Service bulletin LI77.30-P-070145

A bulletin is a manufacturer's communication to its dealers, as NHTSA indexes it. The summary is NHTSA's. The document is the manufacturer's: read it at NHTSA. A bulletin is not a recall, and listing a model year does not mean every vehicle of it is concerned.

NHTSA's summary

Complaint Damaged cords/tensioning cables at the soft top interior trim with the following characteristics: - Cord/tensioning cable torn - Cord/tensioning cable worn - Cord/tensioning cable torn out - Cord/tensioning cable - sheathing damaged Cause High tensile stresses on the cords/tensioning cables during the soft top sequence Remedy 1.) Check which cord(s)/tensioning cable(s) is/are damaged: • If damage is found on one of the cords/tensioning cables of the soft top interior trim, always replace the cords on the left and right as a pair. • If damage is determined at one of the cords from among no. 3 (if present), no. 4 or no. 7 from the soft top interior trim, then preventively replace all cords/tensioning cables of no. 3 (if present), no. 4 and no. 7 on the left and right. • This also applies to the new version of the soft top interior trim cords/tensioning cables for no. 4 and no. 7 (without cord/tensioning cable no. 3) on the left and right. 2.) Cut off the fastening rivets/eyelets: • See Fig. 6 - Illustrates a riveted fastening of the eyelet. See also document AR77.33-P-2500LWR - Remove/install tensioning cables of the headliner. 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 and for routing the new cord/tensioning cable: • Briefly heat the end of the new cord/tensioning cable with a lighter or similar tool. This will strengthen the fibers at the front somewhat and slightly round them off, • which will then make it easier to pull them through the duct with a cutting wire. • See Fig 9. - Slightly heating the end of the cord/tensioning cable with a lighter or similar tool 6.) Attach auxiliary cutting wire (0.3 mm or 0.8 mm) at the end of the new cord/tensioning cable: • Perforate/attach cutting wire approx. 5 mm from the end of the cord/tensioning cable. • Bend the cutting wire into shape and position the cord/tensioning cable. • See Fig. 10 – Auxiliary cutting wire. 7.) Pull the new cord/tensioning cable through the duct with the auxiliary cutting wire and, if necessary, with pliers: • See Fig. 11 – Auxiliary cutting wire/pliers. 8.) Attach the clamping ring at the cord/tensioning cable with pliers and leave the cord/tensioning cable protruding by approx. 3 mm ±1. Crush the clamping ring to a thickness of 3.75 mm ±0.25: • See Fig. 12 - Receptacle for clamping ring connection/soft top interior trim. Note/recommendation: • To facilitate the work, the pull-off device/workshop equipment W 221 589 04 33 can also be used to crush the clamping ring or the cable lug. • See Fig. 12A – Auxiliary tool/pull-off device. 9.) Press the clamping ring connection into the receptacle provided, and install the eyelet with the rivet in the intended position: • See Fig. 13 - Receptacle for clamping ring connection/soft top interior trim. • See Fig. 14 - Positioning the rivet with eyelet - example. Further information on optimizations: Due to optimization measures, all new soft top interior trim parts are manufactured without the cord/tensioning cable no. 3. In series production and in repair cases, the cord/tensioning cable no. 3 is no longer required. Therefore, in repair cases, it is only replaced if it is already present in the vehicle. All cords/tensioning cables currently used in series production and as replacement parts have a high resistance to abrasion. - Tape guide for the cords no. 3 (if present) and no. 7: • Make sure that cords/tensioning cables 3 (if present) and 7 are routed behind the tape. As a reference dimension, the tape should be positioned approx. 10 mm from the guide eyelet. • See attachment for further instructions.

The document

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Components

Body and frame

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