NHTSA ID Number: 10164805
Manufacturer Communication Number: LI77 30-P-070145
TSB/Document Date: 2019-09-16
Summary
Fraying Headliner Cords
Fraying Headliner Cords
Topic number
LI77.30-P-070145
Version
1
Function group
77.30 Vario roof, soft top - complete
Date
08-15-2019
Validity
205 and 238 cabrios produced before June 2019
Reason for change
Reason for block
Complaint:
Damaged cords on the soft top interior trim with the following characteristics:
- Cord snapped
- Cord worn
- Cord torn out
- Cord sheathing damaged
Cause:
Possible high tensile stresses on the cords during the soft top sequence.
Remedy:
1.) Check which cord(s) is/are damaged:
If damage is found on one of the cords of the soft top interior trim, always replace the cords on the left and right in
pairs.
If damage is found on one of the cords no. 3, 4 or 7 of the soft top interior trim, replace all the cords nos.3, 4 and 7 on
the left and right as a preventive measure. See figure 4 for labelling of the cord.
This also applies to the new version of the soft top interior trim cords, no. 4 and no. 7 on the left and right.
2.) Cut off the fastening rivets/eyelets:
See Fig. 6. - Illustrates a riveted fastening of the eyelet. Also see document AR68.30-p-4303-01lwr.
3.) Press the clamping ring connection out of the receptacle in the soft top interior trim:
See Fig. 7. - Illustrates the receptacle/clamping ring of the soft top interior trim.
4.) Cut/remove the clamping ring connection from the cord using side cutting pliers:
See Fig. 8. - Separating the clamping ring connection using side cutting pliers.
5.) After removing the clamping ring connection, attach a makeshift thread to the end of the defective cord in order to
route the new cord:
Pull the damaged cord through the duct, leaving the thread inside the duct to facilitate installation. Detach the thread
from the damaged cord.
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See Fig. 9. - Attaching the makeshift thread.
6.) Attach the makeshift thread to the end of the new cord. Carefully pull the cord through the duct and then remove
the makeshift thread after pulling it through:
See Fig. 10. - Makeshift thread.
7.) Attach the clamping ring to the cord with pliers and leave the cord protruding by approx. 3 mm ±1. Crush the clamping ring to a thickness of 3.75 mm ±0.25:
See Fig. 11. Attaching/crushing the clamping ring.
8.) Press the clamping ring connection into the receptacle provided, and install the eyelet with the rivet in the intended
position:
See Fig. 12. Receptacle for clamping ring connection/ soft top interior trim.
See Fig. 13. Positioning the rivet with eyelet - Example.
Note:
Due to optimization measures, all new soft top interior trim parts are manufactured without the cord no. 3.
In series production and in repair cases, the cord no. 3 is no longer required. Therefore, in repair cases, it is only replaced if it is present in the vehicle.
Further information on optimizations:
- Adhesive tape guide for the cords no. 3 and no. 7:
Make sure that cords 3 and 7 are routed behind the adhesive tape. As a reference dimension, the adhesive tape
should be positioned approx. 10 mm from the eyelet.
See Fig. 20.
- Adhesive tape guide for the cord no. 7:
In vehicles where cord 7 is present, route only cord 7 behind the adhesive tape.
See Fig. 21.
- Produce the adhesive tape guide:
If a new adhesive tape guide is required for routing the cords, the area where the cords are routed should be covered
with a smaller piece of adhesive tape,
to prevent the cords from sticking.
See Fig. 22.
- Old/new bellcrank end stop:
The repair kit also includes new end stops. Replace both sides on left and right.
See Fig. 23. - Old
See Fig. 24. - New
- New version of soft top interior trim:
With the new soft top interior trim, the cord no. 3 has been discontinued and the design line improved in the area of
the C-pillar. Only new parts are available as replacements.
In vehicles produced prior to the change, which require a new soft top interior trim in repair cases, the tensioning strap
is fastened
to the wiring harness with a small cord strap.
See Fig. 25.
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See Fig. 26.
Attachments
File
Description
Abb.1.jpg
Technical data of cords
Abb.2.jpg
Measure cord from center of eyelet
Abb.3.jpg
Cord with clamping ring
Abb.4.jpg
Illustration of the cords on the right roof lining
Abb.5.jpg
Color coding of the cords
Abb.6.jpg
Illustrates a riveted fastening of the eyelet
Abb.7.jpg
Illustrates the receptacle/ roof lining clamping ring
Abb.8.jpg
Separating the clamping ring connection using side cutting pliers
Abb.9.jpg
Attaching the makeshift thread
Abb.10.jpg
Makeshift thread
Abb.11.jpg
Attaching/crushing the clamping ring
Abb.12.jpg
Receptacle for clamping ring connection/ roof lining
Abb.13.jpg
Positioning the rivet with eyelet
Abb.20.JPG
Adhesive tape guide, cords 3, 7
Abb.21.JPG
Adhesive tape guide, cord 7
Abb.22.JPG
Producing the adhesive tape guide
Abb.23.JPG
Old bellcrank end stop
Abb.24.JPG
New bellcrank end stop
Abb.25.JPG
Attachment of tensioning strap (sail)
Abb.26.JPG
Left rear tensioning strap (sail)
Symptoms
Body / Roof system / Convertible top/vario roof / Chafing/paint damage
Parts
Part number
ES1 ES2 Designation
A 205 778 03 00
A 006 989 84 85
10
Quantity Note
EPC
RS TRIM
1
Repair kit - Soft top interior trim
X
1
Cutting length per vehicle approx.
220 mm
X
Operation numbers/damage codes
Op. no.
Operation text
Time
Damage
code
Note
02-1251
REPLACE TENSIONING CABLES ON
SOFT TOP INTERIOR TRIM
23
77N06 07
Use the right-hand damage code for
consistent cost settlement; left and
right
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Attachments
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Abb.8.jpg:
Abb.9.jpg:
Abb.10.jpg:
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Abb.11.jpg:
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Abb.20.JPG:
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TSB/Document ID: LI77 30-P-070145
Replacement Service Bulletin Number:
MFR Communication Date: 2019-08-15
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT
MFR Component System:
MFR Component Subsystem:
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