54 37 031 Replacing Butyl At Seal, Roof Shell Centre Left or Right

54 37 031 Replacing Butyl At Seal, Roof Shell Centre Left Or Right

Special tools required:







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 as a video.







Removing the seal:







Move soft top into position shown.

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







Move soft top into position shown.







Release screw (1) at rear left.







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.







Release screws (1).

Tightening torque: 54 37 01AZ.







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.







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.







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







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







Clean adhesive area with adhesive remover.

Air drying time: ≥ equal to 1 minute

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







Prepare butyl flat tape 30 mm long.

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







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

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).







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

Affix butyl rope in area (1).







Prepare butyl flat tape 30 mm long.

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







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

Affix butyl rope (1) at radius.







Prepare butyl rope dia. 4 mm.

Affix butyl rope (1).







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

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







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).







IMPORTANT:
- Risk of leak.
- Connect and smooth all butt joins of butyl ropes.







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 seal is correctly seated.

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: 54 37 01AZ.







Tighten screw (1) at rear left.

Tightening torque: 54 37 01AZ.







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.