Removing and installing roof module (M4 Convertible)

Special tools required:

54 0 190
54 0 180
54 0 101
54 0 102
54 0 130
2 360 046
54 0 131
54 0 132
00 9 461
54 0 120
00 9 450

Necessary preliminary tasks:

Connect BATTERY CHARGER .
Remove left and right WEATHER STRIP .
Remove AIR OUTLET ORNAMENTAL GRILLE .
Remove TRIM PANEL FOR LUGGAGE COMPARTMENT PARTITION WALL
Remove LEFT BACKREST SIDE SECTION
Remove COVER FOR LUGGAGE COMPARTMENT .
Remove REAR MODULE .
Remove left and right luggage compartment wheel arch panels. Refer to REMOVING AND INSTALLING/REPLACING LEFT LUGGAGE COMPARTMENT WHEEL ARCH PANEL and REMOVING AND INSTALLING/REPLACING RIGHT LUGGAGE COMPARTMENT WHEEL ARCH PANEL .

Removal:

For the following work the soft top must be in the position shown.

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Unfasten screw connection (1).

Remove the torsion cover (2).

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Left side:

Detach plug connections (1) from support (2).

Unlock plug connections (1) and disconnect.

Unscrew nuts (3).

Thread out support (2).

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Left side:

Release cable straps on hydraulic lines.

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Unlock plug connections and disconnect.

Feed out associated cables.

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Right side:

Release screws (1).

Take off holder (2).

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Right side:

Release cable strap (1).

Unclip cable clip (2).

Unfasten plug connection (3) and disconnect.

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Release left and right screws (1).

Slacken lock nuts with special tool 54 0 190.

Unscrew barrel screws using special tool 54 0 180.

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

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

NOTE: Carry out work on the right side in the same way as for the left side illustrated here.

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

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Carefully insert folded 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.

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Assemble linkage and screw down.

Adjust rotary sleeve (1) if necessary.

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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.

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Lay linkage (1) for luggage compartment partition.

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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 effort, pull tensioning rods outwards over rotary sleeves.

Slide retaining sleeve (1) over pivot joint.

Feed out control unit (1).

Use a hexagon socket (AF 4) to slowly open the shutoff valve on the hydraulic unit by three turns.

NOTE: Shutoff valve is found under a plastic funnel.

With roof shells lowered, close shutoff valve.

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Fix hydraulic unit (1) and hydraulic cylinder (2) by cable straps to assembly carrier.

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

IMPORTANT: Note the weight of the roof shells!

It is imperative that you only grasp the front roof shell when lowering the roof shells.

Place roof module in luggage compartment.

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Carefully set down the roof shells.

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

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Remove left and right facings (1).

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Release left and right screws (1).

Remove left and right holders (2).

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

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

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

Turn barrel screw back.

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Feed out cable.

Unfasten plug connection (1) and disconnect.

Detach water drain hose (2).

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

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

Adjust eye (1) as per dimension (A).

Dimension (A) = 57 cm

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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 straps to assembly carrier.

Attach rear strap to assembly carrier.

IMPORTANT: Straps must not be twisted!

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To lift out the soft top uniformly, make sure the special tool is aligned parallel to the roof module.

Lifting out roof module carefully and in stages with lifting gear.

Check freedom of movement of roof module with respect to body.

Carefully set roof module down on a suitable surface (e.g. squared beams on pallet).

Replacement only:

Refer to REPLACING ROOF MODULE .

Set removed roof module down on inside of lid of transportation crate and bolt down.

Change assembly carrier to new roof module and install roof module in vehicle.

Set down removed roof module with assembly carrier from inside of transportation crate and bolt down.

Remove assembly carrier.

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Installation:

Adjust eye (1) as per dimension (A).

Dimension (A) = 57 cm

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Mount assembly carrier on roof module.

Do not twist straps!

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.

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

Check freedom of movement of roof module with respect to body.

Lift in roof module carefully and in stages with lifting gear.

Detach rear strap on assembly carrier.

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Detach strap from assembly carrier.

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NOTE: For purposes of clarity, shown with roof module deployed.

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

Gauge coupling lock.

IMPORTANT: To prevent damaging the coupling lock gauge, set the coupling lock gauge down only in the transportation crate or on the cross member.

The coupling lock gauge is a highly sensitive measuring instrument which reacts even to light impacts with distortion.

The coupling lock gauge must be checked for dimensional accuracy on a master gauge after being subjected to impact or dropped.

Mount BASIC GAUGE .

NOTE: Basic setting of coupling lock must be ensured.

For purposes of clarity, washers (1 and 2) are pulled out.

Only one washer (1 and 2) per side may be fitted.

Washer (1) = 0.5 mm

Washer (2) = 1 mm

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Before remounting the washers, mark the position of the lock (4).

Slacken screw (3) and fit corresponding washers (1 and 2).

Tighten screw (3).

Step 1:

Special tool 54 0 130 must be equipped with correct special tool (1).

Special tool (1) without labelling only matches E93.

Special tool (1) with labelling "2 360 046 A" only matches F33/F83.

Remount SPECIAL TOOL (1) as necessary.

