Vario Roof

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

 Objectives

Upon 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

2
 Vario Roof Construction

Refined design consisting of:

• Tubular frame
• 7-joint hinges (2)
• Load assist feature
(easy pack)

3
 Load Assist (Easy Pack)

• 1 - Vario roof
• 2 - luggage partition cover
• 3 - load assist (easy pack) switch

4
 How to Operate the Vario Roof

• Vario roof switch (N72s16)

• SmartKey (A8/1)

5
 Function Prerequisites
Using 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 closed

6
 Function Prerequisites
Using 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 <1s
• Luggage partition cover closed
• Within approximately 4 ft of infra red receiver
7
 Safety Parameters

• Using top switch - if roof

switch is released, it will
hold in that position for 7
minutes
• Using SmartKey - if
button is released it will
hold in that position for 7
seconds
• In both cases a gong will
sound before roof begins
to move

8
Vario Roof Communication

9
 Rear SAM Control Module (N10/8)

Recognition and evaluation of trunk lid lock rotary tumbler limit switch

10
 Vehicle Power Supply Control
Module (N82/1)
Over and undervoltage will affect operation of the roof

11
 Left & Right Door Control Module
(N69/1 & N69/2)
Recognition of “short stroke” position of front windows when roof is activated

12
 Overhead Control Panel Control
Module (N70)
Recognition of Vario roof (closed) limit switch (S69/1)

13
 PSE Control Module (A37)

Recognition of luggage partition cover closed limit switch (S69/10)

14
 Lower Control Panel Control Module
(N72)
Recognition and evaluation of Vario roof control switch

15
 Instrument Cluster (A1)

Recognition of current speed, actuation of warning gong and roof operations

16
 COMMAND (A40) & AAC
Pushbutton Control Module (N22)
Roof position affects AM antenna switchover and AAC output

17
 Rollover Bar / Vario Roof Control
Module (N52)
Evaluates limit switches and controls actuation of hydraulic cylinder valves

18
 Left & Right Rear Power Window
Motors (M10/5) & (M10/6)
Evaluates window position via hall sensors

19
 Side Flap Motor Open / Closed
(M49/1)
Opens and closes side flaps

20
 Rollover Bar Solenoid Valve (Y57/1)
& Rollover Bar Limit Switch (S83/10)
Controls crash actuation and position of rollover bar (raised/lowered)

21
 Rollover Bar / Vario Roof Hydraulic
Unit (A7/5)
Activation of valve block (Y55/1)

22
 Load Assist (Easy Pack) Switch
(S114)
This switch operates the load assist (easy pack) feature (red switch in trunk)

23
SmartKey (A8/1) Communication

24
 What Blocks Vario Roof Operation?

• System battery voltage too high or low

• Vehicle speed > 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

27
Vario Roof Limit Switches

28
 Vario Roof Limit Switch (S69/1)

• Single contact
switch
• Indicates if the
roof is closed
• Communication
via OCP (N70)

29
 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

30
 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
module

32
 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 module
33
 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

34
 Tubular Frame Raised Limit Switch
(S119)
• Single contact
switch
• Indicates if the
trunk lid is
tilted back
completely
• Hard wired to
RVC control
module
35
 Trunk Lid Open Limit Switch (S124)

• Single contact
switch
• Used when trunk
lid is open
• Hard wired to
RVC control
module

36
 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 module
37
Vario Roof Limit Switches Wiring

38
 Vario Roof Limit Switches Legend
A1 Instrument cluster S69/3 Vario roof locked limit switch
A7/5 RVC hydraulic unit S69/10 Luggage compartment partition limit switch
A7/5b1 Temperature sensor S69/11 Vario roof raised/lowered limit switch
A7/5k1 Relay S83/10 Rollover bar raised/lowered limit switch
A7/5m1 Motor S114 Load assist (Easy Pack) switch
A37 PSE control module S117 Load assist top/bottom limit switch
M10/5 Left rear power window motor S118/1 Left tubular frame locked limit switch
M10/6 Right rear power window motor S118/2 Right tubular frame locked limit switch
M49/1 Side flaps motor S119 Tubular frame open limit switch
N10/8 Rear SAM control module S124 Trunk lid open limit switch
N22 AAC pushbutton control module S126/1 Left side flap closed/opened limit switch
N52 RVC control module S127/1 Right side flap closed/opened limit switch
N69/1 Left door control module Y55/1 Vario roof valve block
N69/2 Right door control module Y55/1y1 Main valve
N70 Overhead control panel control module Y55/1y2 Raise rollover bar solenoid valve
N72 Lower control panel control module Y55/1y3 Close vario roof solenoid valve
N72s16 Vario roof switch Y55/1y4 Open vario roof solenoid valve
N72s17 Rollover bar switch Y55/1y5 Tubular frame and vario roof lock solenoid valve
N82/1 Vehicle electrical system control module Y55/1y6 Load assist (Easy Pack) solenoid valve
S69/1 Vario roof limit switch Y57/1 Rollover bar deployment solenoid
S69/2 Vario roof locked limit switch

39
 RVC Hydraulic Unit (A7/5) Location

• Accessed by
removing
spare tire cover
• Left side of trunk

40
 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

41
 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 Y55/1y6
42
Vario Roof Hydraulic Cylinders

43
 Hydraulic Cylinder Legend

3 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 block
44
 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

45
 Left & Right Tubular Frame Lock
Cylinders (4 & 5)
• Locks and unlocks
the tubular frame

46
 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

47
 Trunk Lid Cylinder (8)

• Raises and lowers

the trunk lid

48
 Left & Right Load Assist
(Raise/Lower) Cylinders (9 & 10)

• Provide the
load assist
(easy pack)
feature
• This feature is
also required
for roof
operation

49
Hydraulic Cylinder Operation

50
 Service Notes

When 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 roof’s
51
 Rollover Bar System
Consists 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 damper
52
 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
solenoid 53
 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-8400R
54
 Rollover Bar Crash Deployment

Deployment occurs when:

Integrated sensor in RVC (N52) signals vehicle tilt

angle of 57º for more than 100ms
OR
Vehicle acceleration in any direction > 3 times normal
G-force

55