54 37 130 Removing and installing roof module

Special tools required:

Necessary preliminary tasks:

Connect battery charger.
Remove TRIM PANEL FOR PASSENGER COMPARTMENT PARTITION WALL .
Remove TRIM PANEL FOR LUGGAGE COMPARTMENT PARTITION WALL .
Remove luggage compartment trim panel . See 51 47 220 REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT TRIM PANEL ON RIGHT SIDE PANEL or 51 47 210 REMOVING AND INSTALLING/REPLACING TRUNK TRIM PANEL ON LEFT SIDE PANEL .
Remove 51 46026 REMOVING AND INSTALLING OR REPLACING FRONT AIR OUTLET TRIM GRILLE .
Remove REAR MODULE .
Remove WEATHER STRIP .
Remove LOWER SECTION OF SIDE TRIM PANEL .

Move soft top for following work into position.

Fig 1: Moving Roof Module

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Release screws (1).

Remove cover (2) for hydraulic unit.

Fig 2: Identifying Hydraulic Unit Cover And Screw

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Unclip all cable clips on hydraulic lines on left and right.

Fig 3: Locating Hydraulic Lines Cable Clips

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NOTE: Only in case of optional equipment with CD changer.

Slacken screws and slide CD changer back.

Fig 4: Sliding CD Changer

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Unlock plug connections (1) on left in luggage compartment and disconnect.

Fig 5: Identifying Luggage Compartment Plug Connections

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Lever out clips (1) on left and right trim panel.

Remove trim panel (2) on right and left.

Fig 6: Identifying Roof Module Panel And Clips

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Release screws (1).

Remove load protective plate on left and right.

NOTE: For right load protective plate, remove CONTROL UNIT if necessary.

Fig 7: Identifying Vehicle Protective Plate Screws

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WARNING: Danger of injury!
Fit special tool 54 0 220 prevent unintentional triggering of rollover protection system.

Fig 8: Identifying Special Tool (54 0 220)

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Release left and right screws (1).

Tightening torque: 54 37 13AZ .

Slacken lock nuts with special tool 54 0 190 .

Turn back barrel screws by approx. 3 mm.

Tightening torque: 54 37 22AZ .

Installation note:

Tighten barrel screws only with special tool 54 0 180 in conjunction with 00 9 450 .

Fig 9: Identifying Roof Module Lock Nuts

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Release screws (1) on left and right coupling locks.

Tightening torque: 54 37 12AZ .

Fig 10: Identifying Coupling Lock Screws

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Installation note:

Bushings (1) must be replaced and screwed before installation of soft top into body up to shortly before limit position.

Bushing (1) stretches as screw (2) is tightened against coupling lock (3).

Tightening torque: 54 37 12AZ .

Fig 11: Locating Roof Module Coupling Lock

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

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

Fig 12: Identifying Roof Module Metal Plate And Mounting Cover

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Place two shanks of special tool 54 0 101 as close together as possible.

Fig 13: Placing Special Tool (54 0 101)

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Carefully insert folded special tool 54 0 101 .

Fig 14: Inserting Special Tool (54 0 101)

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NOTE: The bolts have different lengths. Install bolts as follows:

Short bolts
Long bolts

Tighten down bolts on main bearings on left and right.

Fig 15: Identifying Roof Module Bolts

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Assemble linkage and screw down.

Adjust rotary sleeve (1) if necessary.

Fig 16: Adjusting Rotary Sleeve

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Adjust the length of the linkage with rotary sleeve (1) until the bolting point fits in the barrel screw.

IMPORTANT: Brass pin can break off.
Tightening torque for nut (2): 8 Nm.

Tighten nut (2) on left and right. The taper is secured in the barrel screw.

Fig 17: Adjusting Rotary Sleeve Linkage Length

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Lay linkage (1) for luggage compartment partition.

Fig 18: Removing Luggage Compartment Partition Linkage

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Fig 19: Sliding Retaining Sleeve

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Installation note:

The assembly carrier must rest free of tension on the main bearing. Otherwise stress may occur at the main bearing that could cause faulty installation.

Without using excessive force, pull tensioning rods outwards over rotary sleeves.

Slide retaining sleeve (1) over pivot joint.

Secure hydraulic unit (1) with cable straps to assembly carrier.

Fig 20: Locating Hydraulic Unit Assembly Carrier

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Secure hydraulic cylinders (1) on left and right to assembly carrier with cable strap.

Fig 21: Identifying Hydraulic Cylinders

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Unclip cable clip (1).

Fig 22: Identifying Roof Module Cable Clip

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Fig 23: Identifying Roof Module Nuts

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Release front nuts (1) on left and right roof module main bearings.

Tightening torque: 54 37 20AZ .

Open hardtop (roof module lowered).

IMPORTANT: Tape off corners (1) of roof shells. Risk of damage when positioning gauge for coupling lock and installation work.

Fig 24: Identifying Roof Shell Corners

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Release left and right screws (1).

Remove holder on left and right.

Fig 25: Identifying Basic Gauge Screws

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Release screws (1) on left and right coupling locks.

Tightening torque: 54 37 12AZ .

Release screws (2) on ground strap on left and right.

Fig 26: Identifying Coupling Locks Screws

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Release lock nut (1) with special tool 54 0 190 .

Tightening torque: 54 37 24AZ .

Turn barrel screw back.

Tightening torque: 54 37 22AZ .

Installation note:

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

Fig 27: Identifying Roof Module Lock Nut

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Installation note:

Gauge COUPLING LOCK .

Observe screwing sequence of coupling lock:

Z-direction (coupling lock to screwing plate, rollover protection system)
Y-direction (coupling lock to side panel)
X-direction (roof frame to partition wall)

Tightening torque: 54 37 22AZ .

Fig 28: Identifying Roof Module Main Bearings Rear Nuts

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Release rear nuts (1) on left and right roof module main bearings.

Tightening torque: 54 37 20AZ .

IMPORTANT: Soft top must not be moved after the nuts on the main bearing have been released.

NOTE: Shown here without roof shells for a better overview.

Unlock plug connection (1) on right in luggage compartment and disconnect.

Fig 29: Identifying Roof Module Plug Connection

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Unfasten plug connection (1) and disconnect.

Fig 30: Identifying Roof Module Plug Connection

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Detach water drain hose (1).

Unclip cable clip (2).

Fig 31: Identifying Water Drain Hose And Clip

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Unlock plug connections (1) and disconnect.

Unclip cable clips.

Fig 32: Identifying Roof Module Plug Connections

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Fig 33: Positioning Special Tool (54 0 102)

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NOTE: Carry out this part of the work with the assistance of two other persons.

Position special tool 54 0 102 with workshop crane over roof module.

IMPORTANT: Use lifting gear and assembly carrier only in conjunction with BMW WJN.10 workshop crane (special lifting arm with 1690 mm arm length) or a crane with comparable specifications.

Feed in belts between rollover protection system and roof module.

Do not twist straps!

Attach strap to assembly carrier.

Attach rear strap to assembly carrier.

IMPORTANT: Straps must not be twisted!

Fig 34: Attaching Strap To Assembly Carrier