54 37 005 Replacing Front Roof Shell Gasket

54 37 005 Replacing Front Roof Shell Gasket

Special tools required:







IMPORTANT:
- Sealing systems with different production dates are installed.
- Mixed installation is not permitted.
- Distinguishing features, sealing system.







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 83 22 2 159 535
- Butyl rope dia. 7 mm 83 19 0 416 659
- Butyl flat tape 1.5 mm x 15 mm 83 19 0 153 321

These repair instructions are also available on video.







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







A. between roof shell and trim strip
B. between front and middle trim strips

Note down gap dimensions.







Necessary preliminary work:
- Move into working position







Release left and right screws (1).

Tightening torque: 54 37 01AZ.







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







Release left and right screws (1).

Tightening torque: 54 37 01AZ.

Remove seal.







Preparation:







On-the-job safety:
- Comply with the relevant safety regulations







Remove Butyl remnants from roof shell.

Clean the bonding area with adhesive remover.

Air drying time: ≥ 1 minute

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







Apply the Butyl flat tape (1) at 30 mm length on the roof shell corner. Adhere to 20 mm distance to the threaded socket.

Prepare the Butyl rope dia. 7 mm and length of 250 mm.







Apply the Butyl rope beginning from the gasket support to the threaded socket and remove excess Butyl.







Apply the Butyl flat tape (1) at 30 mm length on the roof shell corner. Adhere to 20 mm distance (Dimension a) to the threaded socket.







Prepare the Butyl rope dia. 4 mm and length of 30 mm.

Apply Butyl rope dia. 4 mm (1) along the elongated hole.

Prepare the Butyl rope dia. 7 mm and length of 150 mm.

Apply the Butyl rope dia. 7 mm (2) along the edge.







Apply the Butyl rope dia. 7 mm (1) and discard excess Butyl.







Prepare the Butyl rope dia. 4 mm and length of 150 mm.

Apply Butyl rope in area (1).







Apply the Butyl rope in area (1) and discard excess Butyl.







Apply the Butyl rope in area (1) and discard excess Butyl.







Prepare the Butyl rope dia. 7 mm and length of 500 mm.

Apply Butyl rope in area (1). Make sure the Butyl rope (1) is correctly positioned in the radius of the roof shell (2).

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







IMPORTANT:
- Risk of leak.
- Connect all contact points of the Butyl ropes and smooth them out.







Installing the gasket:







Install the gasket beginning in front.

Align the attachment point (1) of the gasket with the thread.

Press the gasket on in front and on the side.







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

Evenly distribute Butyl under the tabs.

Loosely screw the new screws in.

Remove the support and close the roof.







Align the gasket flush in front and back and screw tight. Check gap dimensions.

Tightening torque: 54 37 01AZ.







Checks:
- Check gasket for Butyl leak. If possible, let the vehicle stand with closed roof for several hours. Repeat check.
Remove any leaked out Butyl.

- Check that screws are firmly seated. There may not be a gap between the screw head and the gasket.
- Carry out leakage test. Attach the hose on the roof and let water run over the affected area for 20 minutes.