Remove/Install Vario Roof - AR77.50-P-3000W
Model 172.4
| Remove | |||
| 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 | |
| Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC) | Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines. | AS00.00-Z-0035-01A | |
| 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 | |
| Notes on MAGIC SKY CONTROL | AH77.00-P-0001-01A | ||
| Notes on Vario roof assembly work | AH77.30-P-0002-01R | ||
| 1 | Switch on the ignition and press and hold the Vario roof actuation switch until the trunk lid is at the limit stop. Then, switch off the ignition. | ||
| 2 | Remove tank cover at top | AR64.20-P-1080W | |
| 3 | Disconnect ground line of battery | AR54.10-P-0003W | |
| 4 | Disconnect electrical connection (4) | ||
| 5 | Remove left and right trunk lid actuation hydraulic cylinders (2) from the body and tubular frame (3), and place to one side with the connected hydraulic lines | AR77.37-P-3550W | |
| 6 | Disconnect electrical connectors (5) and expose the associated lines as far as left Vario roof main bearing (7) | ||
| 7 | Disconnect rear shelf electrical connector (X23/9) and electrical connector for rear shelf limit switch (X23/20) and expose the associated lines as far as left Vario roof main bearing (7) | ||
| 8 | Disconnect heatable rear window electrical connector (+) (X19/4) and expose the associated line as far as right Vario roof main bearing (7) | ||
| 9 | Expose the hydraulic lines of left and right trunk lid actuation hydraulic cylinders (2) as far as left and right Vario roof main bearing (7) | ||
| 10 | Unscrew bolt (8) on left and right Vario roof main bearing (7) | ||
| 11 | Insert rubber bumpers (9) into left and right mounts (10) | ||
| 12 | Open emergency operation valve (11) | Open emergency operation valve (11) by a maximum of two turns. Otherwise the Vario roof control hydraulic unit (A7/5) can be damaged. |
|
| 13 | Lay Vario roof (1) down into trunk by hand with aid of helper | Move Vario roof (1) only at C-pillar top sections. Otherwise, Vario roof (1) may be damaged. |
|
| 14 | Expose Vario roof control hydraulic unit (A7/5) in vehicle interior | AR77.37-P-3500W | |
| 15 | Disconnect MAGIC SKY CONTROL electrical connector (X1333) | With code 412 (Vario roof in glass version) | |
| 16 | Disconnect electrical connectors (20) from Vario roof control unit (N52) | ||
| 17 | Disconnect heated rear window electrical connector (-) (X19/5), Vario roof stowed electrical connector (X23/23) and Vario roof locked electrical connector (X23/26), and remove the associated electrical wiring harnesses from Vario roof crossmember (12) | ||
| 18 | Remove both belt guide brackets (13) from Vario roof crossmember (12) | ||
| 19 | Remove left and right outer sealing rail (14) | Fig 2 | |
| 20 | Remove left and right inner sealing rail (15) | Fig 2 | |
| 21 | Loosen both ends of trunk lid seal (16) in the area of left and right center pillars (17) | AR88.50-P-5010W | |
| 22 | Attach eyelets (19) to both Vario roof main bearings (7) | Fig 3 | |
| 23 | Unscrew bolts (18) on left and right center pillars (17) | ||
| 24 | Use cable ties to secure left and right trunk lid actuation hydraulic cylinder (2) to Vario roof crossmember (12) | ||
| 25 | Lift Vario roof (1) out of the vehicle using an engine hoist and a helper | Carefully lift out Vario roof (1). Otherwise, Vario roof (1) or adjacent components may be damaged. |
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| 26 | Remove compensating elements (21) | ||
| Install | |||
| 27 | Detach overhead control panel control unit and let hang with connected electrical lines | AR82.20-P-1000W | |
