Remove/install Vario roof

AR77.50-P-3000R

Remove/install Vario roof

28.5.10

 

Remove/install

 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 performing assembly work on Vario roof

AH77.30-P-0002-01R

1

Close Vario roof (1) with Vario roof switch

2

Remove left and right side paneling in trunk

AR68.30-P-4800R

3

Remove guide eye (2)

4

Remove ground line (4) from ground (left wheel well in luggage compartment) (W6)

 Reinstall remaining ground lines to ground (left wheel well in luggage compartment) (W6).

5

Disconnect electrical connectors (3) from rear shelf antenna amplifier (A2/67)

6

Remove left and right C-pillar paneling from Vario roof (1).

AR68.30-P-4500R

7

Remove paneling from Vario roof rear section

AR68.30-P-4380R

8

Remove support for securing intermediate position of Vario roof (1) and close Vario roof (1) with Vario roof switch



*230589046300

9

Remove paneling on Vario roof (1) at front

AR68.30-P-4350R

10

Remove support for securing intermediate position of Vario roof (1) and completely open Vario roof (1) with Vario roof switch



*230589046300

11

Remove roll bar

AR91.50-P-2355R

12

Remove power window on left and right rear side window

 Do not remove rear side windows from power windows.

AR67.39-P-4150R

13

Remove interior trim at roll bar

AR68.30-P-1380R

14

Remove panelings (5)

 The panelings (5) are attached with nine bolts each.



*BA68.30-P-1004-01A

15

Remove load assist "up/down" limit switch (S117) from left main bearing (6) and lay down to side with electrical lines connected

AR77.39-P-3692R

16

Remove Vario roof "up/down" limit switch
(S69/11) from left main bearing (6) and lay down to side

AR77.39-P-3694R

17

Remove Vario roof load assist position hydraulic cylinder (8) from left main bearing (6) and right main bearing (7) and lay down to side

AR77.37-P-3600R

18

Remove trunk lid seal (9) in area of left and right center pillar

19

Unscrew bolts (10) from left main bearing (6) and right main bearing (7)



*BA77.33-P-1007-01A

20

Install strut (11) between left main bearing (6) and right main bearing (7)



*230589036300

21

Mechanically close Vario roof (1)

 Do not lock front catch (16)

AR77.30-P-6235R

22

Move Vario roof (1) to intermediate position with Vario roof switch and secure

AR77.50-P-3000-01R



*230589046300

23

Remove Vario roof actuation hydraulic cylinder (12) from left main bearing (6) and right main bearing (7) and lay down in trunk

AR77.37-P-3490R

24

Disconnect electrical connector (13) on rear window wiring harness (14) on center pillar

25

Remove Bowden cables (15) from front catch (16)

AR77.33-P-3471R

26

Remove support for securing intermediate position of Vario roof (1)



*230589046300

27

Mechanically close Vario roof (1)

 Do not lock front catch (16).

AR77.30-P-6235R

28

Install assembly strut on C-pillar for Vario roof (1)

AR77.30-P-4000-01R



*230589126300

29

Remove front catch (16)

AR77.33-P-3400R

30

Unscrew bolts (17) from left main bearing (6) and right main bearing (7)

 Installation: Slide left main bearing (6) and right main bearing (7) to X-stop (19), center Vario roof (1) and tighten bolts (17).



*BA77.33-P-1007-01A

31

Separate left and right water drain hose (18)

32

Install roof hoist (20)
on Vario roof (1)

 Observe installation position shown for roof hoist (20) on Vario roof (1).

Motor-Dirigent engine hoist

gotis://H_00.12_04.0

Vario roof lifting device

gotis://K_68-80_07.0

33

Lift Vario roof (1) and remove from vehicle

 Carefully lift Vario roof (1) to prevent damaging electrical and hydraulic lines.

34

Install removed Vario roof (1) to roof mounting frame

AR77.50-P-3000-03R

Motor-Dirigent engine hoist

gotis://H_00.12_04.0

Vario roof lifting device

gotis://K_68-80_07.0

Vario roof mounting frame

gotis://K_68-80_07.0

35

Install detachable body components on Vario roof (1)

When replacing Vario roof (1).

36

Install in the reverse order

37

Adjust contour of Vario roof (1)

AR77.50-P-3040R

38

Remove side flap (1) for Vario roof

AR77.30-P-6373R

Number

Designation

Model
230

BA68.30-P-1004-01A

Screw side interior compartment paneling to roll bar, rear wall

Nm

8

Number

Designation

Model
230

BA77.33-P-1007-01A

Bolts, main bearing to B-pillar

Nm

22