Remove/install rear panoramic glass roof - AR77.21-P-0600LW

MODEL 205.0/1/2 with CODE 413 (Automatic panoramic sliding sunroof) 

MODEL 253 with CODE 413 (Automatic panoramic sliding sunroof) 

Shown on model 205.0 

MODEL 205.2, 253, shown on MODEL 205.2 

Shown on model 205.0 

Shown on model 205.0 

	Risk of injury  during testing and repair operations related to pyrotechnical components	Do not expose pyrotechnical components to temperatures above 100 °C or 212 °F. Disconnect current supply when working on such components.	AS91.00-Z-0008-01A
	Risk of injury  from cutting wire tearing or becoming hot and from splinters of glass when cutting out bonded windows	Wear protective gloves and safety glasses.	AS67.00-Z-0004-01A
	Notes on removal/installation of windows		AH67.10-P-1000-02RT
	Information, assessment and legal requirements when working with, handling and storing pyrotechnical components		AH91.00-Z-0000-10A
	Remove
1	Open driver-side window	To prevent rear panoramic roof (1) just glued in from being pressed outwards by the air pressure when closing the doors.
2	Determine gap dimension between rear panoramic roof (1) and front panoramic roof and note	Model 205.0/1 with code 413 (Automatic panoramic sliding sunroof)
3.1	Determine gab (A) between rear panoramic roof (1) and rear window (2) and note	Model 205.0/1 with code 413 (Automatic panoramic sliding sunroof)
		Feeler gauge	Fig 5
3.2	Center gap dimension (B) between rear panoramic roof (1) and rear roof paneling (22) and note	Model 205.2, 253 with code 413 (Automatic panoramic sliding sunroof)
		Feeler gauge	Fig 5
4.1	Remove left and right drip rail (3)	Model 205.0/1 with code 413 (Automatic panoramic sliding sunroof)
4.2	Remove left and right roof railing	Model 205.2, 253 with code 413 (Automatic panoramic sliding sunroof)
			AR77.40-P-5000LW
5	Remove rear window (2)	Model 205.0/1 with code 413 (Automatic panoramic sliding sunroof)	AR67.20-P-2000LW
6.1	Remove headliner with aid of helper through body cutout for rear window (2) from vehicle	Model 205.0/1 with code 413 (Automatic panoramic sliding sunroof)
			AR68.30-P-4300LW
		Do not remove front seats and center console.
6.2	Remove headliner and remove through opening in liftgate from vehicle with aid of helper	Model 205.2, 253 with code 413 (Automatic panoramic sliding sunroof)
			AR68.30-P-4300LWS
7	Remove roller sun blind (4) at rear		AR77.21-P-0201NKX
8	Detach ground line of on-board electrical system battery		AR54.10-P-0003LW
9	Disconnect electrical connector (5) from left and right windowbag unit until (6)
10	Unscrew bolt (7) from left and right windowbag unit (6)
11	Carefully push left and right windowbag unit (6) toward front and guide out of mount (9) at bolts (8) on side roof frame
12	Remove left and right rear grab handle mount (10)
13.1	Remove left and right rear roof rack mount (11)	Model 205.0/1 with code 413 (Automatic panoramic sliding sunroof)
13.2	Unscrew bolts (23) on left and right side on rear panoramic roof (1)	Model 205.2, 253 with code 413 (Automatic panoramic sliding sunroof)
14	Punch through rear adhesive beads (12) at rear left or right corner on rear panoramic roof (1) with pull-in device (13), as shown and guide cutting wire (14) into vehicle interior	Helper required to guide cutting wire (14). Gap dimension (a): 30 mm
15	Cut through rear adhesive beads (12)	Helper required. While cutting protect adjacent paint surfaces with shields (15) against damage. The profiling at the rear roof frame makes it difficult to cut through the rear adhesive beads (12), because the cutting wire (14) runs directly on the sheet metal flange.
		Set of shields	Fig 6
16	Punch through (arrow B) front adhesive beads (16) at rear left or right corner on rear panoramic roof (1) with pull-in device (13), as shown and guide cutting wire (14) into vehicle interior	Helper required to guide cutting wire (14).
17	Cut through front adhesive bead (16)	Helper required. While cutting protect adjacent paint surfaces with shields (15) against damage. Protect seal (17) against damage with suitable cut protector (18) while cutting.
		Set of shields	Fig 6
18	Cut off and remove remaining excessive adhesive material in area of left and right reinforcement (19) so that the front sheet metal edge (arrow C) on the reinforcement (19) is exposed	So that the cutting wire (14) can run under the left and right reinforcement (19) when cutting through adhesive bead (20) on left and right sides.
19	Position cutting wire (14) as shown on rear panoramic roof (1) (arrows D) and simultaneously cut through left and right adhesive bead (20)	Helper required. When starting to cut, ensure that the cutting wire (14) does not run between the left and right reinforcement (19) and rear panoramic roof frame (1), but below the left and right reinforcement (19). Protect adjacent paint surfaces in cutting area with shields (15) against damage.
		Set of shields	Fig 6
20	Remove rear panoramic roof (1) with helper from body
	Install
21	Mask seal (17) with suitable adhesive tape	To protect against dirt from adhesive material when later applying front adhesive bead (16).
22	Prepare new rear panoramic roof (1) for installation		AR77.21-P-0600-02CW
		Before starting work, all components, materials and tools must be prepared for installing the rear panoramic roof (1). Otherwise it may not be possible to maintain permissible processing and joining times. Always observe instructions described in the document reference for preparing ear panoramic roof (1). Otherwise the strength of the adhesive connection can be impaired and proper adhesion of the adhesive material is not ensured.
