Removing and installing vario-roof - AR77.50-P-3000G: Notes

MODEL 170 

Assembly sequence, lifting out vario-roof 

Checking roof contour Use of template on vario-roof 

	Removal
1	Remove side paneling in trunk	Remove only side paneling on right	AR68.30-P-4800G
2	Disconnect connector on limit switch (S69/10) and insert bridge in connector
3	Remove paneling on tank partition
4	Expose hydraulic lines on right in trunk up to hydraulic unit	Open cable straps or cut
5	Unclip hydraulic lines from left main cylinder in trunk above tank
6	Open vario-roof	Leave trunk lid pivoted to rear
7	Unscrew screw (1) and remove cover (2)
8	Unscrew screws (3, 4) and remove cover (5)
9	Remove cover above cross member for roll-bar
10	Unhook rubber strap (6) from rear shelf on main mount
11	Close vario-roof	Vario-roof should only make contact at front, do not lock front catch
12	Remove limit switch (S69/11) on right main mount
13	Remove insert clip (7) and pin (8)
14	Remove snap ring (9) and pin (10)
15	Remove main cylinder (11) from main mount toward front and hang in vehicle passenger compartment on rear wall	Do not damage piston rod when pulling out
16	Mark position of main mount (12) on B-pillar (arrows)
17	Measure interval (a) between vario-roof C-pillar and fender with feeler gauge and note		Fig 11
18	Unscrew screw (13) on inside at rear of main mount
19	Remove connector (14) and separate from holder in direction of arrow
20	Separate hydraulic lines no. 31 and no. 33 from hydraulic unit	Pressure is present in the hydraulic lines when the vario-roof has been moved with the roof switch and the ignition is not switched off. When separating hold a rag around the hydraulic lines, because hydraulic oil continues to run out.
		for plugging hydraulic unit	Fig 9
		for plugging hydraulic lines	Fig 10
21	Attach hydraulic lines and electrical wires with tape	To prevent the lines from catching when the vario-roof is lifted out
22	Open emergency actuation valve (N) on hydraulic unit to stop with 6 mm Allen wrench	Open emergency actuation valve only with roof put down or closed and ignition switched off to avoid damaging the gasket on the emergency actuation valve (N) which would prevent pressure from building up in the system.
23	Put vario-roof down into trunk by hand
24	Unscrew screws (13)
25	Push trunk lid closed and pivot back by hand a number of times	When lifting out the vario-roof it is easier to pivot the trunk lid back
26	Lift out vario-roof with the aid of a second mechanic, set down on roll-bar, push trunk lid closed and set vario-roof down on suitable soft surface after moving across vehicle toward rear
	Installation
27	Align plates (15) on B-pillar	Do not mix up plates, because number of plates on each side may differ
28	Push trunk lid closed, set down vario-roof on roll-bar with the aid of a second mechanic, pivot trunk lid back and set vario-roof down on B-pillars	When installing do not pinch hydraulic lines and electrical wiring
29	Screw in screws (13)
30	Align main mount with mark on B-pillar and tighten screws (13) lightly
31	Pivot vario-roof out of trunk by hand and lay down on supports on cross member above windshield
32	Connect hydraulic lines no. 31 and 33 to hydraulic unit
33	Connect connector (14) and fasten to holder
34	Press cap into front roof paneling
35	Turn catch clockwise to stop with 6 mm Allen wrench (left arrow) and allow to catch, then turn counterclockwise to stop (right arrow) and lock catch	The slide (16) in the catch should engage in the cam (17) on the C-pillar
36	Loosen screws (13) and hit the vario-roof lightly with open hand a number of times in the area of the roof separation	This eliminates any tension in the main mount or moving parts
37	Check the position of the main mount or the interval (a) between the vario-roof and fender and correct, if necessary	Corrections are possible only to a very small extent when the vario-roof is locked at the front.
38	Screw in screw (13) and tighten all screws on main mount		*BA77.33-P-1007-01A
39	Install hydraulic cylinder (11) on main mount (12)
40	Install limit switch (S69/11) on main mount (12)
41	Close emergency actuation valve (N) on hydraulic unit	Tightening torque 3+0.5 Nm
42	Route hydraulic lines and electrical leads in trunk and fasten
43	Hook rubber strap (6) from rear shelf on main mount
44	Open and close vario-roof carefully a number of times with the roof switch
45	Check roof contour with template		Fig 12
		If deviations are present ↓
		Correct adjustment of vario-roof ↓	AR77.50-P-3030G
		Check adjustment of crank windows ↓	AR72.10-P-1950G
		Check adjustment of rear side window	AR67.30-P-4200G
46	Install paneling for tank partition
47	Install paneling on side in trunk		AR68.30-P-4800G
48	Open vario-roof	Leave trunk lid pivoted to rear
49	Install paneling above roll-bar cross member
50	Install cover (5) above B-pillar
51	Perform rain test

Number	Designation		Model 170
BA77.33-P-1007-01A	Screws for main mount on B-pillar	Nm	22