Removing and installing rear module (M4 Convertible)

Special tools required:

2 360 048
54 0 240
54 0 180
00 9 450

Necessary preliminary work:

Connect BATTERY CHARGER .
Remove COVER FROM TAIL PANEL .
Remove luggage compartment trim panel on side panel on left and right. Refer to REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT TRIM PANEL ON SIDE PANEL, LEFT and REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT TRIM PANEL ON SIDE WALL, RIGHT .
Remove TRIM ON SUPPORT TUBE on left and right
Remove TRIM PANEL FOR REAR LUGGAGE COMPARTMENT .

Installation note:

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

Open soft top compartment cover.

Open tailgate at the emergency release.

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Attention!

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

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Release screws (1) on left and right.

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NOTE: To secure the installation position of the rear kinematics to each other, use the special tool 2 360 048 D.

Fully turn back all knurled screw (1) on the special tool 2 360 048 D.

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Insert the special tool 2 360 048 D between the rear kinematics on the left and right.

Turn the screw (1) left and right by approx. 2 turns.

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Center special tool 2 360 048 D.

Turn in the screw (1) with the fitting sleeves on left and right into the rear kinematics evenly and tighten down.

Turn in the screws (2) on left and right until they are in contact with the rear kinematics.

Tighten the screws (3) on the left and right.

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Right side:

Unlock plug connection (1) for the hall effect sensor (2) and disconnect.

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Right side (variant 1):

Open cable routing (1) and detach wiring harness (2).

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Right side (variant 2):

Disconnect and remove cable strap (1).

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Right side:

Pull off plug connection (1) towards bottom.

Unfasten cable strap (2).

Feed out cable towards rear.

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Right side:

Release holder (1) from body, do not disconnect associated plug connections.

Unlock and disconnect plug connections (2 and 5).

Unfasten cable clip (3).

Release cable strap (4).

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Right side:

Release screw (1) from outside.

Detach holder (2) towards top.

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Right side:

Unclip cable clip (1) from holder (2) towards top.

Feed out wiring harness (3).

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Right side:

Release screw (1).

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Right side:

Slightly raise retaining clip (1) and detach hydraulic cylinder (3) from ball head (2).

Unclip cable tie (4).

Feed out hydraulic cylinder (3) with the wiring harness and the hydraulic lines and set down in the luggage compartment.

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Left side:

Pull off plug connection (1) towards bottom.

Detach and disconnect plug connection (2).

Unfasten cable clip (3).

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Left side:

Release screw (1) from outside.

Detach holder (2).

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Left side:

Release screw (1).

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Left side:

Slightly raise retaining clip (1) and detach hydraulic cylinder (3) from ball head (2).

Unclip cable tie (4).

Feed out hydraulic cylinder (3) with the wiring harness and the hydraulic lines and set down in the luggage compartment.

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Clip the special tool 54 0 240 onto hydraulic cylinder (1) on left and right for protection.

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Carefully close the tailgate until the soft-close automatic closes.

First unlock and disconnect plug connection (1) without locking bracket.

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

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Unlock and disconnect plug connections (2) with locking bracket.

Release left and right screws (1).

NOTE: Do not adjust barrel screws.

Only when replacing rear module/rear trim panel:

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

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

Do not release screws.

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Attention!

Risk of damage!

Proceed with the greatest caution when carrying out the following work.

Three helpers are essential for the following work.

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

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Attention!

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 and hold supporting in Z-direction.

NOTE: Console is double-jointed and bends.

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Working with an assistance, release screws (1) on left and right at the same time from the bearing support.

Lift out rear module.

Set down rear module on a suitable support.

Attention!

Do not damage any surrounding parts.

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Installation:

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NOTE: If the special tool 2 360 048 D is removed for repair work, it will need to be inserted before installing the rear module.

The special tool is adjusted to ensure the rear kinematics is at the specification.

Loosely screw on special tool to rear kinematics left and right with bolt (1).

Right side (A):

Screw bolts (2) to block at special tool.

Make sure the dowel pin (3) in the rear kinematics is in the correct position.

Tighten screw (1).

Left side (B):

Fasten screws (2) with spacer (4) to block on the special tool.

Make sure the dowel pin (3) in the rear kinematics is in the correct position.

Tighten screw (1).

Attention!

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 and hold supporting in Z-direction.

NOTE: Console is double-jointed and bends.

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Attention!

Do not damage any surrounding parts.

Insert rear module.

With one person each on the left and right, simultaneously tighten screws (1) at the marks.

Tightening torque 54 37 19AZ .

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Attention!

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

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Tighten screws (1) on left and right.

Tightening torque 54 37 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 37 22AZ .

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Connect connectors (1 and 2).

Open tailgate at the emergency release.

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Remove special tool 54 0 240 on left and right from hydraulic cylinder (1).

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Left side:

Slide retaining clip (1) to the correct position on the hydraulic cylinder (3).

Feed out hydraulic cylinder (3) with the wiring harness and the hydraulic lines.

Clip on the hydraulic cylinder (3) onto the ball head (2).

Clip in cable clip (4).

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Left side:

Tighten screw (1).

Tightening torque 54 37 31AZ .

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Left side:

Attach holder (2).

Tighten screw (1) from outside such that the holder (2) can still be moved.

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Left side:

Connect connectors (1 and 2).

Secure cable clip (3).

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Right side:

Slide retaining clip (1) to the correct position on the hydraulic cylinder (3).

Feed out hydraulic cylinder (3) with the wiring harness and the hydraulic lines.

Clip on the hydraulic cylinder (3) onto the ball head (2).

Clip in cable clip (4).

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Right side:

Tighten screw (1).

Tightening torque 54 37 31AZ .

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Right side:

Feed in wiring harness (3).

Clip cable clip (1) onto holder from top (2).

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Right side:

Attach holder (2).

Tighten screw (1) from outside such that the holder (2) can still be moved.

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Right side:

Fasten holder (1) on body.

Connect connectors (2 and 5).

Attach cable clip (3).

Attach cable strap (4).

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Right side:

Feed in cable from the rear.

Connect cable clip (2).

Connect the connector (1).

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Right side (variant 1):

Attach wiring harness (2) in the cable routing (1).

Lock cable duct (1).

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Right side (variant 2):

Prepare cable strap (part number 61 13 1 367 599) and a 35 mm long piece of adhesive tape.

On the cable strap (1) use adhesive tape to make a limit position (2) at a distance a.

Dimension a=115 mm

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Right side (variant 2):

Thread in cable strap (1) and tighten to the specified limit position.

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Right side (variant 2):

Turn the head (1) inwards.

The cable must be movable.

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Right side:

Connect connector (1) to hall effect sensor (2).

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Turn back screws (1 to 3).

Remove special tool 2 360 048 D.

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Tighten the screws (1) on the left and right.

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Remove support.

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Open the soft top completely.

This process will automatically center the locking plate.

Tighten screw (1).

Tightening torque 54 37 30AZ .

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Installation note:

Check GAP DIMENSIONS and adjust if necessary.

Carry out diagnosis.

Required follow-up work:

Disconnect BATTERY CHARGER
Install TRIM ON TAIL PANEL .
Install luggage compartment trim panel on side panel on left and right. Refer to REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT TRIM PANEL ON SIDE PANEL, LEFT and REMOVING AND INSTALLING/REPLACING LUGGAGE COMPARTMENT TRIM PANEL ON SIDE WALL, RIGHT .
Install TRIM ON SUPPORT TUBE on left and right
Install TRIM PANEL FOR LUGGAGE COMPARTMENT at rear