Mercedes-Benz Vario Roof R171 Guide

Vario Roof R171 Troubleshooting Tree
Status July 18, 2006 Page 1/30
Vario Roof R171 Troubleshooting Tree
Noise, leaktightness, fit and function analyses as well as important
repairs including related damage codes (SSL) and chassis numbers
(VIN).
hen processing complaints and cost settlements for repair orders,
ensure that the specified damage codes and the relevant vehicle
identification numbers are complied with to avoid unnecessary
warranty and goodwill costs.
In case of a complaint, all repair work is to be carried out only on
the basis of the released workshop literature and with the approved
repair materials.
(e.g. noise reduction service kit, part no. A 000 580 03 50)
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R171 Overview of pivots on kinematics
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R171 Overview of pivots on kinematics
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Please use this page for suggestions for and additions to the Vario
roof troubleshooting tree. Fax to [phone]
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Table of contents:
1NOISES..................................................................................................................................7
1.1 General information on noises on the ario roof.............................................................. 7
1.2 Noises while driving ........................................................................................................... 8
1.2.1 Noises on the ario roof seals while driving............................................................................... 8
1.2.2 ario roof/windshield frame area ................................................................................................ 9
1.2.2.1 Rattling noises in the front ario roof lock area.................................................................. 9
1.2.3 Roof frame area ............................................................................................................................ 10
1.2.3.1 Cracking noises in the pivot 1 area on the roof frame...................................................... 10
1.2.3.2 Cracking noises (knocking) in the eccentric area on the roof frame .............................. 11
1.2.3.3 Ripping noises in the Bowden cable joint 2 area ............................................................... 12
1.2.3.4 Noises in the Y-Z fixing stop area ........................................................................................ 13
1.2.3.5 Noises in the rear window control linkage......................................................................... 14
1.2.4 Trunk area ..................................................................................................................................... 15
1.2.4.1 Noises (thumping) in the rear shelf area of the lower rear window................................ 15
1.2.4.2 Noises in the trunk lid area .................................................................................................. 16
1.3 Wind noises....................................................................................................................... 17
1.3.1 Wind noises in the front ario roof joint area to the rear window ......................................... 17
1.3.2 Side window area ......................................................................................................................... 18
1.3.2.1 Wind noises in the side window/rear side window area .................................................. 18
1.3.2.2 Wind noises in the side rear window/lower C-pillar area................................................. 19
1.4 Noises in the body shell ................................................................................................... 20
1.4.1 Cracking noises from the ario roof trunk/C-pillar area......................................................... 20
2FITS......................................................................................................................................21
2.1 Seals (buckling)................................................................................................................. 21
2.1.1 Seal at joint 1 buckled ................................................................................................................. 21
3LEAKTIGHTNESS ................................................................................................................22
3.1 General information on leaktightness check and sprinkling.......................................... 22
3.1.1 Examples of rain check/sprinkling with R230.......................................................................... 23
3.2 Leaktightness in the ario roof interior area .................................................................. 24
3.2.1 Water entry at joint 1/joint 2...................................................................................................... 24
3.3 Leaktightness in the trunk area....................................................................................... 25
3.3.1 Water entry in the joint 5 area of the trunk .............................................................................. 25
3.3.2 Water entry in the trunk on opening the ario roof ................................................................. 26
3.4 Other topics regarding water entry ................................................................................. 27
3.4.1 Water entry in the front footwell................................................................................................ 27
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4EE/HYDRAULIC FUNCTION ..............................................................................................28
4.1 Malfunctions on actuation of the ario roof ................................................................... 28
4.1.1 Roof cannot be opened ................................................................................................................ 28
4.2 Noises in the hydraulic pump .......................................................................................... 29
4.2.1 Intake noises.................................................................................................................................29
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1Noises
1.1 General information on noises on the ario roof
Ensure that the customer removes all personal belongings from the vehicle before the vehicle
analysis. For achieving a correct noise analysis, the customer has to demonstrate the
complaints to the workshop employee.
Dry, dirty seals at the Vario roof are the most common cause for cracking and ripping noises
while driving. Therefore, it is imperative to attend to the seals first.
Ripping and creaking noises in driving can also be transmitted to the Vario roof through the
vehicle shell or loose threaded connections of assembly parts, e.g. C-pillar.
In case of complaint, all repair works are to be carried out only on the basis of the released
workshop literature and with the approved repair materials (e.g. noise reduction service kit,
part no. A 000 580 03 50).
A helpful medium for locating noises in the vehicle is a noise hearing set, e.g. the "Chassis
Ear" from Steelman that Chrysler has employed successfully.
" ireless Chassis Ear"
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1.2 Noises while driving
1.2.1 Noises on the ario roof seals while driving
Complaint: Ripping/friction noises on all the Vario roof seals while driving.
