Convertible Top Hydraulic Cylinder: Service and Repair

618619 Removing And Installing Hydraulic Cylinder

Preliminary work
1. Open convertible top.
2. Remove the rear side trim panel.
3. Removing rear wall trim panel.
4. Remove trim panel for convertible top rest.

Tools and materials

Tools

Assembly tool for Springfix System pin circlips NR.131

Removing hydraulic cylinder

1. Press out the two retaining clips -1- from the lever -2- using assembly tool for Springfix System pin circlips NR.131 and remove lever.

2. Pull the protection plate -3- upwards out of the chamber in the water drip pan -4-.

Disconnecting electric plug connection for hydraulic pump

1. Cut tie-wrap -1- around the wire harness for hydraulic pump.

2. Press lugs -arrows A- and disconnect electric plug connection -2- -arrow B-.
3. Unlock connector -2- by pressing the lug -arrow C- and push out of the bracket -arrow D-.

Removing hydraulic pump

1. Move rubber holder -1- in -direction of arrow A- from the support for hydraulic pump -4-.

2. Unscrew fastening nuts -2- and take out hydraulic pump -3- from the support for hydraulic pump upwards -arrow B-.

NOTE: Before unscrewing the banjo bolts,Lay a cloth underneath to collect emerging hydraulic oil.

3. Unscrew banjo bolts -2A, 2B- on the hydraulic pump -1- and take out hydraulic lines -A, B- with sealing rings -3, 4-.

4. Unscrew silent mount -5-.

Installing hydraulic cylinder

CAUTION: Damage to hydraulic lines.

- Do not bend, trap or crush hydraulic lines when removing and installing.
- Pay special attention when routing hydraulic lines in the clips.

1. Position hydraulic cylinder -6- with the lever on the convertible-top support. Insert potentiometer fork into the pin of the hydraulic housing (on the left side only).
Lay hydraulic line -Figure A- in the clip under the water drain hose. In -Figure B- and -Figure C- press the hydraulic lines into the clips. Tighten fastening nuts -5-. Tightening torque: 17 Nm (13 ftlb.)± 2 Nm (±1.5 ftlb.)

2. Fit lever -2- and secure with retaining clip -1-.

3. Insert protection plate -3- in chamber of water drip pan -4-.

Installing hydraulic pump

2. Push on sealing rings -3, 4- and hydraulic lines -A- with the red ring. Screw in banjo bolt -2A- on the lower or right side of the hydraulic pump -1- . Tightening torque Tightening torque: 9 ftlb.+1.5 ftlb.
3. Push on sealing rings -3, 4- and hydraulic lines -B- with the blue ring. Screw in banjo bolt -2B- on the upper or left side of the hydraulic pump -1- . Tightening torque Tightening torque: 9 ftlb.+1.5 ftlb.
4. Position hydraulic pump -3- on holder for hydraulic pump -4- -arrow A- and screw down the fastening nuts -2-.

5. Push in rubber holder -1- in support for hydraulic pump -arrow B-.

Locking electric plug connection for hydraulic pump

1. Push plug connection -2- in bracket -arrow A- and join plug connection -arrow B-.

2. Insert new tie-wrap -1- around wire harness for hydraulic pump and fasten.

Opening and closing hydraulic valve of the hydraulic pump

To open, insert the Allen key -A- through the bore -X- of the roll-over bar module into the hydraulic valve -B- and turn approx. 1 turn to the left.

To close, insert the Allen key -A- through the bore of the roll-over bar module -X- into the hydraulic valve -B- and turn to the right.

Bleeding the hydraulic system

CAUTION: Damage to the convertible-top frame if not running synchronously.
- Bleed the hydraulic system only after the hydraulic cylinders have been removed from the convertible-top supports and drive levers on the left and right.

- The system has a self-bleeding feature. Three to four operations will bleed the system. After bleeding, check the oil level in the container on the hydraulic pump and check if necessary.

To bleed, the hydraulic valve must be closed.

Subsequent work
1. Calibrate convertible top.
2. Install trim panel for convertible top rest.
3. Install rear wall trim panel.
4. Install rear side trim panel.