Perform additional operations when replacing electric pop-up roof

AR77.75-S-0011-01E

Perform additional operations when replacing electric pop-up roof

Model

447.8

with code ZK0 (EASY UP pop-up roof, electric)

 Electric pop-up roof

Number

Designation

Model 447.8
with code ZK0 (EASY UP pop-up roof, electric)

BA77.75-N-1006-01D

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

Nm

10

 Electric pop-up roof

Number

Designation

Model 447.8
with code ZK0 (EASY UP pop-up roof, electric)

BA77.75-N-1007-01D

Nut, rail for roof carrier on pop-up roof

Nm

10

Repair materials

Number

Designation

Order number

BR00.45-Z-1084-01A

Rear window sealing profile

A 004 989 60 20

Remove

1

Lay old pop-up roof (1) with bottom upward on suitable assembly stands.

 Helper required.

2

Remove left and right roof bed support strap (2) from old pop-up roof (1).

 Do not remove loosened bolts form mounting roof bed support strap (2), because they are replaced.

3

Remove left and right retaining clip (3) from old pop-up roof (1).

4

Remove front and rear safety net mount (4) from left and right side of old pop-up roof (1).

Shown on removed pop-up roof (1)

5

Remove all profile rails (5) and corner reinforcements (7) together with electrical wiring harness (6) from old pop-up roof (1).

 Side profile rails (5), front profile rails (5) and front corner reinforcements (7) are installed together with electrical wiring harness (6).

6

Remove all blind plugs from bottom of old pop-up roof (1).

7

Lay old pop-up roof (1) with bottom upward on suitable assembly stands.

 Helper required.

8

Remove left and right roof carrier rail (8) from old pop-up roof (1)

Install

9

Lay butyl cord ring-shaped and gap-free down on bottom side of bolt head on bolts for fastening roof bed support straps (2).

 The bolts must be clean and free of grease.
Otherwise leakage is not possible.

 Use new bolts.

10

Install left and right roof bed support strap (2) on pop-up roof (1)  .

11

Install caps on nuts for fastening roof bed support straps (2).

12

Install left and right retaining clip (3) on pop-up roof (1).

13

Install front and rear safety net mount (4) on left and right side of pop-up roof (1).

Shown on removed pop-up roof (1)

14

Install all profile rails (5) together with electrical wiring harness (6) on pop-up roof (1).

15

Install all inner and outer corner reinforcements (7) on pop-up roof (1).

16

Close blind holes not required with blind plugs at bottom of pop-up roof (1)

17

Lay butyl cord ring-shaped and gap-free down on bottom side of bolt head on bolts which are required to close needless through holes on pop-up roof (1).

 The bolts must be clean and free of grease.
Otherwise leakage is not possible.

 Use new bolts.

18

Plug all through holes on pop-up roof (1) not required with previously prepared bolts.

19

Install caps on nuts of previously installed bolts.

20

Lay butyl cord ring-shaped and gap-free down on bottom side of bolt head on bolts for fastening roof carrier rails (8).

 The bolts must be clean and free of grease.
Otherwise leakage is not possible.

 Use new bolts.

21

Install left and right roof carrier rail (8) on pop-up roof (1)  .

22

Install caps on nuts for fastening roof carrier rails (8).

23

Remove needless butyl on bolts head at top of pop-up roof (1) and in roof carrier rails (8)

24

Lay old pop-up roof (1) with top upward on suitable assembly stands.

 Use padded protective base for pop-up roof (1).
Otherwise the painted surface of the pop-up roof (1) can be damaged.

 Helper required.

25

Glue WESTFALIA adhesive label (10) onto pop-up roof (1) by observing dimensions (A, B).

 Dimension (A): 55 mm
Dimensions (B): 25 mm
The reference point for the dimensions (B) is the bottom edge of pop-up roof (1) before installing rubber sealing frame.

Shown on removed pop-up roof (1)