Remove/install electric pop-up roof

AR77.75-S-0011E

Remove/install electric pop-up roof

07.02.2018

Model

447.8

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

Modification notes

29.01.2018

Method revised

Operation steps 1 to 40

Shown on right side of vehicle

1

Pop-up roof

2

Bellows

4

Rear set-up bracket

5

Roof rail

14

Screw

1

Pop-up roof

6

Retaining clips

7

Striker pin mount

8

Cable

Shown on right side of vehicle

2

Bellows

10

Cover

11

Electrical wiring harness

12

Profile rails

13

Outer filler channel

16

Inner filler channel

Shown on right side of vehicle

1

Pop-up roof

2

Bellows

4

Rear set-up bracket

15

Nuts

 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/install

1

Remove awning

AR88.30-S-7000E

2

Remove roof bed frame

Model 447.8
with code ZK0 (EASY UP pop-up roof, electric)
with code ZK8 (Bed in roof)

AR91.75-S-9880E

3

Remove cover (10)

4

Expose electrical wiring harness (11)

5

Disconnect electrical connector of electrical wiring harness (11)

6

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

7

Remove outer filler channel (13)

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

8

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

9

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

10

Remove bolts (14)

11

Remove lock nuts for screws (14)

12

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

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

13

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

AR77.75-S-0001-03E

14

Unscrew nuts (15)

 A helper is required.

15

Lower pop-up roof (1)

 Lower pop-up roof (1) until the clearance from the front roof frame is approx. 15 cm.

16

Remove pop-up roof (1)

 To do this, extend pop-up roof (1) forward out of the roof guide rails (5) and remove pop-up roof (1). 3 helpers required.

17

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.

18

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.

19

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

When replacing pop-up roof (1).

Model 447.8
with code ZK0 (EASY UP pop-up roof, electric)
with code ZK8 (Bed in roof)

AR82.20-S-1125E

20

Change retaining clamps (6) on new pop-up roof (1)

When replacing pop-up roof (1).

21

Change striker pin mount (7) on new pop-up roof (1)

When replacing pop-up roof (1).

 Do not remove cable (8) from striker pin mount (7).



Install

22

Prepare pop-up roof (1) for installation

When replacing pop-up roof (1).

AR77.75-S-0011-01E

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

*BA77.75-N-1007-01D

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

*BA77.75-N-1006-01D

Rear window sealing profile

*BR00.45-Z-1084-01A

23

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

24

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

When replacing pop-up roof (1).

25

Install pop-up roof (1)

 To do this, mount pop-up roof (1) and retract using roof guide rails (5). 3 helpers required.

26

Install lock nuts for screws (14)

27

Screw in new screws (14)


Screws (14) must be clean and free of grease.
Otherwise leakage is not possible.

 Lay seal reinforcer in a ring shape and gap-free on the underside of the bolt heads of the screws (14).

Rear window sealing profile

*BR00.45-Z-1084-01A

 Bolt, front roof rail to pop-up roof

*BA77.75-N-1002-01D

28

Open the pop-up roof (1)

AR77.75-S-0001-03E

29

Attach pop-up roof (1) to rear 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

*BA77.75-N-1004-01D

30

Remove drives of the pop-up roof (1)

AR77.75-S-0010E

31

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

32

Install drives of the pop-up roof (1)

AR77.75-S-0010E

 The boot (2) must not be under tension or pressure.

33

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

34

Route electrical wiring harness (11)

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

35

Install cover (10)

36

Install roof bed frame

Model 447.8
with code ZK0 (EASY UP pop-up roof, electric)
with code ZK8 (Bed in roof)

AR91.75-S-9880E

37

Install awning

AR88.30-S-7000E



Check

38

Check adjustment of pop-up roof (1)

AR77.75-S-0012E

39

Carry out function test of the roof bed reading lamps

Model 447.8
with code ZK0 (EASY UP pop-up roof, electric)
with code ZK8 (Bed in roof)

40

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

AR77.75-S-0001-03E

 Electric pop-up roof

Number

Designation

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

BA77.75-N-1002-01D

Bolt, front roof rail 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-1004-01D

Nut, rear support clamp 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-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-1077-06A

Special lubricant, spray

A 000 989 35 60

BR00.45-Z-1084-01A

Rear window sealing profile

A 004 989 60 20