54 37 031 Replacing butyl at seal, roof shell center left or right (with closed corners)

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

For roof shells with open corners, see REPLACING BUTYL AT SEAL, ROOF SHELL CENTRE LEFT OR RIGHT (WITH OPEN CORNERS) .

Fig 1: Identifying Closed 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

Removing the seal:

Move soft top into position shown in Fig 2.

Tape off seal, roof shell center, with adhesive tape.

Fig 2: Identifying Convertible Top Angle

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Move soft top into position shown in Fig 3.

Fig 3: Moving Soft Top Into Position

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Release screw (1) at rear left.

Fig 4: Identifying Screw At Rear Left

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Move soft top to assembly position .

Detach headliner (1) at side with fishbone 00 9 321.

Installation note:

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

Fig 5: Detaching Headliner

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Release screws (1).

Tightening torque: 5 Nm

Fig 6: Releasing Left And Right Screws

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

Detach outer third of seal (1) at front and rear with fishbone 00 9 321.

Fig 7: Detaching Outer Third Of Seal

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IMPORTANT: Protect seal from damage by masking it off.

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 8: 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

IMPORTANT:

Risk of damage!

Tape off sheet metal tab (1) at front and rear with adhesive tape.

Pull seal off roof panel.

Remove butyl from seal and roof shell.

Fig 9: Taping Off Sheet Metal Tab

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For better accessibility, affix seal (1) to front roof shell with adhesive tape.

Fig 10: Affixing Seal To Front Roof Shell With Adhesive Tape

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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

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

Prepare butyl rope dia. 4 mm, 50 mm long.

Affix butyl rope (1), starting at threaded bush. Completely close gap with butyl rope.

Fig 11: Affixing Butyl Rope

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Prepare butyl rope dia. 4 mm.

Prepare butyl rope dia. 7 mm, 200 mm long.

Affix butyl rope dia. 4 mm at area (1) along entire length of roof shell.

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

Fig 12: Affixing Butyl Rope At Areas Specified

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Prepare butyl rope dia. 4 mm, 70 mm long.

Affix butyl rope in area (1).

Fig 13: Affixing Butyl Rope

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Prepare butyl rope dia. 4 mm, 50 mm long.

Affix butyl rope (1), starting at threaded bush. Completely close gap with butyl rope.

Fig 14: Affixing Butyl Rope Starting At Threaded Bush

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Prepare butyl rope dia. 7 mm, 120 mm long.

Affix butyl rope (1) at radius.

Fig 15: Affixing Butyl Rope At Radius

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Prepare butyl rope dia. 4 mm, 70 mm long.

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

Fig 16: Affixing Butyl Rope

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Prepare butyl rope dia. 4 mm.

Affix butyl rope (1).

Fig 17: 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).

Fig 18: Affixing Butyl Rope Correctly Positioned In Radius Of Roof Shell

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IMPORTANT:

Risk of leak.

Connect and smooth all butt joins of butyl ropes.

Fig 19: Identifying Roof Shell

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Installing the seal:

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

IMPORTANT:

Risk of damage!

Remove adhesive tape from sheet metal tab (1) at front and rear.

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

Fig 20: Identifying Sheet Metal Tab

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Remove support and close roof.

Loosely install new screws.

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

Tightening torque: 5 Nm

Fig 21: Measuring Gap Dimensions

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Tighten screw (1) at rear left.

Tightening torque: 5 Nm

Fig 22: 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.