Removing and Installing Roof Module

Removing And Installing Roof Module


Tools







Technical Values







Preliminary work

1. Remove cover for rear lock support. Refer to Removing and installing cover for rear lock support.
2. Remove trim panel for rear wall. Refer to Removing and installing trim panel for rear wall.
3. Remove roof rail trim. Refer to Removing and installing roof rail trim.
4. Remove front roof trim panel. Refer to Removing and installing front roof trim panel.
5. Remove rear side trim panel. Refer to Removing and installing rear side trim panel.
6. Remove adjustment fitting (seat belt height adjuster). Refer to Removing and installing adjustment fitting (seat belt height adjuster).
7. Remove rear three-point belt. Refer to Removing and installing rear three-point belt.
8. Remove rear window cover. Refer to Removing and installing rear window cover.

Removing roof module

Removing support for rear wall at the left and right

1. Screw off fastening nuts -2- on the rear wall support -1- and remove support for rear wall -1- in an upward direction -Arrow-.







Removing support for side trim panel at the left and right

1. Remove support for side trim panel.
1.1. Screw off fastening nuts -1- on the side trim panel support -2-.
1.2. Unclip side trim panel support -2- at the retaining clips -Arrow A- and lift it up to remove it -Arrow B-.

INFORMATION: Left side only.

1.3. Turn plug connection for roof assembly -3- (-Arrow C-) and remove it from the side trim panel support -Arrow D-.







Removing roof assembly







1. Release plug connection for roof assembly -1- (-Arrows A-) and disconnect it -Arrows B-.







2. Loosen support on the closing aid.
2.1. Screw off fastening nut -1- on the support -2-.
2.2. Disengage support -2- on the closing aid -3- (-Arrow-).







3. Remove sound absorber at the left and right.
3.1. Remove fixing clip -1- (-Arrow A-) and take off sound absorber -2- (-Arrow B-).







4. Remove rear water drains and drive outlet pipes on the roof assembly.
4.1. Pull rear water drains -1 and 2- at the left and right off the roof assembly -Arrows-.
4.2. Pull adhesive tape -3- off the drive outlet pipe -4- at the left and right.







5. Pull front water drain -1- at the left and right off the roof assembly -Arrow-.







6. Unclip contact plate for sun visor -1- at the left and right on the sun visor retaining bracket -Arrow-.







CAUTION: Risk of damage to paintwork when moving the roof assembly in and out.
- The paint on the rear left roof pillar can be damaged if the roof assembly is not moved in and out correctly.
- To protect the paint from damage, generously mask the rear left roof pillar.

7. To protect the paint from damage, generously mask the rear left roof pillar -Area A-.







8. Loosen the roof assembly.
8.1. Cover the dashboard.
8.2. Move both seat backrests back fully.

CAUTION: Unscrewing all fastening screws before loosening the roof assembly
- Risk of damage to roof assembly
- To secure the roof assembly, only loosen three fastening screws on the left and right side by up to two turns.

8.3. Loosen three fastening screws -2- on the left and right side only by up to two turns and unscrew the remaining fastening screws -2- at the sides completely on the roof assembly -1- (-Arrow-).
8.4. Unscrew front fastening screws -2- on the roof assembly -1- (-Arrow-).
8.5. Screw off fastening nuts -3- at the back -Arrow-.
8.6. Loosen the roof assembly -1- at the front left and right close to the water drain connections using a plastic wedge.
8.7. Unscrew the three remaining fastening screws -2- on each side -Arrow-.







CAUTION: Roof assembly moved in and out incorrectly
- Risk of damage to components in passenger compartment
- Four people are required to move the roof assembly in and out.

9. Move the roof assembly out.
9.1. Press the roof assembly -1- inwards -Arrow B-.
9.2. Move the roof assembly -1- out of the threaded bolts in the rear area and push it forward towards the windscreen -Arrow A-.

INFORMATION: Make sure not to damage the metal clips -2- when moving the roof assembly out.

9.3. Tip the front right of the roof assembly -1- diagonally downwards -Arrow B- and move it backwards out of the vehicle -Arrow C-.







