ACCESSORIES & EQUIPMENT Convertible Top - Repair - Cooper REMOVING AND INSTALLING/REPLACING REAR WINDOW BACKFITTING CONVERTIBLE TOP WITH STOWAGE LOCK (FROM 09/2005) Special tools required: 54 3 180 NECESSARY PRELIMINARY TASKS Remove complete convertible top Secure convertible top on convertible top mounting INSTALLATION Microencapsulated screws (Loctite) must be replaced and may not be reused Screw connection must be completed within 20 mins. (start of curing) Microencapsulated screws must not be retightened Thread of nut must be cleaned beforehand in event of repeated use OVERVIEW OF BACKFITTING KIT 1. Cable strap 2. Stowage centering (without lock) 3. Screw for stowage centering 4. Bracket stowage centering 5. Screws for stop 6. Screw for Hall sensor 7. Stop for Hall sensor NOTE: The rear window is replaced complete with the Convertible Top Fabric. 2006 MINI Cooper ACCESSORIES & EQUIPMENT Convertible Top - Repair - Cooper 2006 MINI Cooper ACCESSORIES & EQUIPMENT Convertible Top - Repair - Cooper Fig. 1: Backfitting Kit Components Courtesy of BMW OF NORTH AMERICA, INC. Cover convertible top frame. Chips must not get into the mechanism. Saw off pin (1) from collar with hand saw. IMPORTANT: Do not flex. Risk of damage! Deburr collar with file. 2006 MINI Cooper ACCESSORIES & EQUIPMENT Convertible Top - Repair - Cooper Fig. 2: Pin Courtesy of BMW OF NORTH AMERICA, INC. Measure gap A between stowage lock (1) and main bearing (2). Note down gap A. INSTALLATION Adjust stowage without lock to gap A and screw down. 2006 MINI Cooper ACCESSORIES & EQUIPMENT Convertible Top - Repair - Cooper Fig. 3: Measuring Gap A Between Stowage Lock And Main Bearing Courtesy of BMW OF NORTH AMERICA, INC. Release screw (1). Remove stowage lock (2). Release screws (3) and angle. 2006 MINI Cooper ACCESSORIES & EQUIPMENT Convertible Top - Repair - Cooper Fig. 4: Removing Stowage Lock Courtesy of BMW OF NORTH AMERICA, INC. Mount convertible top on special tool 54 3 180 and move with adapter cable until Hall sensor 5 is accessible. See CONVERTIBLE TOP TAKE-UP FIXTURE Release clip (1) from main bearing. Release fabric tape (2) from clip. Remove clip. 2006 MINI Cooper ACCESSORIES & EQUIPMENT Convertible Top - Repair - Cooper Fig. 5: Releasing Clip From Main Bearing Courtesy of BMW OF NORTH AMERICA, INC. Release screw (1) and feed Hall sensor (2) out of main bearing in upward direction. 2006 MINI Cooper ACCESSORIES & EQUIPMENT Convertible Top - Repair - Cooper Fig. 6: Removing Screw And Feed Hall Sensor Out Of Main Bearing Courtesy of BMW OF NORTH AMERICA, INC. Insert stop screw (3) for Hall sensor into main bearing. Check that Hall sensor (4) is flush with edge of main bearing (2). Insert screw (1) with Loctite and tighten down. IMPORTANT: Hall sensor must not turn when it is tightened down. Check again that Hall sensor is flush. 2006 MINI Cooper ACCESSORIES & EQUIPMENT Convertible Top - Repair - Cooper Fig. 7: Inserting Stop Screw For Hall Sensor Into Main Bearing Courtesy of BMW OF NORTH AMERICA, INC. Reposition cable loom (1) and secure to main wiring harness (3) with fabric adhesive tape (2) or cable strap. 2006 MINI Cooper ACCESSORIES & EQUIPMENT Convertible Top - Repair - Cooper Fig. 8: Positioning Cable Loom And Securing To Main Wiring Harness With Fabric Adhesive Tape Courtesy of BMW OF NORTH AMERICA, INC. EMERGENCY RELEASE OF CONVERTIBLE TOP FASTENER IN EVENT OF FAULTY FOLDING SUNROOF DRIVE CABLE NECESSARY PRELIMINARY TASKS Remove Convertible Top Drive Unit Open complete side windows IMPORTANT: If the drive cables are torn, it is no longer possible to effect emergency release of the retaining hooks via the folding sunroof drive unit. Always conduct convertible top movements with the assistance of a second person (risk of damage). Make sure force is always exerted uniformly to the convertible top sides otherwise the frame will be bent. 2006 MINI Cooper ACCESSORIES & EQUIPMENT Convertible Top - Repair - Cooper UNLOCKING RETAINING HOOKS Raise rotary latch (1) on left and right with plastic wedge or similar from striker and slide back. Fig. 9: Raising Rotary Latch On Left And Right Courtesy of BMW OF NORTH AMERICA, INC. RELEASING CONVERTIBLE TOP FRAME AND ROOF CROSSBAR Lever out locking hook (1) between front and middle seals with screwdriver. 2006 MINI Cooper ACCESSORIES & EQUIPMENT Convertible Top - Repair - Cooper Fig. 10: Releasing Locking Hook Between Front And Middle Seals With Screwdriver Courtesy of BMW OF NORTH AMERICA, INC. OPENING SHUT-OFF VALVE Open shut-off valve for emergency opening at hydraulic line with offset Allen key by one and a half turns. 