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Step 2:

NOTE: Coupling lock may not be screwed for adjustment work (barrel screws move freely).

Insert special tool 54 0 130 in coupling lock (1).

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Step 3:

Screw coupling lock gauge 54 0 131 left and 54 0 132 right to basic gauge with special tool 00 9 461.

Tightening torque 6 Nm

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NOTE: While aligning the coupling lock gauge 54 0 130 to basic gauge 54 0 120, only the new bolts (1) from delivery specification 2 360 046 may be used.

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Step 4:

Position L-piece (1) under stop screw (2) of coupling lock.

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Step 5:

Screw guide pin (1) into coupling lock (2).

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Step 6:

Make sure special tool is in correct position:

Stop screw (1) to limit position (2)
L-piece (4) to stop screw (1)

Tighten screw (3) for L-piece (4).

Stop screw (1) must not be adjusted.

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Repeat steps 1 to 6 on right side of vehicle.

Installation note:

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 .

Step 7:

Bring barrel screws (1) into contact with special tool 54 0 180 in conjunction with 00 9 450.

Tightening torque 54 37 22AZ .

Tighten lock nuts (2) with special tool 54 0 190.

Tightening torque 54 37 24AZ .

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Step 8:

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

Tightening torque 54 37 13AZ .

Mount left and right ground straps and tighten screws (2).

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Step 9:

NOTE: When tightening the screw (2), make sure the bush (1) rotates out until it is contacting on the coupling lock (3).

Tighten screw (2).

Tightening torque 54 37 12AZ .

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Repeat steps 7 to 9 on right side of vehicle.

Step 10:

Unscrew guide pin (1) from coupling lock (2).

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Step 11:

Feed out L-piece (1) under stop screw (2) of coupling lock.

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Step 12:

Dismount coupling lock gauge 54 0 131 left and 54 0 132 right from basic gauge and remove.

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Repeat steps 10 to 12 on right side of vehicle.

Remove BASIC GAUGE .

Step 13:

Connect connector (1) and feed in cable. (Left side only)

Connect water drain hose (2).

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Step 14:

Insert left and right holders (2).

Tighten screws (1) on left and right.

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Step 15:

Insert left and right facings (1).

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Repeat steps 13 to 15 on right side of vehicle.

IMPORTANT: Pay attention to the weight of the roof module!

Secure vehicle to prevent it rolling.

A second person is needed to help lift out the roof module.

It is imperative that you only grasp the front roof shell when lifting out the roof module.

Lift roof module out of luggage compartment.

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The roof module must be in the position shown.

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Release hydraulic unit (1) and hydraulic cylinder (2) from assembly carrier and place in luggage compartment.

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Slacken nuts (1).

Pull off linkage (2) from barrel screw.

Release screw (3).

Disconnect the linkages (2) from each other.

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Release screws on left and right main bearings.

Push back sleeve (1).

Fold special tool 54 0 101 inwards and carefully take it out of the luggage compartment.

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Set roof module manually to position shown.

Close shutoff valve of hydraulic unit (see next step).

Make sure the roof module cannot move for the following operations. Have a second person secure it as necessary.

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Slowly close shutoff valve on hydraulic unit using a hexagon socket (AF 4).

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To avoid tension, slacken nuts (1) on left and right.

Insert front nuts (1) on left and right.

Tighten all nuts (1) on left and right.

Tightening torque 54 37 20AZ .

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Installation note:

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

Tightening torque 54 37 22AZ .

Tighten lock nuts with special tool 54 0 190.

Tightening torque 54 37 24AZ .

Tighten screws (1) on left and right.

Tightening torque 54 37 13AZ .

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Set roof module manually to position shown.

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Insert cover (2) and attach expanding rivet (1).

NOTE: Carry out work on the right side in the same way as for the left side illustrated here.

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Right side:

Attach cable strap (1).

Attach cable clip (2).

Connect connector (3).

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Right side:

Insert holder (2).

Tighten down screws (1).

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Feed in cable.

Connect connector.

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Left side:

Attach cable straps on hydraulic lines.

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Left side:

Feed in support (2).

Tighten down nuts (3).

Connect the plug (1).

Attach connector (1) in support (2).

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Insert torsion cover (2).

Tighten down nuts (1).

Tightening torque 51 71 11AZ .

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Required follow-up work:

Install the luggage compartment wheel arch panel on the left and right. Refer to REMOVING AND INSTALLING/REPLACING LEFT LUGGAGE COMPARTMENT WHEEL ARCH PANEL and REMOVING AND INSTALLING/REPLACING RIGHT LUGGAGE COMPARTMENT WHEEL ARCH PANEL .
Install REAR MODULE .
Install left and right WEATHER STRIP .
Install AIR VENT ORNAMENTAL GRILLE .
Install LUGGAGE COMPARTMENT PARTITION WALL TRIM PANEL
Install COVER FOR LUGGAGE COMPARTMENT .
Install LEFT BACKREST SIDE SECTION
Disconnect BATTERY CHARGER .

Check GAP DIMENSIONS and adjust if necessary.

Carry out diagnosis.