematics

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Remove hydraulic cylinder for tailgate:

Release screw (1).

Fig 4: Identifying Tailgate Screw

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Slide retaining clip (1) upwards.

Detach ball socket at side.

NOTE: Close trunk lid carefully.

Fig 5: Identifying Retaining Clip

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Disconnect all cable straps.

Installation note:

Replace faulty cable straps.

Fig 6: Locating Cable Straps

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Feed hydraulic line (1) with hydraulic cylinder out of wiring harness (2).

Installation note:

Make sure hydraulic line is routed correctly behind wiring harness.

Close rear lid.

Fig 7: Identifying Hydraulic Line And Wiring Harness

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Release left and right screws (1).

Remove fixture cover (2) left and right.

Fig 8: Identifying Fixture Cover And Screws

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NOTE: Operation not mandatory, only if roof module must be subsequently moved.

Secure metal plate (1) over hall effect sensor in left mounting cover (2).

Metal plate (1) simulates a closed luggage compartment partition.

Fig 9: Identifying Metal Plate And Cover

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IMPORTANT: You must observe the disconnection order of the plug connections!

Plug connection (1) with locking bracket must first be unlocked and disconnected.

NOTE: When the Automatic Soft Close system of the tailgate opens, close the plug connections again and change the disconnection order.

Tailgate must be in the closed state.

Fig 10: Identifying Plug Connection

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Connect special tool 54 0 200 to vehicle-side connector for rear module.

NOTE: Adapter simulates closed tailgate. Retractable hardtop without tailgate not in working order.

Fig 11: Connecting Special Tool 54 0 200 To Vehicle Side Connector For Rear Module

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Unlock and disconnect plug connections (1) without locking bracket.

US only:

Unlock and disconnect plug connection for SDARS.

Fig 12: Identifying Plug Connections

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Release left and right screws (1).

Tightening torque 54 34 19AZ .

NOTE: Do not adjust barrel screws.

Replacement only:

Bring barrel screws into contact with special tool 54 0 180 in conjunction with special tool 00 9 450 .

Tightening torque 54 34 22AZ .

Fig 13: Identifying Barrel Screws

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NOTE: Before removing, mark position of screws (1) to ensure correct alignment during installation.

Do not release screws.

Fig 14: Identifying Mark Position Of Screws

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IMPORTANT: Proceed with the greatest possible caution when carrying out the following tasks.
Risk of damage!
Three helpers are essential for the following work.

Generously cover bumper area (loading edge) with protective covers (1).

Fig 15: Identifying Protective Covers

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IMPORTANT: Rear module sinks if incorrectly supported. Risk of damage!

Position a helper on both the left and right sides of the rear module.

Grip rear module with two hands on rear module kinematics assembly and support in Z-direction.

NOTE: Console is double-jointed and bends.

Fig 16: Helper On Left And Right Sides Of Rear Module

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With one person each on the left and right, simultaneously release screws (1) from the bearing support.

Tightening torque 54 34 19AZ .

Remove rear module.

Set down rear module on a suitable support.

IMPORTANT: Do not damage any surrounding parts.

Fig 17: Identifying Rear Module Screws

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Installation note:

Check BODY GAP DIMENSIONS and if necessary adjust.

Carry out diagnosis.