Vario Roof

318 HO Vario Roof (WFF) 1/24/02

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ObjectivesUpon completing this section of the program you will be able to: Operate the Vario roof using the switch and SmartKey Identify the electronic system components Identify the hydraulic system components Explain each stage of Vario roof operation and indicated which components, hydraulic and electric are involved (order of operation) Perform the manual/emergency Vario roof closing procedure

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Vario Roof ConstructionRefined design consisting of: Tubular frame 7-joint hinges (2) Load assist feature (easy pack)

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Load Assist (Easy Pack) 1 - Vario roof 2 - luggage partition cover 3 - load assist (easy pack) switch

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How to Operate the Vario Roof Vario roof switch (N72s16)

SmartKey (A8/1)

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Function PrerequisitesUsing Vario roof switch (N72s16) Circuit 15 ON Voltage not too high or low Trunk lid locking pawl closed Vehicle speed < 3 mph Rollover bar crash actuation not active Luggage partition cover closed6

Function PrerequisitesUsing SmartKey Circuit 15C OFF Voltage not too high or low Trunk lid and locking pawl closed Rollover bar crash actuation not active Press lock / unlock button on A8/1 3 mph Luggage partition cover open Diagnostic trouble codes Hydraulic pump temperature sensor Trunk lid open N82/1 (BNS) Consumer prioritization (will close only)25

Vario Roof Electronic System Vario roof control switch (N72s16)

Rollover bar / Vario roof (RVC) control module (N52) 13 limit switches (verifies hydraulic movements) 4 window motors 1 side flap motor Rollover bar / Vario roof (RVC) hydraulic unit (A7/5) - Vario roof valve block (Y55/1)26

RVC Control Module (N52) Location Under right rear storage area Accessed by removing false bottom cover

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Vario Roof Limit Switches

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Vario Roof Limit Switch (S69/1) Single contact switch Indicates if the roof is closed Communication via OCP (N70)

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Vario Roof Locked Limit Switches (S69/2 & S69/3) Single contact switches Indicates the roof lock position when closed and open Hard wired to RVC control module

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Luggage Compartment Partition Switch (S69/10) Single contact switch Indicates if the luggage partition cover is open or closed Communication via PSE (CAN-B)31

Vario Roof Raised/Lowered Limit Switch (S69/11) Single contact switch Indicates if the roof is raised or lowered Hard wired to RVC control module32

Load Assist Limit Switch (S117) Dual contact switch Must see if the roof position is up (in easy pack) or down (stowed in trunk) before continuing roof operation Hard wired to RVC control module33

Left & Right Tubular Frame Locked Limit Switches (S118/1 & S118/2) Single contact switches Indicates if the tubular frame is locked or unlocked Hard wired to RVC control module

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Tubular Frame Raised Limit Switch (S119) Single contact switch Indicates if the trunk lid is tilted back completely Hard wired to RVC control module35

Trunk Lid Open Limit Switch (S124) Single contact switch Used when trunk lid is open Hard wired to RVC control module

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Left & Right Side Flap Closed/Open Limit Switches (S126/1 & S127/1) Dual contact switches Must see position (open/close) of side flaps before motor will actuate flaps Hard wired to RVC control module37

Vario Roof Limit Switches Wiring

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Vario Roof Limit Switches LegendA1 Instrument cluster A7/5 RVC hydraulic unit A7/5b1 Temperature sensor A7/5k1 Relay A7/5m1 Motor A37 PSE control module M10/5 Left rear power window motor M10/6 Right rear power window motor M49/1 Side flaps motor N10/8 Rear SAM control module N22 AAC pushbutton control module N52 RVC control module N69/1 Left door control module N69/2 Right door control module N70 Overhead control panel control module N72 Lower control panel control module N72s16 Vario roof switch N72s17 Rollover bar switch N82/1 Vehicle electrical system control module S69/1 Vario roof limit switch S69/2 Vario roof locked limit switch S69/3 S69/10 S69/11 S83/10 S114 S117 S118/1 S118/2 S119 S124 S126/1 S127/1 Y55/1 Y55/1y1 Y55/1y2 Y55/1y3 Y55/1y4 Y55/1y5 Y55/1y6 Y57/1 Vario roof locked limit switch Luggage compartment partition limit switch Vario roof raised/lowered limit switch Rollover bar raised/lowered limit switch Load assist (Easy Pack) switch Load assist top/bottom limit switch Left tubular frame locked limit switch Right tubular frame locked limit switch Tubular frame open limit switch Trunk lid open limit switch Left side flap closed/opened limit switch Right side flap closed/opened limit switch Vario roof valve block Main valve Raise rollover bar solenoid valve Close vario roof solenoid valve Open vario roof solenoid valve Tubular frame and vario roof lock solenoid valve Load assist (Easy Pack) solenoid valve Rollover bar deployment solenoid

