Sunroof Cassette - Installation Instructions
Group 54Special Roofs
Bulletin Number
54 03 95 (4250)
Woodcliff Lake, NJ
August 1995
Product Engineering
SUBJECT:
Sunroof Cassette Installation Instructions
MODELS:
E36
Situation:
The replacement sunroof cassettes supplied through the parts system have been superseded by the later style cassettes that have been used in production since 11/94. These replacement cassettes are supplied without the drive motor, sliding headliner, and the slides and lick arm for the headliner. The parts fiche shows that an installation kit, part number 54 12 8 206 384, must be used when installing the new cassettes in cars produced before 11/94.
The installation kit contains the new style headliner slides and locking arm that must be used in the late cassettes. The drive motor and headliner are to be transferred from the old cassette.
Since the new cassettes use a white plastic torsional locking arm similar to the mechanism in the E38 to engage the sliding headliner, a technician may encounter difficulty in installing the parts the first time he attempts it.
Please use the following procedure as a guide until the repair manual is updated.
Procedure:
Remove the old cassette and lay it out on a bench near the new cassette in order to transfer parts.
The cassette is generally shipped with the lid mechanism in the full open position. Transfer the drive motor and use a hex driver to operate the cables.
Crank the mechanism forward and continue cranking until the pin on the headliner cable is about 15-20 mm in front of the notch in the left rail.
Install the white nylon torsional lock arm in the rail at the rear and slide forward until it slips into the notch in the rail.
Crank the headliner cable to the rear until it engages the notch on the torsional lock arm.
Install the aluminum headliner slides. The rear of the left slide will connect to the torsional lock arm.
Transfer the sliding headliner. Make sure that the left rear corner fits into the hook on the top of the torsional lock arm. Check for proper operation and continue installation.