Remove/install roll bar

AR91.50-P-2355R

Remove/install roll bar

30.10.08



Removing

 Danger!

Risk of injury when performing check and repair work in area of rollover bar

Extend roll bar before working in the roll bar area Keep body parts away from the moving area of the roll bar mechanical system.

AS91.00-Z-0003-01R

1

Fully open Vario roof using Vario roof switch

2

Remove left and right rear side paneling

AR68.30-P-4780R

3

Completely retract roll bar using roll bar switch

4

Raise roll bar mechanically

AR91.50-P-8400R

5

Remove paneling from top of left and right center pillars

AR68.30-P-1077R

6

Remove retaining plate for power window on left and right rear side window

AR67.39-P-4150-01R

7

Remove left and right guides (2)

8

Detach electrical connector (3) on roll bar raise/lower limit switch (S83/10)

9

Detach electrical connector (4) on roll bar deployment solenoid (RB) (Y57/1)

10

Rotate hydraulic cylinder lock pawl (5) by 90°, retract safety clip (11) and remove hydraulic cylinder lock pawl (5) from left support element (6) and right support element (7)

11

Remove bolts (8)

12

Undo both main bearing bolts (9)

13

Lift up roll bar element (1) with the aid of an assistant until the hydraulic cylinder roll bar operation (10) is accessible

14

Detach holddown clip (12) and remove hydraulic cylinder roll bar operation (10) from right support element (7)

15

Remove roll bar unit (1) from vehicle together with an assistant



Install

16

Position roll bar unit (1) with the aid of an assistant in the vehicle and install the hydraulic cylinder roll bar operation (10) at right support element (7)

17

Insert holddown clip (12)

 Arrow on holddown clip (12) must face upwards.

18

Connect electrical connector (4) to RB [ÜRB] deployment solenoid (Y57/1)

19

Connect electrical connector (3) to roll bar "down/up" limit switch (S83/10)

20

Screw in left and right main bearing bolts (9)

 Do not tighten main bearing bolts (9).

21

Screw in bolts (8)

 Do not tighten down the bolts (8).

22

Insert hydraulic cylinder lock pawl (5) into left support element (6), rotate by 90°, and press in safety clip (11) using the fitting tool (14)

 Ensure that safety clip (11) is seated properly.



*230589006100

23

Insert hydraulic cylinder lock pawl (5) into right support element (7), rotate by 90°, and press in safety clip (11) using the fitting tool (14)

 Ensure that safety clip (11) is seated properly.



*230589006100

24

Apply load to roll bar in rear section and tighten main bearing bolts (9)

 Applying a load to the roll bar heads (13) should serve to help them reach their highest position.



*BA91.50-P-1002-01A

25

Tighten bolts (8)



*BA91.50-P-1003-01A

26

Switch on ignition, extend hydraulic cylinder roll bar operation (10) using roll bar switch, and couple with RB [ÜRB] deployment solenoid (Y57/1)

 Before doing so ensure that the roll bar deployment solenoid is (RB) (Y57/1) unlocked. If this is not the case, then the RB [ÜRB] deployment solenoid (Y57/1) must be manually activated.
Refer to: 

Lower and raise roll bar mechanically

AR91.50-P-8400R

27

Adjust roll bar

AR91.50-P-9200R

28

Install left and right guides (2)

29

Install retaining plate for power window of left and right rear side windows

 Pay attention to installation markings.

AR67.39-P-4150-01R

30

Install paneling at top of left and right center pillars

AR68.30-P-1077R

31

Install left and right rear side paneling

AR68.30-P-4780R

Number

Designation

Model
230

BA91.50-P-1002-01A

Bolt, roll bar to tapping plate

Nm

70

BA91.50-P-1003-01A

Bolt, roll bar to supporting element

Nm

28