Installing roof module

Preparing roof assembly and vehicle for installation

1. Remove sealing strip.
1.1. Pull sealing strip off the roof assembly.
1.2. Remove adhesive residue on the roof assembly using a film eraser Nr.174 Pos.1 and support Nr.174 Pos.2.
1.3. Prime bonding areas to which the sealing strip will be affixed on the roof assembly with Primer 4297 from 3M.







2. Clean the vehicle flanges.
2.1. Prime the vehicle flanges and rails, which come into contact with the sealing strip in the interior of the vehicle, with Primer 4297 from 3M (-Arrows-).







3. Affix the sealing strip.
3.1. Starting at the centring pin at the front -Arrow A-, affix the sealing strip all the way around on the roof assembly -Arrow B-.







Installing roof assembly

CAUTION: Roof assembly moved in and out incorrectly
- Risk of damage to components in passenger compartment
- Four people are required to move the roof assembly in and out.

1. Move the roof assembly in.
1.1. Tip the front right of the roof assembly -1- diagonally downwards, guide it into the vehicle -Arrow A- and then turn it horizontally -Arrow B-.
1.2. Guide the roof assembly -1- forwards towards the windscreen -Arrow C-.
1.3. Pull protective film off the sealing strip.
1.4. Guide the roof assembly -1- in over the threaded bolts -X- in the rear area.
1.5. Guide the roof assembly -1- into the windscreen frame using the centring pin -Y-.
1.6. Secure the roof assembly -1- in place with three fastening screws -2- on each side.







2. Secure the roof assembly.
2.1. Secure the roof assembly -1- with the fastening nuts -3- (-Arrow-). Tightening torque: 10 Nm (7.5 ftlb.)
2.2. Secure the roof assembly -1- with the fastening screws -2- (-Arrow-). Tightening torque: 10 Nm (7.5 ftlb.)







3. Clip in contact plate for sun visor -1- at the left and right on the sun visor retaining bracket -Arrow-.







4. Connect front water drain -1- at the left and right to the connections on the roof assembly -Arrow-.







5. Fit rear water drains and drive outlet pipes on the roof assembly.
5.1. Connect rear water drains -1 and 2- at the left and right to the connections on the roof assembly -Arrows-.
5.2. Secure drive outlet pipe -4- at the left and right to the inner side panel with adhesive tape -3-.







6. Install sound absorber at the left and right.
6.1. Position sound absorber -2- on the side wall -Arrow A- and screw in fixing clip -1- (-Arrow B-).







7. Secure support on the closing aid.

INFORMATION: Make sure that the support on the closing aid runs between the two wire harnesses.

7.1. Engage support -2- on the closing aid -3- (-Arrow-).
7.2. Tighten fastening nuts -1-.







8. Connect plug connection for roof assembly -1- (-Arrows-) until the plug connection -1- engages securely.







Installing support for side trim panel at the left and right

1. Install side trim panel support.

INFORMATION: Left side only.

1.1. Insert plug connection for roof assembly -3- into the side trim panel support -2- from below -Arrow A- and turn it -Arrow B-.
1.2. Insert side trim panel support -2- (-Arrow C-) and clip it in using the retaining clip -Arrow D-.
1.3. Tighten fastening nuts -1-. Tightening torque: 5 Nm (3.5 ftlb.)







Installing support for rear wall at the left and right

INFORMATION: The fastening nuts -2- must generally be replaced following removal.

1. Position support for rear wall -1- on the threaded bolts -Arrow- and secure with the fastening nuts -2-. Tightening torque: 2.5 Nm (2.0 ftlb.)







Subsequent work

1. Install rear window cover. Refer to Removing and installing rear window cover.
2. Install rear three-point belt. Refer to Removing and installing rear three-point belt.
3. Install adjustment fitting (seat belt height adjuster). Refer to Removing and installing adjustment fitting (seat belt height adjuster).
4. Install rear side trim panel. Refer to Removing and installing rear side trim panel.
5. Install front roof trim panel. Refer to Removing and installing front roof trim panel.
6. Install roof rail trims. Refer to Removing and installing roof rail trim.
7. Install trim panel for rear wall. Refer to Removing and installing trim panel for rear wall.
8. Install cover for rear lock support. Refer to Removing and installing cover for rear lock support.