Remove/install Vario roof - AR77.50-P-3000RK
MODEL 231
| Remove | |||
| Risk of injury caused by body parts being trapped or crushed when working on a partially open Vario roof (in stop mode) or in its closing area as a result of the Vario roof suddenly collapsing | Secure Vario roof with a suitable special tool. | AS77.50-Z-0001-01A | |
| 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 | |
| Notes on Vario roof assembly work | AH77.30-P-0002-01R | ||
| Notes on MAGIC SKY CONTROL | AH77.00-P-0001-01A | ||
| 1 | Remove tank cover (1) | AR64.20-P-1080RK | |
| 2 | Remove right and left roll bar unit | AR91.50-P-2355RK | |
| 3 | Remove belt guide bracket | AR91.40-P-1030RK | |
| 4 | Expose vario roof control hydraulic unit (A7/5) in trunk | ||
| 5 | Open emergency operation valves (5) | Open emergency operation valve (5) max. 2 turns. Otherwise the Vario roof control hydraulic unit (A7/5) can be damaged. |
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| 6 | Manually move Vario roof (2) to intermediate position | Move vario roof (2) only at C-pillar top sections. Otherwise the Vario roof (2) can be damaged. |
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| 7 | Secure vario roof (2) with support (3) | Figure | |
| Figure | |||
| 8 | Remove remote trunk closing hydraulic cylinder and lay down to side with hydraulic lines connected | Model 231 with code 881 (Remote boot lid closing) |
AR88.50-P-5071RK |
| 9 | Remove left and right remote trunk closing hydraulic cylinder and lay down to side with hydraulic lines connected | AR77.37-P-3550RK | |
| 10 | Remove water drain hoses (4) on right and left from Vario roof (2) | ||
| 11 | Expose hydraulic lines (6) in trunk | ||
| 12 | A7Disconnect Vario roof hydraulic unit electrical connector 1 (/5x1) and Vario roof hydraulic unit electrical connector 2 (A7/5x2) | ||
| 13 | Disconnect electrical connector from heated rear window (-) (X19/5) | ||
| 14 | Disconnect MAGIC SKY CONTROL electrical connector (X1333) | Model 231 with code 412 (Glass Vario roof) |
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| 15 | Disconnect electrical connector from Vario roof put down limit switch (S69/11x1), electrical connector from loading aid limit switch 2 (S117/3x1) and electrical connector from loading aid limit switch 1 (S117x1) | ||
| 16 | Expose electrical wiring harnesses and hydraulic lines on Vario roof crossmember (7) | ||
| 17 | Remove left and right inner sealing rail (8) | Figure | |
| 18 | Lay Vario roof (2) down into trunk by hand with aid of helper | Move vario roof (2) only at C-pillar top sections. Otherwise the Vario roof (2) can be damaged. |
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| 19 | Detach trunk lid seal (9) in front area (arrow) | ||
| 20 | Remove eyelets (10) on left and right Vario roof main bearing (11) | Fig 11 | |
| 21 | Unscrew bolts (12) from Vario roof crossmember (7) | ||
| 22 | Unscrew bolts (13) on left and right Vario roof main bearing (11) | ||
| 23 | Lift Vario roof (2) out of vehicle | Carefully lift out Vario roof (2). Otherwise the Vario roof (2) or adjacent components can be damaged. |
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| 24 | Remove compensating elements (14) | ||
| Install | |||
| 25 | Remove seal from windshield crossmember (16) | AR77.50-P-4050RK | |
| 26 | Detach paneling (15) on roof frame and fix in place with assembly wedge (arrow) | Figure | |
| 27 | Install new expansion elements (14) | Completely screw in compensation elements (14). Otherwise the compensation elements (14) can be damaged when positioning the Vario roof (2). |
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| 28 | Position Vario roof (2) between both Vario roof main bearings (11) | Load tilter |
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| 29 | Remove eyelets (10) | ||
| 30 | Align Vario roof (2) | AR77.50-P-3000-04RK | |
| *BA77.33-P-1007-01A | |||
| Fig 9 | |||
| 31 | Screw in screws/bolts (12) and tighten them | ||
| 32 | Remove assembly wedge for fixing in place between paneling (15) and roof frame | Figure | |
| 33 | Install seal on windshield crossmember (16) | AR77.50-P-4050RK | |
| 34 | Fasten trunk lid seal (9) | ||
| 35 | Install left and right inner sealing rail (8) | ||
| 36 | Expose electrical wiring harnesses and hydraulic lines on Vario roof crossmember (7) | ||
| 37 | Connect electrical connector for Vario roof put down limit switch (S69/11x1), electrical connector for loading aid limit switch 2 (S117/3x1) and electrical connector for loading aid limit switch 1 (S117x1) | ||
| 38 | Connect MAGIC SKY CONTROL connector (X133/3) | Model 231 with code 412 (Glass Vario roof) |
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| 39 | Connect electrical connector for heated rear window (X19/5) | ||
| 40 | Raise Vario roof (2) by hand and close | Move vario roof (2) only at C-pillar top sections. Otherwise the Vario roof (2) can be damaged. Before closing the Vario roof (2) ensure that the front locks (17) are unlocked. |
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| 41 | Install water drain hoses (4) on right and left on Vario roof (2) | ||
| 42 | Connect Vario roof hydraulic unit electrical connector 2 (A7/5x2) and Vario roof hydraulic unit electrical connector 1 (A7/5x1) | ||
| 43 | Close emergency operation valves (5) | *BA77.37-P-1001-01A | |
| 44 | Install left and right trunk lid actuation hydraulic cylinder | AR77.37-P-3550RK | |
| 45 | Install remote trunk closing hydraulic cylinder | Model 231 with code 881 (Remote boot lid closing) |
AR88.50-P-5071RK |
| 46 | Properly route hydraulic lines on left and right trunk lid actuation hydraulic cylinder and fasten | ||
| 47 | Install belt guide bracket | AR91.40-P-1030RK | |
| 48 | Install right and left rollbar unit | AR91.50-P-2355RK | |
| 49 | Install tank cover (1) | AR64.20-P-1080RK | |
| 50 | Connect ground line to on-board electrical system battery | AR54.10-P-0003RK | |
| 51 | Check/correct oil level of hydraulic unit | AR77.37-P-3501RK | |
| 52 | Reinstall all components removed to expose the Vario roof control hydraulic unit (A75) | ||
| 53 |
Connect STAR DIAGNOSIS and read out fault memory | AD00.00-P-2000-04A |
SOFT TOP MECHANICAL COMPONENTS
| Number | Designation | Model 231 | |
|---|---|---|---|
| BA77.33-P-1007-01A | Bolts, main bearing to B-pillar | Nm | 21 |
SOFT TOP HYDRAULIC SYSTEM
| Number | Designation | Model 231 | ||
|---|---|---|---|---|
| BA77.37-P-1001-01A | Emergency operation valve at hydraulic unit | Nm | 2, 5 | |
| - | - | |||