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RVC Hydraulic Unit (A7/5) Location Accessed by removing spare tire cover Left side of trunk

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RVC Hydraulic Unit (A7/5) A - fluid filling port B - pressure test port C - pressure release screw D - relay (A7/5k1) E - connector X8/4

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Vario Roof Hydraulic System Rollover bar / Vario roof (RVC) hydraulic unit (A7/5)

- Temperature sensor (A7/5b1) - Relay (A7/5k1) - Motor (A7/5m1) 8 hydraulic cylinders Vario roof valve block (Y55/1) - Valves Y55/1y1 to Y55/1y642

Vario Roof Hydraulic Cylinders

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Hydraulic Cylinder Legend3 Front vario roof lock hydraulic cylinder 4 Left tubular frame lock hydraulic cylinder 5 Right tubular frame lock hydraulic cylinder 6 Left vario roof (open/close) hydraulic cylinder 7 Right vario roof (open/close) hydraulic cylinder 8 Trunk lid hydraulic cylinder 9 Left load assist (raise/lower) hydraulic cylinder 10 Right load assist (raise/lower) hydraulic cylinder A7/5 RVC hydraulic unit A7/5k1 Relay Y55/1 RVC valve block44

Front Vario Roof Lock Cylinder (3) Controls the actuation of the roof locks to windshield header Also controls the actuation of the roof locks when stowed

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Left & Right Tubular Frame Lock Cylinders (4 & 5) Locks and unlocks the tubular frame

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Left & Right Vario Roof (Open/Close) Cylinders (6 & 7) Opens and closes the Vario roof These cylinders take over after the load assist (easy pack) cylinders have moved the roof out of the trunk

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Trunk Lid Cylinder (8) Raises and lowers the trunk lid

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Left & Right Load Assist (Raise/Lower) Cylinders (9 & 10) Provide the load assist (easy pack) feature This feature is also required for roof operation

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Hydraulic Cylinder Operation

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Service NotesWhen repairing or replacing hydraulic system components, keep the following in mind: Release hydraulic system pressure Hydraulic cylinders are replaced with lines Test adapter needed for pressure testing Fluid replenishment with syringe Fluid same as other Vario roofs51

Rollover Bar SystemConsists of the following: RVC control module (N52) Rollover bar switch (N72s17) Top / bottom rollover bar limit switch (S83/10) Rollover bar deployment solenoid (Y57/1) RVC hydraulic unit (A7/5) RVC valve block (Y55/1) Main valve (Y55/1y1) Rollover bar up solenoid valve (Y55/1y2) Hydraulic cylinder Spring with integrated oil damper52

Rollover Bar 1 - rollover bar 2 - hydraulic cylinder 3 - left / right supporting element 4 - left / right locking pawl cylinder 5 - crash deployment spring 7 - lock Y57/1 deployment solenoid53

Rollover Bar Supporting Element 3 - supporting element 3a - rack 3b - locking pawl 4 - locking pawl cylinder Mechanically raising and lowering rollover bar - AR91.50-P-8400R54

Rollover Bar Crash DeploymentDeployment occurs when:Integrated sensor in RVC (N52) signals vehicle tilt angle of 57 for more than 100ms OR Vehicle acceleration in any direction > 3 times normal G-force55