2006 MINI Cooper ACCESSORIES & EQUIPMENT Convertible Top - Repair - Cooper Fig. 11: Opening Shut-Off Valve Courtesy of BMW OF NORTH AMERICA, INC. STOWING CONVERTIBLE TOP BY HAND Contact points at guide rails (1). Raise front bow. Fold convertible top and stow on stowage shelf. If necessary, close shut-off valve for emergency opening again to secure convertible top in end position. 2006 MINI Cooper ACCESSORIES & EQUIPMENT Convertible Top - Repair - Cooper Fig. 12: Contact Points At Guide Rails Courtesy of BMW OF NORTH AMERICA, INC. FURTHER WORK STEP Replace faulty pitch cables of folding sunroof CONVERTIBLE TOP (SPECIAL TOOL - CONVERTIBLE TOP HOLDERS) Special tools required: 00 2 030 54 3 180 54 3 201 61 2 071 61 2 080 61 2 090 2006 MINI Cooper ACCESSORIES & EQUIPMENT Convertible Top - Repair - Cooper POSITIONING REMOVED CONVERTIBLE TOP Mount convertible top holders 54 3 180 on support tube 54 3 201 and fit on universal lifter 00 2 030 Play convertible top on both sides on threaded bolts and secure with original nuts. If necessary, lay hydraulic unit on special tool rest. Fig. 13: Mounting Convertible Top Holders On Support Tube Courtesy of BMW OF NORTH AMERICA, INC. WARNING: You are exposed to the risk of trapping body parts when working on the installed or removed convertible top. IMPORTANT: Use special tools only in conjunction with universal lifter 00 2 030. There is a risk of tilting over if other lifting equipment is used. IMPORTANT: Pay attention to cables and hydraulic lines when fitting convertible top. 2006 MINI Cooper ACCESSORIES & EQUIPMENT Convertible Top - Repair - Cooper CLOSING CONVERTIBLE TOP MANUALLY OR ELECTRICALLY Always move the convertible top manually with a 2nd person helping (risk of damage). Make sure force is always exerted uniformly to the convertible top sides otherwise the frame will be bent. Connect Adapter Cable Folding roof and catch check: connect power supply cable 61 2 071 and adapter cable 61 2 090 for activating convertible top catch to white plug. Convertible top check: connect power supply cable 61 2 071 and adapter cable 61 2 080 for activating hydraulic pump to black plug. Cables/lines must not be trapped. IMPORTANT: Avoid extended actuation of convertible top against end points (overflow function of hydraulic system). Do not carry out more than 10 operations in 1 hour (then allow to cool down for approx. 1 hour). 2006 MINI Cooper ACCESSORIES & EQUIPMENT Convertible Top - Repair - Cooper Fig. 14: Connecting Power Supply Cable And Adapter Cable Courtesy of BMW OF NORTH AMERICA, INC. OPENING AND CLOSING LOADING AID (EASYLOAD) NECESSARY PRELIMINARY TASKS Open rear lid. Unlock convertible top at rear Set tension bar lock (1) on left/right down on rear lid striker (2). 2006 MINI Cooper ACCESSORIES & EQUIPMENT Convertible Top - Repair - Cooper Fig. 15: Setting Tension Bar Lock On Left/Right Down On Rear Lid Striker Courtesy of BMW OF NORTH AMERICA, INC. IMPORTANT: Tension bar lock (1) must press on switch for convertible top/tension bar (2) (convertible top operation not functioning). 2006 MINI Cooper ACCESSORIES & EQUIPMENT Convertible Top - Repair - Cooper Fig. 16: Tension Bar Lock Courtesy of BMW OF NORTH AMERICA, INC. OVERVIEW OF MICROSWITCHES 1. Stowage shelf 2. Tension bar 2006 MINI Cooper ACCESSORIES & EQUIPMENT Convertible Top - Repair - Cooper Fig. 17: Microswitch Components Courtesy of BMW OF NORTH AMERICA, INC. OPENING/CLOSING CONVERTIBLE TOP IN EVENT OF A TECHNICAL FAULT NECESSARY PRELIMINARY TASKS Check convertible top function problems Front doors must be permanently opened Lower rear side windows fully IMPORTANT: Always conduct convertible top movements with the assistance of a second person (risk of damage). Make sure force is always exerted uniformly to the convertible top sides otherwise the frame will be bent. 2006 MINI Cooper ACCESSORIES & EQUIPMENT Convertible Top - Repair - Cooper Open shut-off valve for emergency opening at hydraulic line with offset Allen key by one and a half turns. Fig. 18: Opening Shut-Off Valve Courtesy of BMW OF NORTH AMERICA, INC. UNLOCKING RETAINING HOOKS Lever out roof crossbar cover (1) with plastic wedge. Insert offset hexagon socket and strike attachment with ball of hand until coupling can be felt to snap into place. Unlock retaining hooks completely by turning counterclockwise. If necessary, refit cover (1). 2006 MINI Cooper ACCESSORIES & EQUIPMENT Convertible Top - Repair - Cooper