Disclaimer2000 BMW 328i (E46) Technical Service Bulletin # 540506 Date: 060601
Body - Various Sunroof Failures/Malfunctions
SI B54 05 06
Special Roofs
June 2006
Technical Service
This Service Information bulletin supersedes S.I. B54 04 03 dated May 2006.
[NEW] designates changes to this revision
SUBJECT
Sunroof Repairs
MODEL
E46 (3 Series) up to [NEW] 09/03 production
SITUATION
The customer may complain of various failures associated with the sunroof or sliding headliner. If components of the sunroof are damaged, it was
previously necessary to replace the entire sunroof cassette assembly, since separate components were not replaceable.
CORRECTION
Separate replacement parts and repair procedures have been developed for vehicles produced prior to September 2003.
Note:
A modified sunroof cassette assembly, including the sliding headliner and drive components, was introduced on vehicles produced from
September 2003.
PROCEDURE
Remove the sunroof glass per Repair Instructions RA 54 12 115.
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Check the slide driver (2) for damage. If no damage is visible, check the vertical clearance as follows:
Carefully insert a feeler gauge (1) under the slide driver (2) and check the vertical clearance between the driver and the guide rail (3).
Test Result
The slide driver is not damaged and the vertical clearance is less than 2.5 mm.
Necessary Measure
Check the sliding headliner as well as the left and right side slide elements for damage. Refer to the chart shown for necessary component
replacement and repair procedure.
PARTS INFORMATION
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Parts information is included with the respective repair procedure.
WARRANTY INFORMATION
Warranty information is included with the respective repair procedure.
NOTE:
If repairs similar to those noted on this SIB are made on a vehicle outside of the noted production range, use the appropriate regular defect code,
instead of those listed in these repair procedures.
ATTACHMENTS
attachment B540506 Repair Procedure 1
attachment B540506 Repair Procedure 2
attachment B540506 Repair Procedure 3
Disclaimer
Repair Procedure # 1
REPAIR PROCEDURE 1
Repair instructions for replacing the driver's side slide element(s).
PARTS INFORMATION
Note:
The driver's side elements can be replaced individually or in pairs as required.
Select the driver's side slide element according to the version of the sliding headliner installed on the vehicle.
(1) Slide element for sliding headliners used up to 09/2003 (dimension A = 13 mm).
(2) Slide element for sliding headliners used from 09/2003 (dimension B = 21 mm).
PROCEDURE
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To replace the defective slide element on the front of the sliding headliner:
Note:
The sunroof glass was already removed before inspecting the driver.
Remove the screws of the defective driver's side slide element at the front and/or rear of the sliding headliner.
Push the defective slide element on the front of the sliding headliner forward along the guide rail and remove.
481
Working from the front of the sliding headliner, install a replacement front slide element on the guide rail and slide it into position.
To replace a defective slide element on the rear of the sliding headliner:
Remove the screws of the defective driver's side slide element at the rear of the sliding headliner.
482
Push the defective slide element on the rear of the sliding headliner back along the guide rail and remove.
Working from the rear of the sliding headliner, install a replacement rear slide element on the guide rail and slide it forward into position.
Important:
483
The rear slide element (1) must be fitted behind the driver (2).
Secure the front and/or rear slide element(s) with the screws provided.
Tightening torque: 1.0 Nm
Reinstall the sunroof glass per Repair Instructions RA54 12 115.
WARRANTY INFORMATION
Covered under the terms of the BMW New Vehicle Limited Warranty.
Repair Procedure # 2
REPAIR PROCEDURE 2
Repair instructions for replacing the sliding headliner and/or the passenger's side slide elements.
484
PARTS INFORMATION
PROCEDURE
Note:
The sunroof glass was already removed before inspecting the driver.
Remove the screws from the front and rear driver's side slide elements.
485
Push the slide element located on the front of the sliding headliner forward along the guide rail and remove.
Push the slide element located on the rear of the sliding headliner back along the guide rail and remove.
Pull the sliding headliner along with the passenger's side slide elements up and out of the guide rail.
486
Note:
When replacing the sliding headliner (2), the passenger's side slide elements (1) are already fitted to the new sliding headliner.
