Replacing the middle roof shell headliner (4' Series Convertible)

Special tools required:

2 359 116
51 0 310
54 0 230
2 327 752

The following new parts are required (see applicable BMW parts catalogue):

Middle roof shell headliner (roof attachment set (2) is included in delivery specification)

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Necessary preliminary tasks:

Connect battery CHARGER
Fold both backrests forwards and move the seats to the furthest forward position
Remove rear INTERIOR ROOF LIGHT

WARNING: Danger of injury!
Only perform work if the hydraulic system is functioning.
In the event of a loss of pressure, immediately end the work and rectify the fault.

Removal:

Open the soft top until the displayed position is reached.

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Step 1:

Disconnect tension cable (1) with diagonal cutting pliers.

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Step 2:

Release screws (1) and (2).

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Step 3:

Release bottom screw (1) on guide loop (2).

Slacken upper screw on guide loop.

Pull guide loop (2) towards rear and feed out tension cable.

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Step 4:

View from inside:

Release screw (1) for tension cable on soft top linkage.

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Step 5:

View from inside:

Release screw (1) of guide lugs for tension cable on rear roof shell.

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Step 6:

Release furthest forward clamp (2) with screwdriver.

Release headliner (1) at side with quick jerk.

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Repeat steps (1) to (6) on right side of vehicle.

Step 7:

Open the soft top until the displayed position is reached.

Main pillar (1) is in vertical position.

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Step 8:

Release expanding rivet (1) and remove cover (2).

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Step 9:

NOTE: Depending on version, the additional tension cable (1) is fitted to the C-pillar flap travel limiter.
A tension cable (1) that has already been installed must be installed again.

Mark position of the tension cable (1) on the guide (3) (arrow).

Slacken screw (4) and detach tension cable (1) from guide (3).

Detach tension cable (1) from tension cable (2).

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Step 10:

Disconnect tension cable (1) in front of and behind clamp (2) with diagonal cutting pliers.

Disconnect tension cable (3) with diagonal cutting pliers.

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Step 11:

Release Torx screw (1) on main bearing with special tool 2 359 116.

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Step 12:

Release Torx screws (1) on C-pillar flap holder.

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Repeat steps (8) to (12) on right side of vehicle.

View from front:

Unclip headliner with special tool 51 0 310.

IMPORTANT: Clamps are very securely fixed.
To prevent the clamps breaking, position the special tool precisely.

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View from rear:

Unclip headliner with special tool 51 0 310.

IMPORTANT: Clamps are very securely fixed.
To prevent the clamps breaking, position the special tool precisely.

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Unscrew nuts (1).

Remove retractor mechanism (2) on left and right.

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Preparation of new part:

Connect four protective grommets (1) to springs (2).

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Release retractor mechanism (1) from roofliner.

Release clip (2) if necessary.

Do not open nodes in the tension cables (3).

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Installation:

Soft top must be in position shown.

Main pillar (1) is in vertical position.

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View from inside:

Check that clamps (1) are fitted correctly. Position clamps at the stages of the inner panel.

Replace missing or faulty clamps.

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Microencapsulated screws (Loctite) must be replaced and may not be reused

Screw connection must be completed within 20 min. (start of hardening)
Microencapsulated screws must not be retightened
Thread of nut must be cleaned beforehand in event of repeated use

Step 1:

Install retractor mechanism (1) on left and right.

Installation note:

Opening (3) for tension cable points outwards in the direction of travel.

Replace nuts (2).

Tightening torque 54 37 18AZ .

Step 2:

Install roofliner.

Engage 10 clips and 3 clamps per side.

Step 3:

Install left and right C-pillar flap.

Tightening torque 54 37 21AZ .

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Overview of tension cables:

Headliner tension cable (1) for C-pillar flap operation
Tension cable at side (2)
Tension cable (3) for C-pillar flap travel limiter (installation is dependent on the version)

Step 4:

Feed out left and right tension cable (1).

Step 5:

Screw left and right tension cable on to main bearing.

Tightening torque 54 37 16AZ .

Step 6:

NOTE: This must only be installed again if there is a previously installed tension cable (2).

Attach tension cable (1) in tension cable (2) and tighten.

Lay tension cable (1) around guide (3).

Position tension cable (1) to guide (3) using the mark (arrow).

Tighten screw (4).

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NOTE: The length of the tension cable (1) from attachment point up to mark is 135 mm.

Close soft top until the displayed position is reached.

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Step 7:

View from inside:

Position eye (1) in recess on roofliner.

Tighten screw (2).

Tightening torque 54 37 15AZ .

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Step 8:

View from inside:

Tighten screw (1).

Tightening torque 54 37 16AZ .

Installation note:

Eye must be flexible after fastening.

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Step 9:

Check position of headliner (1).

IMPORTANT: Risk of damage!
If positioned incorrectly, the headliner will become jammed when closing the soft top.

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Repeat steps (6) to (9) on right side of vehicle.

Step 10:

Remove headliner clips (1).

Feed out tension cable (2) for loop formed in retaining lug (3).

Pull back tension cable (2) until eye (3) rests against retaining lug (2).

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Step 11:

Tighten screws (1) and (2).

Tightening torque 54 37 14AZ .

Installation note:

Secure tension cable together with screw (2).

Release safety node by pulling jerkily on the tension cable.

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Step 12:

Feed out tension cable and screw on guide loop (2).

Tightening torque 54 37 15AZ .

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Repeat steps (10) to (12) on right side of vehicle.

Step 13:

Feed out O-ring (1) on tension cable (2).

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Step 14:

View from below:

Feed out tension cable (1) from front to rear in guide (2).

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Step 15:

Pull off 3 protective films (1) from C-pillar flap.

Installation note:

Only pull off protective films (1) immediately before affixing, as the adhesive reacts with atmospheric oxygen.

Stick on headliner crease-free.

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Step 16:

Turn and press down headliner in area (1).

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Step 17:

Feed out tension cable (1) through O-ring.

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Step 18:

IMPORTANT: Risk of damage to the tension cable.

Edges of the plastic holder (5) must be burr-free .

Deburr if necessary.

Feed out tension cable (1) in plastic holder (5).

Pull on tension cable (1) until headliner (2) rests against gasket (3).

Fasten tension cable (1) with retainer (4).

Install insert 54 0 230 in pliers 2 327 752.

Insert new retainer (1) in special tool 54 0 230 and crimp.

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Repeat steps (13) to (18) on right side of vehicle.

Install rear INTERIOR ROOF LIGHT .

Perform function check of soft top.