54 37 015 Replacing middle roof shell seal (with open corners)

The following repair instructions apply to roof shells with open corners (1) only  .

For roof shells with closed corners, see Replacing middle roof shell seal (with closed corners) .

Fig 1: Identifying Open Corners

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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 Ø 4 mm 83 22 2 159 535
• Butyl rope Ø 7 mm 83 19 0 416 659
• Butyl flat tape 1.5 mm x 15 mm 83 19 0 153 321

Removing the seal: 

Move soft top into position shown in Fig 2.

Fig 2: Moving Soft Top Into Position

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Release left and right screws (1).

Fig 3: Identifying Screw At Rear Left

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Move soft top to service position .

Release the side of the interior roof lining (1) with a folding tool 00 9 321.

Installation note: 

Retainers must not be damaged and must be pre-installed on headliner.

Fig 4: Detaching Headliner

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Release left and right screws (1).

Tightening torque: 5 Nm

Fig 5: Releasing Left And Right Screws

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Heat seal to approx. 60 °C with hot air blower.

Loosen the front and back of the seal (1) with a folding tool 00 9 321 and thread out.

Remove the seal with a helper.

Remove butylene remnants  from roof shell.

Fig 6: Detaching Outer Third Of Seal

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On-the-job safety: 

• Comply with the relevant safety regulations

Clean adhesive area with adhesive remover.

Air drying time: = 1 minute

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

Affix butyl rope (1), starting at threaded bush.

Fig 7: Affixing Butyl Rope Starting At Threaded Bush

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Prepare butyl rope dia. 4 mm.

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

Affix butyl rope dia. 4 mm at area (1).

Affix butyl rope dia. 7 mm at area (2).

Fig 8: Affixing Butyl Rope At Areas Specified

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

Affix butyl rope in area (1).

Fig 9: Affixing Butyl Rope

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

Affix butyl tape (1), starting at threaded bush.

Fig 10: Identifying Butylene Flat Tape Laying On Rear Roof Shell Corner, Left/Right

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

Affix butyl rope (1) at radius.

Fig 11: Affixing Butyl Rope At Radius

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Prepare butyl rope dia. 4 mm.

Affix butyl rope (1).

Fig 12: Affixing Butyl Rope

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Prepare butyl rope dia. 4 mm, 150 mm long

Affix butyl rope (1) and cut off excess butyl.

Fig 13: Affixing Butyl Rope

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

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

Apply the Butyl on the right side of the vehicle in the same manner as the left side.

Fig 14: Affixing Butyl Rope Correctly Positioned In Radius Of Roof Shell

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Installing the seal: 

A second person will be needed to help install the seal.

Set seal in place at front and rear and adjust it sideways to correct position. Ensure that gasket is correctly seated.

Loosely install new screws.

Complete and close the roof.

Align seal flush at front and rear and tighten screws to secure. Check gap dimensions.

Tightening torque: 5 Nm

Fig 15: Measuring Gap Dimensions

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Tighten screw (1) at rear left and right.

Tightening torque: 5 Nm

Fig 16: Identifying Screws At Rear Left And Right

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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.

  If squeezed out, remove 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.