Cause: Dry, dirty seals on the Vario roof are the most common cause for cracking and ripping
noises while driving.
Measure: Treat the seals on the Vario roof and the bar seal on the upper rear side window
(pos. 1) with a special antifriction agent, part no. A 001 989 50 51 or A 000 989 36
60, see AF77.30-P-1501AG.
Note: Observe the soaking time of the special antifriction agent.
SSL: 7921736 Upper rear window seal noises
7205136 Windshield frame seal noises
7922036 Lower rear window frame seal noises
7922536 Interior C-pillar seal noises
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1.2.2 ario roof/windshield frame area
1.2.2.1 Rattling noises in the front ario roof lock area
Complaint: Rattling noises in the front Vario roof lock support when driving on rough roads.
Cause: Funnel opening of the support (pos. 1) can be too large for the locking pin (pos. 2). As
a result, noises may occur in the front Vario roof area when driving on rough roads.
Measure: See GI77.33-P-035782.
SSL: 7920636 Front ario roof locking pin support noises
Important: Do not replace the complete front ario roof lock.
Important: ehicles are OK from IN 048760
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1.2.3 Roof frame area
1.2.3.1 Cracking noises in the pivot 1 area on the roof frame
Complaint: Cracking noises in the pivot 1 area on the roof frame.
Cause: asher and safety clip at pivot point 1 stuck together.
Measure: Remove safety clip and washer (pos. 1, 2). Clean the contact surfaces of the safety
clip, washers and roof frame and afterwards grease with low-friction paste, part no.
A 001 989 46 51. Press the handle (pos. 4) a bit to the inside and grease the pin
(pos. 3) on pivot 1 with low-friction paste, see GI77.33-P-036569.
SSL: 7920336 ario roof frame noises
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1.2.3.2 Cracking noises (knocking) in the eccentric area on the roof frame
Complaint: Cracking noises while driving.
Cause: Eccentric is loose since:
1. Contact surface of the countersunk bolt in the roof frame is too small.
2. Contact surface of the eccentric to the roof frame is painted.
Measure: 1. Only if the eccentric is loose:
Remove eccentric (pos. 1), drill bore (pos. 2) in the handle (6.2 mm), apply corrosion
protection (briefcase black) in the bore, see GI77.33-P-032755.
Remove paint from the contact surface (pos. 3) of the eccentric.
Install and adjust eccentric again, see AR77.33-P-3475V, ensure correct position of
the gate valve (pos. 4) in the locked Vario roof.
2. For fixed eccentric with rattling noises – adjust gate valve,
see AR77.33-P-3475V.
SSL: 7920836 Roof frame latch noises (assigned damage code)
Important: ehicles are OK from IN 082324
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1.2.3.3 Ripping noises in the Bowden cable joint 2 area
Complaint: Fine ripping noises in the Bowden cable joint 2 area.
Measure: Replace omega clips (pos. 1) (with short foot), part no. A 000 995 54 44.
SSL: 7921536 Roof frame latch cable noises
Important: ehicles are OK from IN 007366
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1.2.3.4 Noises in the Y-Z fixing stop area
Complaint: Noises in the Y-Z fixing stop area of the upper/lower rear window.
Cause: 1. Adjustment of the stops is not OK.
2. Stops not/insufficiently greased.
Measure: Check the position of the rear window, if necessary adjust, see AR67.20-P-3002V.
Grease rear window stops with (pos. 1 and 6) with low-friction paste, part no. A 001
989 46 51.
Note: hen doing adjustment operations, bear in mind the fit of the rear window to the
Vario roof.
SSL: 7921036 Rear window adjustment buffer noises
7923336 Lower rear window XY guide noises
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1.2.3.5 Noises in the rear window control linkage
Complaint: Ripping noise/crackling noise/cracking noise from the Vario roof C-pillar.
Cause: 1. Residues of thread lock paint and cataphoretic immersion primer in the bushings
and between the pivots (DA16, DA17).
Measure: 1. Remove screw completely at DA16.
Note: When removing the screw, pay attention to the washer on the pivot.
Clean the bushing, remove the residues of thread lock and cataphoretic immersion
primer and turn in and tighten the screw with thread locking agent, part no.: A 003
989 31 71 (tightening torque 20 Nm).
2. Remove screw completely at DA17.
Note: When removing the screw, pay attention to the washer on the pivot.
Clean the bushing, remove the residues of thread lock and cataphoretic immersion
primer and turn in and tighten the screw with thread locking agent, part no.: A 003
989 31 71 (tightening torque 20 Nm).
SSL: 7920336 ario roof frame noises
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1.2.4 Trunk area
1.2.4.1 Noises (thumping) in the rear shelf area of the lower rear window
Complaint: Noises (thumping) in the rear shelf area of the lower rear window while driving.
Cause: Insufficient pre-tension of the rear shelf to the rear window frame.