Note:
The following step only needs to be performed when replacing the passenger's side slide element:
Slide the passenger's side slide element (1) completely onto the springs (2) of the sliding headliner (3).
487
Install the sliding headliner with the pre-installed passenger's side slide elements into the guide rail.
Note:
Make sure that the pre-installed front and rear passenger's side slide elements are inserted into the upper channel of the guide rail.
488
Note:
Both driver's slide elements must be replaced when installing a new sliding headliner.
Working from the front of the sliding headliner, install the driver's side front slide element onto the guide rail and slide it into position.
Working from the rear of the sliding headliner, install the driver's side rear slide element onto the guide rail and slide it forward into position.
Note:
The driver's side rear slide element (1) must be fitted behind the driver (2).
489
Secure the front and/or rear slide element(s) with the screws provided.
Tightening torque: 1.0 Nm
Reinstall the sunroof glass per Repair Instructions RA54 12 115.
WARRANTY INFORMATION
Covered under the terms of the BMW New Vehicle Limited Warranty.
Repair Procedure # 3
REPAIR PROCEDURE 3
Repair instructions for replacing the sliding headliner and/or the slide driver.
490
PARTS INFORMATION
PROCEDURE
Remove the complete sunroof cassette per Repair Instructions RA 54 12 211.
Place the sunroof cassette on a work bench.
Carefully unclip the left and right water channel brackets from the linkage arms.
491
Guide the water channel slide element out of the passenger's side guide rail through the opening provided for this purpose.
Remove the left slide element together with the water channel from the guide rail.
Detach the water channel by pulling in an upward direction.
Remove the retaining screws from both drivers' side slide elements.
492
Push the slide element located on the front of the sliding headliner forward along the guide rail and remove.
Push the slide element located on the rear of the sliding headliner back along the guide rail and remove.
Lift out the sliding headliner.
493
Peel a section of the foam seal from the driver's side rear corner of the frame so that the two rivets securing the ends of the plastic corner piece to the
frame are exposed.
Note:
The adhesive tape may leave residue on the frame.
Drill out both rivets securing the corner piece (one rivet on each end).
494
Use a heat gun to warm the aluminum frame and break the adhesive holding the corner piece to the frame by prying with a screwdriver or putty
knife. Work the tool carefully, using small bites, to prevent damage to the frame.
Remove the old adhesive from the frame with a razor blade.
Remove the drive slide from the track, and clean the tracks of any broken plastic pieces, dirt and old grease.
Lubricate the track with Wurth Glide grease, article number 0893898. Use of other types of grease may react with any grease remaining in the track
and cause the mechanism to bind and stick.
Install the new drive slide from the kit into the track from the rear of the guide rail.
495
Note:
In contrast to the old slide driver, the new slide driver (1) wraps around the guide rail (2) and must be installed from the end of the guide rail (2).
Clean and lubricate the passenger's side tracks with Wurth Glide grease, article number 0893898.
Install the new sliding headliner with the preassembled passenger's side slide elements into the upper channel of the guide rail.
496
Install both new driver's side slide elements with the screws provided and tighten to 1.0 Nm.
Note:
The rear driver's side slide element (1) must be fitted behind the slide driver (2).
Apply a strip of 1/4" thick 3M Window Weld Ribbon Sealer approximately 20 cm (8") long, adjacent to the lip in the new corner piece. This will
seal the plastic to the frame to prevent water leakage into the car.
497
Reinstall the tabs of the corner piece into the frame and press into place to ensure a good seal to the frame.
Pop rivet the corner piece into the existing holes.
498
Apply the double-sided tape from the kit to the frame corner piece (see hatched area).
Reinstall the foam seal and press into place on the adhesive tape.
Install the new water channel with slide element on driver's side guide rail.
499
Insert the water channel slide on the passengers side in the opening in the guide rail provided for this purpose.
Clip the left and right water channel brackets into the linkage arms.
Reinstall the sunroof cassette per Repair Instructions RA54 12 211.
Reinstall the sunroof glass per Repair Instructions RA54 12 115.
500
WARRANTY INFORMATION
Covered under the terms of the BMW New Vehicle Limited Warranty.
