Remove/install Vario roof actuation hydraulic cylinder

AR77.37-P-3490R

Remove/install Vario roof actuation hydraulic cylinder

30.10.08



Removing

 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 left and right side paneling in trunk

AR68.30-P-4800R

2

Remove left and right paneling on upper center pillar.

AR68.30-P-1077R

3

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

AR67.39-P-4150-01R

4

Move Vario roof load assist position with load assist switch and secure

 If the trunk partition has been removed, the trunk partition limit switch must be mechanically or electrically bridged.

AR77.50-P-3000-02R



*230589066300

5

Pull out retaining clips (3) and remove front bolt (2) as well as rear bolt (4) from Vario roof actuation hydraulic cylinder (1)

6.1

Expose hydraulic lines No. 41 and 51 in trunk to RVC [UVS] hydraulic unit

When removing Vario roof actuation left hydraulic cylinder (1).

6.2

Expose hydraulic lines No. 42 and 52 in trunk to RVC [UVS] hydraulic unit

When removing Vario roof actuation hydraulic cylinder (1).

 For this purpose, remove battery support of on board electrical system battery and open cable shafts.

7.1

Remove hydraulic lines No. 41 and 51 from RVC [UVS] hydraulic unit

When removing Vario roof actuation left hydraulic cylinder (1).

AR77.37-P-3500R

 Do not separate electrical connectors at the RVC [UVS] hydraulic unit.

7.2

Remove hydraulic lines No. 42 and 52 from RVC [UVS] hydraulic unit

When removing Vario roof actuation hydraulic cylinder (1).

AR77.37-P-3500R

 Do not separate electrical connectors at the RVC [UVS] hydraulic unit.

8

Remove Vario roof actuation hydraulic cylinder (1)
toward rear from trunk

 Do not kink hydraulic lines to prevent damage.



Install

9.1

Install hydraulic lines No. 41 and 51 on RVC [UVS] hydraulic unit

When installing left Vario roof actuation hydraulic cylinder (1).

AR77.37-P-3500R

9.2

Install hydraulic lines No. 42 and 52 on RVC [UVS] hydraulic unit

When  installing right Vario roof actuation hydraulic cylinder (1).

AR77.37-P-3500R

10

Position Vario roof actuation hydraulic cylinder (1)
through trunk on installation location

 Do not kink hydraulic lines to prevent damage.

11

Install front bolt (2) and rear bolt (4) together with retaining clips (3).

12.1

Route hydraulic lines No. 41 and 51 to RVC [UVS] hydraulic unit and fasten.

When installing left Vario roof actuation hydraulic cylinder (1).

 Do not kink hydraulic lines to prevent damage.

 Replace cable ties.

Ensure that distance dimension (A) of hydraulic line No. 41 to crossmember spacer (5) is approx. 10 mm.

12.2

Route hydraulic lines No. 42 and 52 to RVC [UVS] hydraulic unit and fasten.

When installing right Vario roof actuation hydraulic cylinder (1).

 Do not kink hydraulic lines to prevent damage.

 Replace cable ties.

Ensure that distance dimension (A) of hydraulic line No. 42 to crossmember spacer (5) is approx. 10 mm.

13

Remove supports for securing load assist position

AR77.50-P-3000-02R



*230589066300

14

Completely close Vario roof with load assist switch.

 If the trunk partition has been removed, the trunk partition limit switch must be mechanically or electrically bridged.

15

Actuate Vario roof switch at least 10 s in the opening direction.

When installing new Vario roof actuation hydraulic cylinder (1).

 For bleeding new Vario roof actuation hydraulic cylinder (1).

If the trunk partition has been removed, jumper trunk partition switch mechanically or electrically.

16

Install retaining plate for power window on rear side window

AR67.39-P-4150-01R

17

Install paneling at upper center pillar

AR68.30-P-1077R

18

Install paneling on side in trunk

AR68.30-P-4800R

19

Check Vario roof for proper function

 Particularly check line routing for electrical and hydraulic lines.