Measure: Install damping material, part no. A 171 694 00 92, with fleece tape (pos. 1). Fasten
damping material to the rear window frame with superglue. Parts were modified while
retaining the previous part no.
SSL: 6901536 Rear shelf noises
Important: ehicles are OK from IN 073287
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1.2.4.2 Noises in the trunk lid area
Complaint: Noises when cornering or on rough roads
Cause: Stops on the side of the trunk lid (pos. 1) cause ripping/friction noises if fitted too
tightly.
Measure: 1. Adjust stops (pos. 1) in such a way that they rest against the fixings (pos. 2) when
the trunk lid is closed, then push 1 mm to the outside (pre-tension) and tighten, see
AR88.50-P-5200V.
2.Grease trunk lid guide (pos. 1) with low-friction paste, part no. A 001 989 46 51.
Note: Apply a thin coat of low-friction paste.
Always observe 1 mm pre-tension.
SSL: 7500136 Trunk lid noises (assigned damage code)
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1.3 Wind noises
1.3.1 Wind noises in the front ario roof joint area to the rear window
Complaint: ind noises from approx.140 km/h in the B/C pillar area.
Cause: Eccentric is loose
See 1.2.3.2
Measure: 1. Only if the eccentric is loose:
Remove eccentric (pos. 1), drill bore (pos. 2) in the handle (6.2 mm), apply corrosion
protection (briefcase black) in the bore, see GI77.33-P-032755.
Remove paint on the contact surface (pos. 3) of the eccentric,
Install and adjust eccentric again, see AR77.33-P-3475V, ensure correct position of
the gate valve (pos. 4) in the locked Vario roof.
2. For fixed eccentric with rattling noises – adjust gate valve,
see AR77.33-P-3475V, ensure the correct position of the gate valve (pos. 4) in the
locked Vario roof.
SSL: 7920836 Roof frame latch noises (assigned damage code)
Important: ehicles are OK from IN 082324
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1.3.2 Side window area
1.3.2.1 Wind noises in the side window/rear side window area
Complaint: ind noises in the side window/rear side window area
Cause: edge-shaped gap in the bar seal area (B-pillar)
between the side window and rear side window.
Adjustment of the rear side window is not OK.
Measure: 1. Treat the exterior C-pillar bottom seal with special antifriction agent,
part no. A 001 989 50 51 or A 000 989 36 60, see AF77.30-P-1501AG.
Observe the soaking time of the special antifriction agent.
2. Adjust rear side window, see GI72.10-P-020305 Release 3.0.
SSL: 6712442 Poor rear side window fit
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1.3.2.2 Wind noises in the side rear window/lower C-pillar area
Complaint: ind noises from 80 km/h
Cause: Gap dimension (arrow) between exterior C-pillar seal and rear fender is too large.
Measure: Mount exterior C-pillar seal lower.
Note: Loosen only the lower screws (pos. 2) of the retaining rail (pos. 3) and pull the seal
(pos. 1) lower. The seal can be pulled lower up to 1.5 mm. Do not pull it out of the
retaining rail as there is a seal mass below the retaining rail and this could cause
leakages, see AR77.50-P-6766V.
SSL: 7705539 Joint 6 gap wind noises on left exterior C-pillar
7705639 Joint 6 gap wind noises on right exterior C-pillar
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1.4 Noises in the body shell
1.4.1 Cracking noises from the ario roof trunk/C-pillar area
Complaint 1: Cracking/ripping noises from the trunk area.
Complaint 2: Cracking/ripping noises from the trunk area when the vehicle is started or braked
sharply.
Cause 1: Decrease in torque of the threaded connections (pos. 1, 2) of the tank cover in the
trunk.
Cause 2: Plastic spacer (pos.3) at stud support for Vario roof main bearing.
Note: This cracking noise can also be transmitted to the ario roof C-pillar area and
is, therefore, often assigned to the ario roof.
Measure1: Loosen all threaded connections and re-tighten them.
Tightening torque for the screws (pos. 1): 10 Nm
Tightening torque for the nuts (pos. 2): 6 Nm
Tightening torque for the screws (pos. 3): 6 Nm, see GI68.64-P-038163.
Recommendation: When handling the tank cover, the plastic spacer (pos. 4) should also be
removed, see measure 2.
Important: For complaint 1: ehicles are OK from IN 119481
Note: If the tank cover does not rest on the longitudinal member, washers may have to be
inserted in the screw connections (pos. 2). This prevents the studs from breaking off
when being tightened.
Measure 2: Remove plastic spacer (pos. 3), to do so, remove trim on the left and right side in the
trunk, see AR68.30-P-4800V.
Important: Do not loosen screws on the main bearing of the ario roof.
SSL: 6400136 Rear wall noises
SSL: 7920336 ario roof frame noises
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