Remove/install manual pop-up roof

AR77.70-S-0001E

Remove/install manual pop-up roof

07.02.2018

Model

447.7/8

with code ZK9 (Lifting roof hatch)

Modification notes

29.01.2018

Method revised

Operation steps 1 to 34

Shown on right side of vehicle

1

Pop-up roof

2

Bellows

3

Gas-filled strut

4

Support clamp

15

Nuts

Shown on right side of vehicle

1

Pop-up roof

2

Bellows

3

Gas-filled strut

4

Support clamp

10

Cover

11

Electrical wiring harness

12

Profile rails

13

Outer filler channel

16

Inner filler channel

 Warning

Risk of injury caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof.

No parts of the body or limbs should be within the operating area when the components are moving.

AS00.00-Z-0011-01A

Topical note

Notes on carrying out repair work in the vehicle interior

AH68.00-N-0001-01S



Remove

1

Remove awning

AR88.30-S-7000E

2

Remove roof bed frame

Model 447.7/8
with code ZK8 (Bed in roof)
with code ZK9 (Lifting roof hatch)

AR91.75-S-9880E

3

Remove both pneumatic springs (3)

AR77.70-S-0004E

4

Remove cover (10)

5

Expose electrical wiring harness (11)

6

Disconnect electrical connector of electrical wiring harness (11)

7

Mark assembly position of the boot (2) and the outer filler channel (13) on the roof

8

Remove outer fill channel (13)


Carefully remove outer filler channel (13).
Otherwise, the boot (2) may be damaged.

9

Remove boot (2) from bottom profile rail (12)

10

Lift boot (2) and fasten to the pop-up roof (1) using suitable means

11

Mark assembly positions of the folding stands (4) on the pop-up roof (1)

When the pop-up roof (1) is reused.

12

Close pop-up roof (1) but ensure that the nuts (15) are still accessible

  Remove locating tool for the roof support. A helper is required for support.

 Fixing device

*639589003100

13

Unscrew nuts (15)

 A helper is required for support.

14

Remove pop-up roof (1)

 To do this, remove pop-up roof (1) from the folding stands (4) and take off pop-up roof (1). 3 helpers required.

15

Place pop-up roof (1) down on a suitable base


Always use a protective mat for the pop-up roof (1).
Otherwise, the pop-up roof (1) may be damaged.

 A helper is required.

16

Remove boot (2) from pop-up roof (1)

When replacing pop-up roof (1).

AR77.70-S-0080-03E


While doing this, carefully remove inner filler channel (16).
Otherwise, the boot (2) may be damaged.

17

Change both roof bed reading lamps on the new pop-up roof (1)

When replacing pop-up roof (1).

Model 447.7/8
with code ZK8 (Bed in roof)
with code ZK9 (Lifting roof hatch)

AR82.20-S-1125E

18

Change both upper sections of the lock on the new pop-up roof (1)

When replacing pop-up roof (1).

AR77.70-S-0012E



Install

19

Install new rubber seal frame

When replacing pop-up roof (1).

AR77.70-S-0016E

20

Prepare pop-up roof (1) for installation

When replacing pop-up roof (1).

AR77.70-S-0001-05E

 Nut, rail for roof carrier on pop-up roof

*BA77.70-N-1007-01B

 Nut, closing strap on pop-up roof

*BA77.70-N-1008-01B

 Pneumatic spring ball stud bracket to vehicle roof

*BA77.70-N-1005-01B

 Nut, support strap for roof bed to pop-up roof

*BA77.70-N-1006-01B

Rear window sealing profile

*BR00.45-Z-1084-01A

21

Install boot (2) on pop-up roof (1)

When replacing pop-up roof (1).

AR77.70-S-0080-01E

Special lubricant, spray

*BR00.45-Z-1077-06A

 Roller

*639589086300

 Long wedge

*115589035900

22

Fasten boot (2) to the pop-up roof (1) using suitable means

When replacing pop-up roof (1).

23

Install pop-up roof (1)

 To do this, mount pop-up roof (1) and install  locating tool. 3 helpers required.

 Fixing device

*639589003100

24

Attach pop-up roof (1) to folding stands (4)

 To do this, screw on nuts (15). A helper is required.

 If the markings were attached during removal, they must be observed accordingly.

 Nut, rear support clamp to pop-up roof

*BA77.70-N-1003-01B

25

Install both pneumatic springs (3) of the pop-up roof (1)

AR77.70-S-0004E

26

Attach boot (2) to the roof

AR77.70-S-0080-02E

 Observe attached markings.

Special lubricant, spray

*BR00.45-Z-1077-06A

 Long wedge

*115589035900

 Roller

*639589086300

27

Connect the contacts of the electrical connector of the electrical wiring harness (11)

28

Route electrical wiring harness (11)

 Ensure that electrical wiring harness (11) is routed correctly.

29

Install cover (10)

30

Install roof bed frame

Model 447.7/8
with code ZK8 (Bed in roof)
with code ZK9 (Lifting roof hatch)

AR91.75-S-9880E

31

Install awning

AR88.30-S-7000E



Check

32

Check adjustment of pop-up roof (1)

AR77.70-S-0002E

33

Carry out function test of the roof bed reading lamps

Model 447.7/8
with code ZK8 (Bed in roof)
with code ZK9 (Lifting roof hatch)

34

Ensure that the boot (2) is seated correctly by completely opening and closing the pop-up roof (1)

AR77.70-S-0001-01E

 Mechanical pop-up roof

Number

Designation

Model 447.7/8
with code ZK9 (Lifting roof hatch)

BA77.70-N-1003-01B

Nut, rear support clamp to pop-up roof

Nm

10

 Mechanical pop-up roof

Number

Designation

Model 447.7/8
with code ZK9 (Lifting roof hatch)

BA77.70-N-1005-01B

Pneumatic spring ball stud bracket to vehicle roof

Nm

18

 Mechanical pop-up roof

Number

Designation

Model 447.7/8
with code ZK9 (Lifting roof hatch)

BA77.70-N-1006-01B

Nut, support strap for roof bed to pop-up roof

Nm

10

 Mechanical pop-up roof

Number

Designation

Model 447.7/8
with code ZK9 (Lifting roof hatch)

BA77.70-N-1007-01B

Nut, rail for roof carrier on pop-up roof

Nm

10

 Mechanical pop-up roof

Number

Designation

Model 447.7/8
with code ZK9 (Lifting roof hatch)

BA77.70-N-1008-01B

Nut, closing strap on pop-up roof

Nm

10

Repair materials

Number

Designation

Order number

BR00.45-Z-1077-06A

Special lubricant, spray

A 000 989 35 60

BR00.45-Z-1084-01A

Rear window sealing profile

A 004 989 60 20