Sunroof - New Repair Kit Available

91mercedes04

REF. NO. 77/25


TO: OUR MERCEDES-BENZ PASSENGER CAR DEALERS

DATE: June 1991


SUBJECT: MODELS 124, 126 AND 201 REPAIR KIT FOR SLIDING/POP-UP ROOF DRIVE


Up to the present time, when the drive of the sliding/pop-up roof needed repair (e.g. at the microswitches and/or actuator wheel), the entire mechanism had to be replaced. This is no longer required, since a repair kit is made available as a replacement part (Part No. 001 820 13 07).


Disassembly of the Motor and Gear Unit

1. Remove the sliding/pop-up roof motor and gear unit, see microfiche repair instruction 77-180.

2. Remove the cover over the relay.

Figure 2:

3. Remove the relay, slide the connector (6) for the relay away from the switch housing (Figure 2).

4. Disconnect the plugs from both microswitches, note the positioning of the plugs (7, Figure 2).

Note: On sliding/pop-up roof drives with 3 microswitches (vehicles produced up to March 1988) the plug for the external microswitch is no longer required with the repair kit is installed. Therefore, cut the black wire from the intermediate plug (6, Figures 1 and 2), insulate the wire and remove the purple wire with the round socket from the relay connector.

Figure 1:

Figure 2:

5. Push center pins through the plastic rivets, then remove rivets (1, Figure 1).

6. Remove the thrust bearing with the adjustment knob (2, Figure 1). This releases the idler gear (4, Figure 2).


7. Remove the switch housing and the actuator wheel (3, Figure 2) from the motor and gear unit.


Reassembly of the Motor and Gear Unit (using repair kit parts)

1. Remount the actuator wheel 3, Figure 2) on the motor and gear unit.

2. Turn the actuator wheel to the marked position (5, Figure 2) and center with the centering pin (5, Figure 1) (Base position).

Figure 3:

Note: If a centering pin is not available, make one according to Figure 3.


3. Install the idler gear 4, between the carrier and the actuator wheel and hold it in place. The teeth must point toward the actuator wheel.

Figure 1:

4. Press the thrust bearing (2, Figure 1) on loosely from the opposite side of the idler gear. The notch in the adjustment knob must point to the centering hole of the carrier.

5. Lock the idler wheel in place.

6. Press in the spreader rivets (1, Figure 1) and lock.

7. Connect the plugs to both microswitches, observe for proper locations and positioning (7, Figure 2).

8. Engage the connector and plug in the relay.

9. Install the cover.

10. Install and adjust the sliding pop-up roof motor and gear unit according to Service Microfiche, Job No. 77-180.


Parts Information

Part Name Part Number

Repair kit (sliding pop-up roof) 001 820 13 07


In Case of Warranty

Operation: Sliding/Pop-up Roof Drive and Motor

Damage Code Operation Number Time Model(s)

78131 36 02-7725 0.3 hr. 00

Note: Please update your latest Time Guide to include Model Indication 84 and 85 for "Sliding Roof Drive and Motor, R & R" with a labor Time of 1.3