Retrofitting manual pop-up roof

AN77.10-S-1500A

28.10.96

MODEL 638
Applicable for front and rear pop-up roof

S77.10-0002-12

1 Pop-up roof frame

2 Bottom paneling

4 Screw

5 Screw

6 Screw

8 Wind deflector

9 Guide

S77.20-0006-01

A Cutout

B Roof paneling

C Pop-up roof frame

S77.20-0005-01

	Removal
1	Cover vehicle passenger compartment
2	Remove headliner
		Front	AR68.30-S-7607A
		Rear	AR68.30-S-7608A
	Installation
3	Cover cutout (A) with body masking tape	 Cover surface to be treated to greatest possible extent.
4	Install positioning template	 Position from inside or outside and fasten with tape.
5	Mark cutout (A)
6	Drill holes at corners with 8 mm sheet metal bit	 Avoid damaging paint.
7	Cut along inner edge with suitable cutting tool (A)
8	Deburr inner edge and treat with corrosion protection agent	 See Paintwork Manual
9	Remove glass cover from frame
			AR77.10-S-2010A
10	Insert pop-up roof frame (1) from below and arrest
11	Screw screw (11) with pop-up roof frame (1) onto roof carrier		*BA77.10-N-1004-01A
12	Install wind deflector (8)	 Start with step 5.
			AR77.20-S-2500A
13	Install glass cover in frame
			AR77.10-S-2010A
14	Install headliner
		Front	AR68.30-S-7607A
		Rear	AR68.30-S-7608A
	Checking
15	Check for proper function

 Mechanical sliding roof

Number	Designation		Model 638


BA77.10-N-1004-01A	Screw of the pop-up roof frame in roof carrier	Nm	3

Parts ordering notes

Part no.	Designation	Quantity
638 780 04 05	Pop-up roof, complete	1
siehe ET-Fiche	Front headliner (specify color code)	1
siehe ET-Fiche	Rear headliner (specify color code)	1