Body - Vario Roof Won't Open/Close
Date: April 30, 2009Order No.: P-B-77.33/76a
Supersedes: P-B-77.33/76 dated February 23, 2009
Group: 77
Revision History
Revision Date Purpose
a 4/30/09 Damage Code Revised
- 2/23/09 Initial issue
SUBJECT:
Model 230.470/471/472/474/475/476/477/479, Up to Production 07/08
Vario Roof Will Not Open or Close
If you receive customer reports in the above model vehicles that the vario roof will not open or close, this may be caused by the piston rod of the roll bar hydraulic cylinder twisting while extending and not being able to lock with the roll bar trigger solenoid. The roof is designed not to move if there are issues with the roll bar system. Perform the procedure outlined below to resolve.
1. Remove the right side paneling in the rear compartment. Refer to WIS document AR68.30-P-4780R
2. Switch on ignition, press the roll bar switch in the UP direction until the piston rod (Figure 1, 1) is locked with the trigger solenoid Y57/1.
Note:
Aid of helper required. Guide the piston rod by hand so it can't twist while extending.
3. Lower the roll bar completely using switch.
4. Switch off the ignition and remove the transmitter key from the EIS control unit. Note: In vehicles with Keyless-Go (code 889), press the Keyless-Go start/stop button until the ignition is switched off. Remove the Keyless-Go transmitter card or key from the vehicle and keep it outside the range of the vehicle minimum 2 meters (7 feet).
5. Remove trim cap (Figure 1, 2) on roll bar in direction of arrow.
6. Aid of helper required. Press the roll bar down by hand and hold in this position, just enough to remove bolt (Figure 1, 3). Replace self locking bolt when installing. Swing roll bar upwards by hand.
7. Remove bolts (Figure 2, 4) then partially remove roll bar support element (Figure 2, 5). Hydraulic cylinder should be accessible.
8. Switch on ignition then press roll bar switch in the UP direction until the piston rod (Figure 1, 1) is fully extended.
9. Switch off the ignition and remove the transmitter key from the EIS control unit.
Note:
In vehicles with Keyless-Go (code 889), press the Keyless-GO start/stop button until the ignition is switched off. Remove the Keyless Go transmitter card or key from the vehicle and keep it outside the range of the vehicle minimum 2 meters (7 feet).
10. Unplug electrical connector 7 (Figure 2, 7) at trigger solenoid Y57/1.
11. Insert guide rail (Figure 3, 8) at hydraulic cylinder (Figure 3, 6) and fasten with cable tie (Figure 3, 9 and 10).
12. Reconnect electrical connector (Figure 2, 7).
13. Switch on ignition switch press roll bar switch in the DOWN direction until the roll bar is completely retracted.
14. Install support element (Figure 2, 5) into longitudinal member and install bolts (Figure 2, 4) do not tighten completely as they are tightened when the roll bar is adjusted 25Nm.
15. Aid of a helper required. Switch on ignition and press roll bar switch in the UP direction while guiding toothed rack of support element (Figure 2, 5) into the mounting at top of roll bar.
16. Install new bolt (Figure 1, 3) and tighten to 28Nm. Install trim cover/cap (Figure 1, 2).
17. Press roll bar switch in the DOWN direction until the roll ball is fully lowered.
18. Adjust roll bar reference. Refer to WIS document AR91.50-P-9200R.
19. Perform function test by raising and lowering the roll bar with the convenience switch several times.
20. Check crash deployment using STAR DIAGNOSIS.
21. Install the right side paneling in the rear compartment. Refer to WIS document AR68.30-P-4780R.
Warning!
Risk of injury in the area of the roll bar when carrying out testing or repair work. Keep your fingers away from the movement radius of the roll bar mechanism.
Parts Information
Note:
The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has been generated on April 30, 2009. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
In Case of Warranty, use the table above.