Remove/Install Front Fixed Element Of Panoramic Sliding Sunroof - AR77.21-P-0803LF

Model 205.0/1/2/3 

with code 413 (Panoramic sliding sunroof/glass roof) 

Model 222 

with code 398 (Panoramic roof with MAGIC SKY CONTROL) 

Model 222 

with code 413 (Panoramic sliding sunroof/glass roof) 

Model 253 

with code 413 (Panoramic sliding sunroof/glass roof) 

Shown on Model 222 with Code 413 (Panoramic sliding roof) 

Courtesy of MERCEDES-BENZ USA

Shown on Model 222 with Code 413 (Panoramic sliding roof) 

Courtesy of MERCEDES-BENZ USA

Shown on model 205.2 with code 413 (Panoramic sliding sunroof) 

Courtesy of MERCEDES-BENZ USA

	Risk of injury  caused by slipping when clamping blade in the multicutter and by splinters when cutting out bonded components	Wear cut-proof gloves and safety glasses. Always interrupt air or current supply when changing the cutting blade.	AS58.00-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
	Risk of injury  caused by scraping or cutting body parts on sharp vehicle parts	Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels.	AS00.00-Z-0017-01A
Topical note	Notes on removal/installation of bonded elements of panoramic roof		AH77.21-P-0001-01A
	Preparation
1	Prepare adhesive cartridge.		AR77.21-P-1000-01A
		Adhesive material can be pressed out with a commercially available electric squeeze gun or a pneumatic squeeze gun with piston rod.
		Adapter	Fig 3
	Remove
2	Remove left and right drip rail.	Model 205.0/1/3 with code 413 (Panoramic sliding sunroof/glass roof) Model 222 with code 398 (Panoramic roof with MAGIC SKY CONTROL) Model 222 with code 413 (Panoramic sliding sunroof/glass roof)
		Model 222 with code 398 (Panoramic roof with MAGIC SKY CONTROL)	AR88.80-P-4000LF
		Model 222 with code 413 (Panoramic sliding sunroof/glass roof)
3	Determine gap dimension (A) between front stationary element (1) and windshield (2) and note down.	Feeler gauge	Fig 1
4	Determine gap dimension (B) between front stationary element (1) and panoramic sliding sunroof (3) and note down.	Feeler gauge	Fig 1
5.1	Cover paint surfaces on left and right in area of front stationary element (1) with shields.	Model 205.0/1/3 with code 413 (Panoramic sliding sunroof/glass roof) Model 222 with code 413 (Panoramic sliding sunroof/glass roof)
		Set of shields	Fig 2
5.2	Mask off left and right roof railing in area next to front stationary element (1) with suitable fabric tape.	Model 205.2 with code 413 (Panoramic sliding sunroof/glass roof) Model 253 with code 413 (Panoramic sliding sunroof/glass roof)
		Adhesive fabric tape	*BR00.45-Z-1062-02A
6	Saw off an approx. 5 mm to 10 mm wide strip from front edge of front stationary element (1).	Saw carefully. Otherwise the seal on the windshield (2) can be damaged. Observe cutting depth when sawing. Otherwise, front panoramic sliding sunroof frame can be damaged. Commercially available devices/tools  Oscillating saw with round sawing blade
7	Saw off an approx. 5 mm to 10 mm wide strip from left and right edges of front stationary element (1).	Saw carefully. Otherwise, left or right roof railing can be damaged. Observe cutting depth when sawing. Otherwise, front panoramic sliding sunroof frame can be damaged. Commercially available devices/tools  Oscillating saw with round sawing blade
8	Open panoramic sliding sunroof (3) completely.
	Risk of injury  due to snapping or warming up of cutting wire and due to splinters when cutting out glued panoramic roofs	Wear cut-proof gloves and safety glasses.	AS77.21-Z-0002-01A
9	Cut out adhesive bead (4) of front stationary element (1) with cutting wire and remove front stationary element (1) from panoramic sliding sunroof frame.	Model 205.2 with code 413 (Panoramic sliding sunroof/glass roof) Model 253 with code 413 (Panoramic sliding sunroof/glass roof) Carefully insert cutting wire in area of left and right roof railing. Otherwise, the left or right roof railing will be damaged. Helper required.
	Install
10	Prepare panoramic sliding sunroof frame for installation of the front stationary element (1).		AR77.21-P-0803-03NKA
		Only use the repair kit approved by the manufacturer from the replacement part system.  Otherwise, adhesion problems will occur.
11	Prepare front stationary element (1) for installation.		AR77.21-P-0803-02NKA
		Before starting work, all component parts, materials, and tools must be prepared for the installation of the front stationary element (1). Otherwise it may not be possible to maintain permissible processing and joining times. Only use the repair kit approved by the manufacturer from the replacement part system.  Otherwise, adhesion problems will occur.
12	Apply adhesive material for the front stationary element (1).		AR77.21-P-0803-04NKA
		Apply adhesive material as quickly as possible and position front stationary element (1) on the body flange and fix it in place. Otherwise, the strength of the adhesively bonded connection is impaired and the required adhesion of the adhesive material is not guaranteed. Only use the repair kit approved by the manufacturer from the replacement part system.  Otherwise, adhesion problems will occur.
13	Close panoramic sliding sunroof (3).
14	Install front stationary element (1) with a helper.		AR77.21-P-0803-05CW
		Do not move vehicle for at least 10 h after gluing in front fixed element (1). Otherwise, the strength of the adhesively bonded connection is impaired and the required adhesion of the adhesive material is not guaranteed. To load front stationary element (1), use weights with large surfaces, e.g. sandbags. Otherwise, front stationary element (1) will be damaged. Observe gap dimensions (A, B) and transitions (C). Front stationary element (1) must be flush with the panoramic sliding sunroof (3) on the left and right. Commercially available devices/tools  Cup suction tool
		Feeler gauge	Fig 1
15	Install left and right drip rail.	Model 205.0/1/3 with code 413 (Panoramic sliding sunroof/glass roof) Model 222 with code 398 (Panoramic roof with MAGIC SKY CONTROL) Model 222 with code 413 (Panoramic sliding sunroof/glass roof)
		Model 222 with code 413 (Panoramic sliding sunroof/glass roof)	AR88.80-P-4000LF
16.1	Remove shields.	Model 205.0/1/3 with code 413 (Panoramic sliding sunroof/glass roof) Model 222 with code 398 (Panoramic roof with MAGIC SKY CONTROL) Model 222 with code 413 (Panoramic sliding sunroof/glass roof)
16.2	Remove tape strips from left and right roof railing.	Model 205.2 with code 413 (Panoramic sliding sunroof/glass roof) Model 253 with code 413 (Panoramic sliding sunroof/glass roof)
		Adhesive fabric tape	*BR00.45-Z-1062-02A
17	Remove strips of adhesive tape and weights for loading the front stationary element (1).	Remove adhesive strips and weights only after adhesive material is cured. Otherwise, the position of front stationary element (1) may change.
	Clean
18	Clean working area.

Number	Designation	Order number
BR00.45-Z-1062-02A	Adhesive fabric tape	A 007 989 28 85