Remove/install catch at front of Vario roof

AR77.33-P-3400R

Remove/install catch at front of Vario roof

28.5.10



Removing

 Danger!

Risk of injury caused by moving parts that can pinch, crush or, in extreme cases, even sever extremities

No parts of the body or limbs should be within the operating range of the mechanism when moving components.

AS00.00-Z-0009-01A

 Danger!

Risk of injury caused by body parts being trapped or crushed when working on partially open Vario roof (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 Vario roof assembly work

AH77.30-P-0002-01R

1

Remove paneling from front Vario roof

AR68.30-P-4350R

2

Remove support for securing intermediate position of Vario roof and close Vario roof with Vario roof switch



*230589046300

3

Switch off the ignition and remove the transmitter key from the EIS [EZS] control unit

 On vehicles with code (889) Keyless-Go, press KEYLESS-GO start/stop button repeatedly until ignition is switched off.

Remove the Keyless Go chipcard or transmitter key from vehicle and store beyond reach of the transmitter (at least 2 m).

4

Expose electrical and hydraulic lines, left Bowden cable (5) and right Bowden cable (6) on Vario roof front section in area of front lock (1).

 Mark installation position of electric and hydraulic lines as well as left Bowden cable (5) and right Bowden cable (6).

The designation of the left Bowden cable (5) and right Bowden cable (6) refers to the installation location of the corresponding C-pillar lock.

5

Unclip ball socket (7) on Bowden cable (5) from right lock outer section (4) and ball socket (7) on right Bowden cable (6) from left lock outer section (3) with suitable screwdriver.

6

Mark position of clips (8) on left Bowden cable (5) and right Bowden cable (6)

7

Remove clips (8) and remove left Bowden cable (5) as well as right Bowden cable (6) from lock center section (2).

8

Unscrew bolts (9, 11) and concealed
bolt (arrow).

9

Unlock front catch (1) from emergency unlocking (10)

10

Remove front catch (1) together with spacer (12)

 Slightly lift Vario roof front section and clamp an approx. 2 to 3 cm thick intermediate piece, e.g. wooden board, between Vario roof front section and crossmember above windshield.

11

Unclip Vario roof "locked" limit switch (right rotary tumbler) (S69/2) from right catch outer section (4) and Vario roof "locked" limit switch (left rotary tumbler) (S69/3) from left catch outer section (3) with suitable screwdriver

12

Remove hydraulic cylinder (13) from catch center section (2)

 Do not actuate Vario roof switch when hydraulic cylinder (13) is removed, otherwise hydraulic cylinder (13) can be damaged.



Install

13

Install hydraulic cylinder (13) on catch center section (2).

14

Clip Vario roof "locked" limit switch (right rotary tumbler) (S69/2) into right catch outer section (4) and Vario roof "locked" limit switch (left rotary tumbler) (S69/3) into left catch outer section (3)

15

Position front lock (1) together with spacers (12) on Vario roof front section and tighten bolts (9) as well as concealed bolt (arrow).



*BA77.33-P-1001-01A

16

Tighten bolts (11) up to contact surface

 Do not tighten down the bolts (11).

17

Hook left Bowden cable (5) and right Bowden cable (6) into holding lug on catch center section (2).

18

Slightly lift Vario roof front section and remove intermediate piece between Vario roof front section and crossmember above windshield.

19

Unlock front catch (1) with emergency unlocking (10), lock and unlock again

20

Tighten bolts (11)



*BA77.33-P-1001-01A

21

Hook left Bowden cable (5) and right Bowden cable (6) into mounts on catch center section (2) and press on clips (8).

 Pay attention to installation markings.

22

Clip ball socket (7) on Bowden cable (5) into right catch outer section (4) and ball socket (7) on right Bowden cable (6) into left catch outer section (3).

23

Fasten electric and hydraulic lines as well as left Bowden cable (5) and right Bowden cable (6) to Vario roof front section

 Observe installation markings for electric and hydraulic lines as well as left Bowden cable (5) and right Bowden cable (6).

When the electric and hydraulic lines as well as the left Bowden cable (5) and right Bowden cable (6) are routed incorrectly, they can be damaged. Replace all cable ties and clips, otherwise permanent mounting of the components is not ensured.

24

Check adjustment of Bowden cables for locking to C-pillar: correct if necessary.

AR77.33-P-3470R

25

Move Vario roof with Vario roof switch to intermediate position and secure

AR77.50-P-3000-01R



*230589046300

26

Install paneling at front of Vario-roof

AR68.30-P-4350R

Number

Designation

Model
230

BA77.33-P-1001-01A

Bolt of catch on Vario roof

Nm

10