Removing and installing vario-roof

AR77.50-P-3000G

Removing and installing vario-roof

28.5.10



Removal

1

Remove side paneling in trunk

 Remove only side paneling on right

AR68.30-P-4800G

2

Disconnect connector on limit switch (S69/10) and insert bridge in connector

3

Remove paneling on tank partition

4

Expose hydraulic lines on right in trunk up to hydraulic unit

 Open cable straps or cut

5

Unclip hydraulic lines from left main cylinder in trunk above tank

6

Open vario-roof

 Leave trunk lid pivoted to rear

7

Unscrew screw (1) and remove cover (2)

8

Unscrew screws (3, 4) and remove cover (5)

9

Remove cover above cross member for
roll-bar

10

Unhook rubber strap (6) from rear shelf on main mount

11

Close vario-roof

 Vario-roof should only make contact at front, do not lock front catch

12

Remove limit switch (S69/11) on right main mount

13

Remove insert clip (7) and pin (8)

14

Remove snap ring (9) and pin (10)

15

Remove main cylinder (11) from main mount toward front and hang in vehicle passenger compartment on rear wall

 Do not damage piston rod when pulling out

16

Mark position of main mount (12)
on B-pillar (arrows)

17

Measure interval (a) between vario-roof
C-pillar and fender with feeler gauge and note



*129589032100

18

Unscrew screw (13) on inside at rear of main mount

19

Remove connector (14) and separate from holder in direction of arrow

20

Separate hydraulic lines no. 31 and no. 33 from hydraulic unit

 Pressure is present in the hydraulic lines when the vario-roof has been moved with the roof switch and the ignition is not switched off.

When separating hold a rag around the hydraulic lines, because hydraulic oil continues to run out.

 for plugging hydraulic unit

*129589009101

 for plugging hydraulic lines

*129589009107

21

Attach hydraulic lines and electrical wires with tape

 To prevent the lines from catching when the vario-roof is lifted out

22

Open emergency actuation valve (N) on hydraulic unit to stop with 6 mm Allen wrench

 Open emergency actuation valve only with roof put down or closed and ignition switched off to avoid damaging the gasket on the emergency actuation valve (N) which would prevent pressure from building up in the system.

23

Put vario-roof down into trunk by hand

24

Unscrew screws (13)

25

Push trunk lid closed and pivot back by hand a number of times

 When lifting out the vario-roof it is easier to pivot the trunk lid back

26

Lift out vario-roof with the aid of a second mechanic, set down on roll-bar, push trunk lid closed and set vario-roof down on suitable soft surface after moving across vehicle toward rear



Installation

27

Align plates (15) on B-pillar

 Do not mix up plates, because number of plates on each side may differ

28

Push trunk lid closed, set down vario-roof on roll-bar with the aid of a second mechanic, pivot trunk lid back and set vario-roof down on B-pillars

 When installing do not pinch hydraulic lines and electrical wiring

29

Screw in screws (13)

30

Align main mount with mark on B-pillar and tighten screws (13) lightly

31

Pivot vario-roof out of trunk by hand and lay down on supports on cross member above windshield

32

Connect hydraulic lines no. 31 and 33 to hydraulic unit

33

Connect connector (14) and fasten to holder

34

Press cap into front roof paneling

35

Turn catch clockwise to stop with 6 mm Allen wrench (left arrow) and allow to catch, then turn counterclockwise to stop (right arrow) and lock catch

 The slide (16) in the catch should engage in the cam (17) on the C-pillar

36

Loosen screws (13) and hit the vario-roof lightly with open hand a number of times in the area of the roof separation

 This eliminates any tension in the main mount or moving parts

37

Check the position of the main mount or the interval (a) between the vario-roof and fender and correct, if necessary

 Corrections are possible only to a very small extent when the vario-roof is locked at the front.

38

Screw in screw (13) and tighten all screws on main mount

*BA77.33-P-1007-01A

39

Install hydraulic cylinder (11) on main mount (12)

40

Install limit switch (S69/11) on main
mount (12)

41

Close emergency actuation valve (N) on hydraulic unit

 Tightening torque 3+0.5 Nm

42

Route hydraulic lines and electrical leads in trunk and fasten

43

Hook rubber strap (6) from rear shelf on main mount

44

Open and close vario-roof carefully a number of times with the roof switch

45

Check roof contour with template



 If deviations are present 

*170589042300

 Correct adjustment of vario-roof 

AR77.50-P-3030G

 Check adjustment of crank windows 

AR72.10-P-1950G

 Check adjustment of rear side window

AR67.30-P-4200G

46

Install paneling for tank partition

47

Install paneling on side in trunk

AR68.30-P-4800G

48

Open vario-roof

 Leave trunk lid pivoted to rear

49

Install paneling above roll-bar cross member

50

Install cover (5) above B-pillar

51

Perform rain test

Number

Designation

Model
170

BA77.33-P-1007-01A

Screws for main mount on B-pillar

Nm

22