Remove/Install Manual Pop-Up Roof - AR77.70-S-0001E

Model 447.7/8 

With Code ZK9 (Lifting roof hatch) 

Shown on right side of vehicle 

Courtesy of MERCEDES-BENZ USA

Shown on right side of vehicle 

Courtesy of MERCEDES-BENZ USA

	Risk of injury  caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof.	No parts of the body or limbs should be within the operating area when the components are moving.	AS00.00-Z-0011-01A
Notice	Notes on carrying out repair work in the vehicle interior		AH68.00-D-0001-01KOS
	Remove
1	Remove awning.		AR88.30-S-7000E
2	Remove roof bed frame.	Model 447.7/8 with code ZK8 (Bed in roof) with code ZK9 (Lifting roof hatch)	AR91.75-S-9880E
3	Remove both pneumatic springs (3).		AR77.70-S-0004E
4	Remove cover (10).
5	Expose electrical wiring harness (11).
6	Disconnect electrical connector of electrical wiring harness (11).
7	Mark assembly position of the bellows (2) and the outer filler channel (13) on the roof.
8	Remove outer filler channel (13).	Carefully remove outer filler channel (13). Otherwise the bellows (2) can be damaged.
9	Remove bellows (2) from bottom profile rail (12).
10	Lift bellows (2) and fasten to pop-up roof (1) using suitable means.
11	Mark assembly positions of the pop-up brackets (4) on the pop-up roof (1).	When the pop-up roof (1) is reused.
12	Remove roof support locating tool and close pop-up roof (1) but ensure the nuts (15) are still accessible.	Helper required.	AR77.00-S-1000E
13	Remove nuts (15).	Helper required to support.
14	Remove pop-up roof (1) from the pop-up brackets (4) and take off pop-up roof (1).	Aid of 3 helpers required.
15	Place pop-up roof (1) down on a suitable base.	Always use protective mat for pop-up roof (1). Otherwise the pop-up roof (1) can be damaged. A helper is required.
16	Remove bellows (2) from pop-up roof (1).	When replacing pop-up roof (1). While doing this, carefully remove inner filler channel (16). Otherwise the bellows (2) can be damaged.	AR77.70-S-0080-03E
17	Remove both roof bed reading lamps.	When replacing pop-up roof (1). Model 447.7/8 with code ZK8 (Bed in roof) with code ZK9 (Lifting roof hatch)	AR82.20-S-1125E
18	Remove both upper locking sections.	When replacing pop-up roof (1).	AR77.70-S-0012E
19	Remove sliding sunroof.	When replacing pop-up roof (1). Model 447.7/8 with code D27 (Electric tilting/sliding glass sunroof) with code ZK9 (Lifting roof hatch)	AR77.20-S-0020E
	Install
20	Install new mounting rails for carrier system.	When replacing pop-up roof (1). The mounting rails cannot be removed without damage and must therefore always be replaced.	AR77.70-S-0005E
21	Install sliding sunroof.	When replacing pop-up roof (1). Model 447.7/8 with code D27 (Electric tilting/sliding glass sunroof) with code ZK9 (Lifting roof hatch) Only install sliding sunroof trim after the function test.	AR77.20-S-0020E
22	Install both upper locking sections.	When replacing pop-up roof (1).	AR77.70-S-0012E
23	Install both roof bed reading lamps.	When replacing pop-up roof (1). Model 447.7/8 with code ZK8 (Bed in roof) with code ZK9 (Lifting roof hatch)	AR82.20-S-1125E
24	Install new rubber seal frame.	When replacing pop-up roof (1).	AR77.70-S-0016E
25	Prepare pop-up roof (1) for installation.	When replacing pop-up roof (1).	AR77.70-S-0001-05E
		Nut, closing strap on pop-up roof	*BA77.70-Z-1008-01KOB
		Pneumatic spring ball stud bracket to vehicle	*BA77.70-Z-1005-01KOB
		Nut, support strap for roof bed to pop-up roof	*BA77.70-Z-1006-01KOB
		Butyl cord Terostat 81 Ø 6 mm	*BR00.45-Z-1085-01A
26	Install bellows (2) on pop-up roof (1).	When replacing pop-up roof (1).	AR77.70-S-0080-01E
		Special lubricant, spray	*BR00.45-Z-1077-06A
		Roller	Fig 2
		Long wedge	Fig 1
27	Fasten bellows (2) to pop-up roof (1) using suitable means.	When replacing pop-up roof (1).
28	Install pop-up roof (1) and fix in place using locating tool.	Aid of 3 helpers required.	AR77.00-S-1000E
29	Attach pop-up roof (1) to pop-up brackets (4) using nuts (15).	Helper required. When the pop-up roof (1) is reused, pay attention to the markings applied. Nut, rear support clamp to pop-up roof	*BA77.70-Z-1003-01KOB
30	Install both pneumatic springs (3) of the pop-up roof (1).		AR77.70-S-0004E
31	Attach bellows (2) to the roof.		AR77.70-S-0080-02E
		Observe attached markings. Special lubricant, spray	*BR00.45-Z-1077-06A
		Long wedge	Fig 1
		Roller	Fig 2
32	Connect electrical connector of electrical wiring harness (11).
33	Route electrical wiring harness (11).	Ensure that electrical wiring harness (11) is routed correctly.
34	Install cover (10).
35	Install roof bed frame.	Model 447.7/8 with code ZK8 (Bed in roof) with code ZK9 (Lifting roof hatch)	AR91.75-S-9880E
36	Install awning.		AR88.30-S-7000E
	Check
37	Check adjustment of pop-up roof (1).		AR77.70-S-0002E
38	Perform function test of the roof bed reading lamps.	Model 447.7/8 with code ZK8 (Bed in roof) with code ZK9 (Lifting roof hatch)
39	Ensure that the bellows (2) are seated correctly by completely opening and closing the pop-up roof (1).		AR77.70-S-0001-01E
40	Perform function test on sliding sunroof.	Model 447.7/8 with code D27 (Electric tilting/sliding glass sunroof) with code ZK9 (Lifting roof hatch)

Fig 1: Identifying Long Wedge (115 589 03 59 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Roller (639 589 08 63 00)

Courtesy of MERCEDES-BENZ USA