Body - Vario Roof(R) Is Inoperative

DTB

Date: September 25, 2008
Order No.: P-B-77.33/64a
Supersedes: P-B-77.33/64 dated July 15, 2008
Group: 77







SUBJECT: Model 230.471/472/474/475/476/477/479
Vario Roof Inoperative / End Position of Side Flaps Not Reached

If you receive customer reports in the above model vehicles with the below conditions, this may be caused by the mounting plate on the drive unit of side flap being bent or broken (Figure 1).







- Vario roof inoperative
- End position of side flap is not reached
- Noises in the area of the side flaps

To resolve, replace both mounting plates of the side flap drive units on both sides of the vehicle as follows:

1. Open trunk lid and cover/protect rear fenders to protect against damage.

2. Turn adjusting nuts on Bowden cable of side flap drive unit on both side flaps, three turns counterclockwise (Figure 2, 1). This eliminates the preload at the side flaps.







3. Unplug electrical connector from microswitch.

4. Detach left and right side flaps from trunk lid, remove nuts (Figure 2, 2).

5. Unscrew torx bolts at rear of mounting plate (Figure 3).







6. Separate side flap from mounting plate.

7. Remove toothed rack (Figure 4, 2) from mounting plate (Figure 4, 1) and disconnect mounting plate from Bowden cable (Figure 4, 3)






8. Attach new mounting plate to Bowden cable. Make sure the new mounting plate is installed flush/flat relative to the slot of the adjusting nut (Figure 5). To install, lubricate the taper of the adjusting nut with grease.






9. Insert toothed rack into mounting plate (Figure 4).

10. Connect side flap to mounting plate (Figure. 6).







NOTE:
- Make sure the side flap is in the position shown in Figure 6. With the aid of a helper, screw in 2 bolts at rear of mounting plate (Figure 3).
- The mounting plate and side flap must be bolted together flush (Figure 7), then tighten the bolts to 10 Nm.






11. Fasten left and right side flaps to trunk lid. Tighten the nuts to 10 Nm (Figure 2).

12. Pull side flaps flush with trunk lid (Figure 8) via adjusting nuts (Figure 2, 1). In order to guarantee the proper preload, turn the adjusting nuts approximately one and a half turns further, refer to WIS document AR77.30-P-6375R.






13. Tighten lock nuts and reconnect electrical connector to micro switch.

14. Close trunk lid.

15. Function test: Open Vario roof (Figure 9). Make sure both side flaps are evenly extended and are flush with the trunk lid.






NOTE: Do not replace complete side flap drive units if the mounting plates are bent.


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 September 25, 2008. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.

In Case of Warranty

Operation: Side flap drive - retractable top, replace (77-6374)
Side flap drive - retractable top, adjust (77-6375)