Z4 fairly unique roof problem

[HertsZ4chap]

Hi all, I've just got a Z4 (2007 2.0L petrol in Black) and the roof doesn't work, I've read all the related posts of this and other forums and I mean all, and I've now got myself into a place which leaves me just needing a steer.

In short I have the red flashing roof light and the roof does not work, based on all the amazing posts on this forum I have done the following;

- Removed the pump from the from it's watery grave
- Brought it back to life with a diesel bath
- Connected it all back up and filled with fluid
- Bypassed the parcel shelf switch with a folded piece of card
- Now I still have the red flashing light but I can here the motor wiring away upon button press, my roof latches and unlatch fine, so that motor is good, but still the roof does not move in either direction.
- I have removed the Bowden connection from the motor, the button was seized but I've now freed it up with some WD40 and a few presses.
- Still the roof does not move in either direction.
- I have now removed the unit from the car connected it up to a battery on the bench and fluid does come out of the port when power is added.
- When connected back up, my roof does not move at all under power, it still moves most of the way manually, but it stops about 6 inches from closing, I then press the Bowden button and the roof drops closed, so i clearly have some pressure in the system somewhere.

I really don't want to remove the roof to check what is going on, any ideas what I can try next - or is it roof off for me?

Thank you for reading my tale of woe!

 

[enuff_zed]

Did you separate the motor from the pump?
If so, when it went back together did you get all three of the tiny lateral pins back in to the metal rotor? If even just one is missing the roof won’t move.

 

[enuff_zed]

Also, do you have the reservoir as full of fluid as possible?

 

[HertsZ4chap]

Hi enuff_zed thank for the response, so yes I checked all three pins were in there and when I connected the pump back to the hydraulic unit, I made sure the pin with the spring on was located in the metal bearing one end and one of the plastic holes on the sleeve the other, I assume that's correct?
When it refused to work, I filled the reservoir all the way to the top in case that was the issue.
When I bench tested the motor and pump the fluid didn't squirt out, it more oozed out is that right?

 

[enuff_zed]

Hi enuff_zed thank for the response, so yes I checked all three pins were in there and when I connected the pump back to the hydraulic unit, I made sure the pin with the spring on was located in the metal bearing one end and one of the plastic holes on the sleeve the other, I assume that's correct?
When it refused to work, I filled the reservoir all the way to the top in case that was the issue.
When I bench tested the motor and pump the fluid didn't squirt out, it more oozed out is that right?

Ok. Now that sounds likely to be the pump being weak.

 

[HertsZ4chap]

When you say pump, do you mean the square metal box attached to the motor? Is that part serviceable? If so, what do you think I do with it?

 

[enuff_zed]

When you say pump, do you mean the square metal box attached to the motor? Is that part serviceable? If so, what do you think I do with it?

That’s the part yes.
Unfortunately, between those of us who do a lot of roof motors we have not yet found a way to overhaul the pumps. A fee have been revived simply by dismantling as much as possible, cleaning and rebuilding but this seems very much hit and miss.
The only sure way is to fit a good replacement one, which won’t be cheap.
I currently don’t have any spares.
Try some of the fb breakers, or GenZed on here.
You may find it easier to find a complete assembly, which would leave you with your current motor as a spare.

 

[enuff_zed]

Just one other thought:
Is the pump running the right way?
Pipes 11/13 and 12/14 should be paired up.
Try swapping the electrical connectors over.

 

[HertsZ4chap]

Thanks again enuff_zed, yes I’ve swapped the power cables around, when I bathed the motor in diesel I removed the hydro pump, would it help do you think the bath it still attached to the pump and run it in there?

 

[enuff_zed]

Thanks again enuff_zed, yes I’ve swapped the power cables around, when I bathed the motor in diesel I removed the hydro pump, would it help do you think the bath it still attached to the pump and run it in there?

I’m not sure exactly what effect diesel would have mixed with hydraulic fluid? But it sounds like you have nothing to lose.
Are you sure the bypass plunger is fully out?
You can remove the blank opposite it and use a thin screwdriver or punch to push it fully out.

 

[HertsZ4chap]

Thanks enuff_zed I'll try that and report back

 

[HertsZ4chap]

Enuff_zed, you are a genius before bathing the whole thing in diesel I checked as you said that the bypass plunger was fully out, the opposite blank port was rusted shut and I rounded the hole trying to force it, however I then realised you could also see the back of the plunger through the open port where the hydro lines go, sure enough I popped in a small screw driver and the plunger moved out only another millimetre or so, but when I put it back together there is now movement on the roof!!!
Still lots of fettling to do to get the roof working perfect im sure, but now it's moving im 99% there.
Thank you for your help and to all those whose posts got me to this stage !

 

[enuff_zed]

Enuff_zed, you are a genius before bathing the whole thing in diesel I checked as you said that the bypass plunger was fully out, the opposite blank port was rusted shut and I rounded the hole trying to force it, however I then realised you could also see the back of the plunger through the open port where the hydro lines go, sure enough I popped in a small screw driver and the plunger moved out only another millimetre or so, but when I put it back together there is now movement on the roof!!!
Still lots of fettling to do to get the roof working perfect im sure, but now it's moving im 99% there.
Thank you for your help and to all those whose posts got me to this stage !

Excellent!

 

[HertsZ4chap]

So, one step forward two steps back, I have a leak, whilst the roof was moving I could hear a squirting noise coming from the passenger side well, the pump is in the boot now so it's definitely where the lines connect to the actuator. When I cleared the well out I found a screw in there, see photo below, I assume this has come from where the lower line attaches to the actuator, so my hope is that it's a connection issue rather than a corrosion or split line one. I've had an endoscope down there and have done my best to film both lines, I can see one screw attached on the lower one, but am hoping there should be two? Would really welcome a steer on exactly how the bottom line connects, I've read posts about a plate being attached, I'm guessing as I still have a screw attached the plate is still there also?

 

[enuff_zed]

That looks like one of the screws from the bottom of the ram?
How far are you from Norfolk?
I can help you lift that side of the roof and get easy access to the ram. I all have some replacement pipes if one has ruptured

 

[HertsZ4chap]

I’m about 2.5 hours away, thank you for the offer really appreciate the support, I’ve had a look at the rams you mention and I agree looks like the screw is from there, I’m going to wire the pump to a battery tomorrow, get the endoscope in and see what’s leaking. Didn’t realise you could just lift one side of the roof! I’ll post back my results thank you again, it may well be that a trip to Norfolk is on the cards!