54 37 080 Replace rear roof shell

Necessary preliminary tasks :

Connect battery CHARGER
Remove ROOFLINER FOR ROOF SHELL AT REAR
Measure and note gap dimensions of rear roof shell

NOTE: Removal of rear roof shell must only be carried out when the center roof shell is fitted.
Never remove roof shells together.

Installation note :

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

Move soft top into service position.

Move soft top so that angle of the hinges is not ≤90°.

IMPORTANT: Risk of damage! Pressure in hydraulic system drops and soft top loses its position.

Fig 1: Moving Soft Top Into Service Position

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Support rear roof shell to soft top cover with suitable auxiliary materials.

Auxiliary materials must lie over wide area and if possible over entire length.

Rear roof shell is supported by auxiliary materials on soft top cover.

Roof shells block each other.

Unscrew left and right nuts (1).

Tightening torque 54 37 17AZ .

Remove ground strap.

Fig 2: Identifying Ground Strap Nut

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Roof shell, left side :

Unlock plug connections (1) on aerial amplifier and disconnect.

Unclip wiring harness.

Unlock plug connection (2) on wave trap and disconnect.

Fig 3: Identifying Amplifier Plug Connections And Wave Trap Plug Connection

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Roof shell, right side :

Unlock plug connection (1) on wave trap and disconnect.

Fig 4: Identifying Wave Trap Plug Connection

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Unclip wiring harness (1) from roof shell.

Installation note :

If necessary, replace faulty clips.

Fig 5: Identifying Wiring Harness And Clips

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NOTE: A second person is required to help in removing the roof shell.

IMPORTANT: Lock barrel screws with a flat wrench without fail.

Mark screws (1) on left and right.

Release screws (1).

Tightening torque 54 37 06AZ .

Remove roof shell.

Do not adjust barrel screws on roof shell.

Fig 6: Identifying Screws

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NOTE: The work scope for removing and installing the roof shell ends here.

Replacement only :

Drill out rivets (2).

Remove clamps (1).

Fig 7: Identifying Clamps And Rivets

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Remove clamps (1) from roof shell.

Fig 8: Identifying Clamps

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Right side :

Unfasten plug connection (1) and disconnect.

Release nut (2) and remove wave trap.

Fig 9: Identifying Wave Trap Plug Connection And Nut

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Left side :

Unfasten plug connection (1) and disconnect.

Release nut (2) and remove aerial amplifier.

Unfasten plug connection (3) and disconnect.

Release nut (4) and remove wave trap.

Fig 10: Identifying Plug Connections And Nuts

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Measure heights of all barrel screws (1) to roof shell with a depth gauge and note down.

Carry over adjustment to new roof shell.

Installation note :

Insert barrel screws with Loctite.

Remove GASKET (2).

Fig 11: Identifying Barrel Screws And Gasket

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Check 41 00... BODY GAP DIMENSIONS . for soft top.