Replacing front roof shell gasket (M4 Convertible)

Special tools required: 

• 00 9 470

With water ingress in the area of the seat bench or the rear footwell: 

Check the water channel of the water discharge (1) for flow and clean where required before seal disassembly.

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Installation note: 

• Screws with sealing compound must be replaced and must not  be reused
• Thread of nut must be cleaned beforehand

New parts required:

• Butyl rope dia. 4 mm, BMW part number 83 22 2 159 535
• Butyl rope dia. 7 mm, BMW part number 83 19 0 416 659
• Butyl flat tape 1.5 mm x 15 mm, BMW part number 83 19 0 153 321

These repair instructions are also available as a video.

Removing the seal: 

Measure gap dimensions in following areas with special tool 00 9 470:

1. between roof shell and trim strip
2. between front and middle trim strips

Note down gap dimensions.

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Necessary preliminary work: 

• Move soft top into SERVICE POSITION .

Release left and right screws (1).

Tightening torque 54 37 01AZ .

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Unbutton the tabs (1) on the left and right.

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Release left and right screws (1).

Tightening torque 54 37 01AZ .

Remove seal.

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On-the-job safety: 

• Comply with the relevant safety regulations

Preparing the roof shell: 

REMOVE  Butyl remnants from roof shell.

Clean adhesive area with adhesive remover.

Air drying time: ≥ 1 minute

Attention! 

Adhesive area must be dry and free from dust and grease.

Apply butyl flat tape (1) to corner of roof shell (30 mm in length). Maintain distance of 20 mm from threaded bush.

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Prepare butyl rope dia. 7 mm, 250 mm long.

Starting at seal carrier, apply butyl rope as far as threaded bushing and cut off excess butyl.

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Apply butyl flat tape (1) to corner of roof shell (30 mm in length). Maintain distance of 20 mm (dimension a) from threaded bushing.

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Prepare butyl rope dia. 4 mm, 30 mm long.

Apply butyl rope ø 4 mm (1) around elongated hole.

Prepare butyl rope dia. 7 mm, 150 mm long.

Apply butyl rope ø 7 mm (2) along edge.

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Apply butyl rope with ø 7 mm (1) and cut off excess butyl.

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Prepare butyl rope dia. 4 mm, 150 mm long.

Affix butyl rope in area (1).

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Apply butyl rope in area (1) and cut off excess butyl.

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Apply butyl rope in area (1) and cut off excess butyl.

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Prepare butyl rope dia. 7 mm, 500 mm long.

Affix butyl rope in area (1). Make sure butyl rope (1) is correctly positioned in radius of roof shell (2).

Apply the Butyl on the right side of the vehicle analogous to the left side of the vehicle.

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Attention! 

Risk of leak.

Connect and smooth all butt joins of butyl ropes.

Installing the seal: 

Fit seal starting from the front.

Align attachment point (1) of seal in relation to thread.

Push on seal at front and side.

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Insert the tabs (1) on the left and right in the roof shell.

Evenly distribute Butyl under the tabs.

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Loosely install new screws.

Remove support and close roof.

Align gasket flush at front and rear.

Check GAP DIMENSIONS .

Observe screw-fitting sequence: 

Tighten screws from rear to front.

Tightening torque 54 37 01AZ .

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Checks: 

• Check seal for butyl squeeze-out. If possible, allow vehicle to stand for several hours with closed roof. Repeat test.

  Remove escaping BUTYL .

• Check that screws are secure. Make sure there is no gap between screw head and seal.
• Carry out leak test. Secure hose to roof and allow water to run over the area in question for 20 minutes.