		2-component adhesive repair kit, Betaforce 2850L	*BR00.45-Z-1154-02A
23	Prepare body flange		AR77.21-P-0600-07NKX
		Always observe instructions described in document reference for preparing bonding surfaces on vehicle. Otherwise the strength of the adhesive connection can be impaired and proper adhesion of the adhesive material is not ensured.
		2-component adhesive repair kit, Betaforce 2850L	*BR00.45-Z-1154-02A
24	Apply adhesive for rear panoramic roof (1)		AR77.21-P-0800-03LF
	000 588 00 72 00 Sealing and corrosion protection gun		WS97.00-P-0001B
		Apply adhesive within 25 min. and position rear panoramic roof (1) within next 15 minutes on body flange and fix in place. Otherwise the strength of the adhesive connection can be impaired and proper adhesion of the adhesive material is not ensured. Always observe instructions described in document reference for applying adhesive material. Otherwise the strength of the adhesive connection can be impaired and proper adhesion of the adhesive material is not ensured.
		2-component adhesive repair kit, Betaforce 2850L	*BR00.45-Z-1154-02A
25	Install rear panoramic roof (1) on body with aid of helper and align		AR77.21-P-0600-06CW
		When installing rear panoramic roof (1), ensure that the rear roller sun blind (4) does not come into contact with the adhesive. Otherwise it is necessary to replace the rear roller sun blind (4), because dirt caused by the adhesive cannot be removed completely. Do not drive vehicle for 10 h after gluing in rear panoramic roof (1). Otherwise the strength of the adhesive connection can be impaired and proper adhesion of the adhesive material is not ensured. Model 205.0/1 with code 413 (Automatic panoramic sliding sunroof) Observe gap dimension between rear panoramic roof (1) and front panoramic roof determined before removal. Model 205.2, 253 with code 413 (Automatic panoramic sliding sunroof) Observe gap dimension (B) determined before removal. Center rear panoramic roof (1) between side roof paneling.
		Feeler gauge	Fig 5
26.1	Install left and right rear roof rack mount (11)	Model 205.0/1 with code 413 (Automatic panoramic sliding sunroof)
		Nut, roof carrier mount	*BA65.10-P-1001-01C
26.2	Tighten bolts (23) on left and right side on rear panoramic roof (1)	Model 205.2, 253 with code 413 (Automatic panoramic sliding sunroof)
27	Place large-surface weights on rear panoramic roof (1) in rear area	Use weights with large surfaces such as sandbags to put load on rear panoramic roof (1). Otherwise the rear panoramic roof (1) can be damaged.
28	Remove cup suction tool
29	Push left and right roller bearing (4.1) on rear roller sun blind (4) toward front until both roller bearings (4.1) completely arrest in the corresponding roller sun blind guide rail (4.2)	Ensure that the catch hooks (4.3) arrest correctly in front cutouts (4.4). Otherwise a teach-in run for the automatic reversing panoramic sliding roof reversing function is not possible later. The rear roller sun blind (4) is located on the new rear panoramic roof (1) in the assembly position and is moved to the end position.
30	Remove left and right guide tube for roller sun blind drive cable (21)		AR77.21-P-0232NKX
31	Install left and right rear grab handle mount (10)
32	Install left and right windowbag unit (6) in mount (9) with bolts (8) at side roof frame
33	Tighten bolt (7) on left and right windowbag unit (6)	Screw/bolt, window airbag gas generator to roof frame	*BA91.60-P-1004-01O
34	Disconnect electrical connector (5) from left and right windowbag unit (6)
35	Lay headliner through body cutout for rear window (2) or liftgate cutout into vehicle with aid of helper
36	Install headliner	Model 205.0/1 with code 413 (Automatic panoramic sliding sunroof)	AR68.30-P-4300LW
		Model 205.2, 253 with code 413 (Automatic panoramic sliding sunroof)	AR68.30-P-4300LWS
37	Install rear window (2)	Model 205.0/1 with code 413 (Automatic panoramic sliding sunroof)	AR67.20-P-2000LW
38.1	Remove left and right drip rail (3)	Model 205.0/1 with code 413 (Automatic panoramic sliding sunroof)
38.2	Install left and right roof railing	Model 205.2, 253 with code 413 (Automatic panoramic sliding sunroof)
			AR77.40-P-5000LW
39	Connect ground line for on-board electrical system battery		AR54.10-P-0003LW
	Check
40	Before initially driving the vehicle, ensure that bonded connection is cured using fabricated reference adhesive bead	Do not drive vehicle for 10 h after gluing in rear panoramic roof (1). Otherwise the strength of the adhesive connection can be impaired and proper adhesion of the adhesive material is not ensured.
41	Aft the adhesive bead is completely cured, remove weights from rear panoramic roof (1)	Do not remove weights before reference adhesive bead is completely cured. Otherwise the strength of the adhesive connection can be impaired and proper adhesion of the adhesive material is not ensured.
42	Synchronize panoramic sliding roof with diagnostic system and perform teach-in run for automatic reversing function	Model 205.0/1/2 with code 413 (Automatic panoramic sliding sunroof) Model 253 with code 413 (Automatic panoramic sliding sunroof)
		Model 205.0/1/2 with code 413 (Automatic panoramic sliding sunroof)	AD00.00-P-2000-04B

Number	Designation		Model 205
BA65.10-P-1001-01C	Nut, roof carrier mount	Nm	14

Number	Designation		Model 205.0/1/2/3	Model 253
BA91.60-P-1004-01O	Screw/bolt, window airbag gas generator to roof frame	Nm	6	6

Number	Designation	Order number
BR00.45-Z-1154-02A	2-component adhesive repair kit, Betaforce 2850L	A 012 989 12 71