Section 6-11

REMOVING AND INSTALLING LIFTING ROOF ELECTRIC DRIVE AND ASSEMBLY KIT

Removing
1. Open luggage compartment lid. Remove clips for trim panel and place trim panel aside.

2. Unscrew nuts on studs and disconnect electric drive assy. at mounting points.

3. Swing electric drive assy. into inside of car slightly. Unscrew cover mounting screws and remove cover.

4. Disconnect plug on electric drive assembly.

5. Unclip the sliding gate drive and remove electric drive with guide rail.

6. Remove lifting roof.

7. Remove caps on heads of screws.

8. Remove mounting screws and washers and take off trim.

9. Pull off edge guard partially.

10. Disconnect roof liner on body partially.

Remove mounting screws of locking tongues and gearbox. If gearbox allen bolts are difficult to remove, apply heat with a soldering iron to loosen locite seal. Remove foam collar from sunroof drive tube and drain tube in C pillar pull out drain tube left rear.

12. Remove assembly from car by pulling guide tube out of C pillar.

Preliminary Adjustments Before Installation
Put cable assembly on a flat surface, supporting the entire unit, with the center gearbox and lifting tongues facing up, as they would when installed in the vehicle.

Check the plastic lifting tongue assembly, the location should be parallel to the center gearbox and at uniform heights with each other.

If this is not correct, use a suitable tube bending tool to slightly reshape the bend of the guide tubes from the center gearbox to the lifting tongue assemblies, insuring a gradual transition of the guide tube through the 90~ turn into the lifting tongue assembly. This will minimize any drag at this sharp change of direction in the guide tube.

Furthermore, the foam insulation on the operating cable guide tube should be taped to the tube on the end, this will prevent the foam cover from being torn during installation.

NOTE:
It might also help in some cases if the sharp edge on the body, where the cable is being inserted in the C-pillar, is being bent down approx. 2-3 mm, for a smoother installation.

Installing

1. Install long guide tube of assembly kit into assembly opening of body. Push guide tube through the C pillar by turning the entire installed part. Do not use force; guide tube must not be bent.

2. Lightly tighten locking tongues of assembly kit on both sides in holders.

3. Mount gearbox in center of roof beam. Use new screws.

4. Bolt locking tongues on roof (without tension) at rear. Adjust front mounting of element guide (see "Adjusting Lifting Roof").

5. The guide tube with lifting cable must protrude into the luggage compartment parallel to the side panel. The distance from the end of the guide tube to the drive is 305 +/- 1.0 mm in pulled state or 40 +/- 1.0 mm in pushed in state. If these distances are not reached, replace the assembly kit. The lifting cable cannot be adjusted. It must be possible to move the lifting cable back and forth by hand. Reinstall foam collars on guide and drain tube. Reconnect drain tube.

6. Check if guide tube has correct position, as it would have in the installed position. If not slightly bend tube. Work drive with lifting cable into guide rail of the electric drive. Route along the rail and clip couterpart in sliding gate.

7. The guide tube must be inserted in the pinion housing together with the sliding gate precisely.

8. Install and bolt down cover.

9. Connect plug. Place holder on end of rail over studs of backup light and install nuts.

10. Attach mount of electric drive in the rear frame profile, screw on nuts and place bracket claws on the edge guard. Tighten all nuts.

11. Adjust lifting roof.