| 28 | Remove the seal from the crossmember above the windshield | AR77.50-P-4050W | |
| 29 | Install new compensating elements (21) | Completely screw in compensating elements (21). Otherwise, compensating elements (21) may be damaged when Vario roof (1) is positioned. |
|
| 30 | Attach suitable lifting gear to eyelets (19) and position Vario roof (1) between both Vario roof main bearings (7) using an engine hoist and a helper | ||
| 31 | Remove eyelets (19) | ||
| 32 | Align Vario roof (1) | AR77.50-P-3000-04W | |
| *BA77.33-P-1007-01A | |||
| Fig 4 | |||
| 33 | Install the seal on the crossmember above the windshield | AR77.50-P-4050W | |
| 34 | Install overhead control panel control unit | AR82.20-P-1000W | |
| 35 | Attach both ends of trunk lid seal (16) in the area of left and right center pillars (17) | AR88.50-P-5010W | |
| 36 | Install left and right inner sealing rails (15) | ||
| 37 | Install left and right outer sealing rails (14) | ||
| 38 | Attach left and right belt guide brackets (13) to Vario roof crossmember (12) | *BA91.40-P-1002-01A | |
| 39 | Connect heated rear window electrical connector (-) (X19/5), Vario roof stowed electrical connector (X23/23) and Vario roof locked electrical connector (X23/26) and attach the associated electrical wiring harnesses to Vario roof crossmember (12) | ||
| 40 | Connect electrical connectors (20) to Vario roof control unit (N52) | ||
| 41 | Connect MAGIC SKY CONTROL electrical connector (X1333) | In vehicles with code 412 (Vario roof, glass version) | |
| 42 | Reinstall all components removed to expose the Vario roof control hydraulic unit (A75) | AR77.37-P-3500W | |
| 43 | Manually set up Vario roof (1) stowed in the trunk with the aid of a helper and lay down toward front on windshield crossmember (22). Insert front latches (23) into mounts (24). | Move Vario roof only at C-pillar top sections. Otherwise, Vario roof (1) can be damaged. |
|
| 44 | Close emergency operation valve (11) | *BA77.37-P-1001-01A | |
| 45 | Unscrew screws (8) on left and right Vario roof main bearing (7) | *BA77.33-P-1007-01A | |
| 46 | Secure the line of heated rear window electrical connector (+) (X19/4) in the trunk and connect heated rear window electrical connector (+) (X19/4) | ||
| 47 | Secure the lines of rear shelf electrical connector (X23/9) and rear shelf limit switch electrical connector (X23/20) in the trunk and connect rear shelf electrical connector (X23/9) and rear shelf limit switch electrical connector (X23/20) | ||
| 48 | Secure the lines of electrical connectors (5) in the trunk and connect electrical connectors (5) | ||
| 49 | Connect electrical connection (4) | ||
| 50 | Attach left and right trunk lid actuation hydraulic cylinders (2) to the body and tubular frame (3) | AR77.37-P-3550W | |
| 51 | Secure the hydraulic lines of left and right trunk lid actuation hydraulic cylinders (2) in the trunk | ||
| 52 | Install tank cover at top | AR64.20-P-1080W | |
| 53 | Attach rubber bumpers (9) to left and right mounts (10) | ||
| 54 | Connect ground line to on-board electrical system battery | AR54.10-P-0003W |
SOFT TOP MECHANICAL COMPONENTS
| Number | Designation | Model 172 | |
|---|---|---|---|
| BA77.33-P-1007-01A | Bolts, main bearing to B-pillar | Nm | 21 |
SOFT TOP HYDRAULIC SYSTEM
| Number | Designation | Model 172 | |
|---|---|---|---|
| BA77.37-P-1001-01A | Emergency operation valve at hydraulic unit | Nm | 2, 5 |
SEAT BELTS/EMERGENCY TENSIONING RETRACTORS
| Number | Designation | Model 172 | |
|---|---|---|---|
| BA91.40-P-1002-01A | Bolt/nut on front seat belt guide bracket | Nm | 35 |