54 37 030 Replacing butyl at front left or right roof shell seal

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: 

Measure gap dimensions in following areas with special tool 00 9 470 (Gap gauge):

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

   Note down gap dimensions.

Fig 1: Measuring Gap Dimensions With Special Tool

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Necessary preliminary tasks: 

• Move soft top to working position.

Release screw (1).

Tightening torque: 5 Nm

Fig 2: Identifying Screws

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Unbutton tab (1).

Fig 3: Identifying Seal

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Release screws (1).

Tightening torque: 5 Nm

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

Remove seal at left side of vehicle.

Fig 4: Identifying Roof Shell Left And Right Screws

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Preparation: 

On-the-job safety: 

• Comply with the relevant safety regulations

Remove residual butyl from roof shell and seal.

Clean adhesive area with adhesive remover.

Air drying time: = 1 minute

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

Fig 5: Identifying Butylene Flat Tape On Front Roof Shell Corner, Left/Right

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Prepare butyl rope Ø 7 mm and 250 mm in length.

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

Fig 6: Applying Butyl Rope As Far As Threaded Bushing

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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.

Fig 7: Applying Butyl Flat Tape To Corner Of Roof Shell

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Prepare butyl rope Ø 4 mm and 30 mm in length.

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

Prepare butyl rope Ø 7 mm and 150 mm in length.

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

Fig 8: Applying Butyl Rope

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

Fig 9: Applying Butyl Rope With Ø 7 Mm

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Prepare butyl rope Ø 4 mm and 150 mm in length.

Apply butyl rope in area (1).

Fig 10: Applying Butyl Rope In Area Specified (1 Of 3)

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

Fig 11: Applying Butyl Rope In Area Specified (2 Of 3)

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

Fig 12: Applying Butyl Rope In Area Specified (3 Of 3)

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Prepare butyl rope Ø 7 mm and 500 mm in length. Apply butyl rope in area (1).

Ensure that butyl rope (1) is correctly positioned in radius of roof shell (2).

Fig 13: Applying Butyl Rope Correctly Positioned In Radius Of Roof Shell

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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.

Fig 14: Aligning Seal With Screw Fastening Point To Thread In Roof Shell

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Button tab (1) into roof shell.

Distribute butyl evenly beneath the tab.

Fig 15: Identifying Seal

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Loosely screw in new bolts.

Remove support and close roof.

Align seal in a flush position at front and rear and screw in position. Check gap dimensions.

Tightening torque: 5 Nm

Fig 16: Measuring Gap Dimensions

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Checks: 

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

  Remove escaping butyl .

• Check that bolts are firmly seated. There must not be a gap between the bolt head and the seal.
• Carry out leak test. To do this, attach a hose to the roof and allow water to run over the affected area for 20 minutes.