Convertible Top Pump: Service and Repair
WM 618419 Removing and installing hydraulic pump
Technical values
Preliminary work
1. Remove trim panel for hood compartment. => 700819 Removing and installing trim panel for hood compartment - section on "Removing"
2. Unlock electric connectors on the DME (DFI) control unit. => 247019 Removing and installing DME (DFI) control unit - section on "Removing"
3. Loosen wire harness for DME (DFI) control unit -1- by opening the tie-wrap -2- on the hydraulic pump holder -3-.
Loosening wire harness
4. Lay wire harness for DME (DFI) control unit -1- aside -arrow-.
Removing hydraulic pump
Installation position of hydraulic pump
CAUTION
Incorrect handling of hydraulic system
- Risk of damage to hydraulic system
- Malfunction in hydraulic system
-> Do not bend, trap or crush hydraulic lines.
-> Protect hydraulic system from contamination.
1. Disconnect plug connection on hydraulic pump.
Disconnecting plug connection on hydraulic pump
1.1. Cut tie-wrap -1- on wire harness for hydraulic pump.
1.2. Release plug connection -2- ( -arrow A- ) and disconnect it -arrow B-.
1.3. Release connector -2- ( -arrow C- ) and slide it down off the console -arrow D-.
2. Remove hydraulic pump.
Removing hydraulic pump
2.1. Screw off fastening nuts -1- ( -arrow A- ).
2.2. Lift up hydraulic pump -2- with the hydraulic pump holder -3- and remove it -arrow B-.
Information
Before unscrewing the banjo bolts, lay a cloth underneath to collect emerging hydraulic oil.
2.3. Unscrew banjo bolts -2A, 2B- on the hydraulic pump -1- and remove the hydraulic lines -A, B- and sealing rings -3, 4-.
Loosening hydraulic lines
Information
Only when replacing the hydraulic pump.
3. Remove hydraulic pump holder.
Removing hydraulic pump holder
3.1. Slide rubber holder -1- off the hydraulic pump holder -4- ( -arrow- ).
3.2. Unscrew fastening nuts -2- and remove hydraulic pump -3-.
3.3. Unscrew silent blocks -5-.
Installing hydraulic pump
CAUTION
Incorrect handling of hydraulic lines.
- Risk of damage to hydraulic lines.
- Malfunction in hydraulic system.
-> Avoid small bending radii when routing hydraulic lines.
-> File down edges and burrs in the routing area or mask them with adhesive tape.
-> Maintain a sufficient distance from components exposed to high temperatures while driving.
1. Install hydraulic pump holder.
Installing hydraulic pump holder
1.1. Tighten silent blocks -5-.
1.2. Position hydraulic pump -3- on the hydraulic pump holder -4- and secure with fastening nuts -2-. => Tightening torque: 10 Nm (7.5 ftlb.)
1.3. Slide rubber holder -1- over the hydraulic pump holder -4- ( -arrow- ).
Information
Always replace sealing rings.
2. Install hydraulic pump.
Connecting hydraulic lines
2.1. Place new sealing rings -3, 4- and the hydraulic lines -A- with the red ring on the banjo bolt -2A-. Screw in banjo bolt at the bottom and on the right side of the hydraulic pump -1- ( -arrow- ). => Tightening torque: 12 Nm (9 ftlb.)+2 Nm (+1.5 ftlb.)
2.2. Place new sealing rings -3, 4- and the hydraulic lines -B- with the blue ring on the banjo bolt -2B-. Screw in banjo bolt at the top and on the left side of the hydraulic pump -1- ( -arrow- ). => Tightening torque: 12 Nm (9 ftlb.)+2 Nm (+1.5 ftlb.)
2.3. Position hydraulic pump -2- with the hydraulic pump holder -3- on the frame for the roll-over protection system -arrow A-.
Installing hydraulic pump
2.4. Tighten fastening nuts -1- ( -arrow B- ).
3. Lock plug connection on hydraulic pump.
Locking plug connection on hydraulic pump
3.1. Slide connector -2- onto the console -arrow A- and connect plug connection -arrow B-.
3.2. Secure wire harness for hydraulic pump with a tie-wrap -1-.
4. Secure wire harness for DME (DFI) control unit -1- with a tie-wrap -2- on the hydraulic pump holder -3-.
Securing wire harness
5. Lock electric connectors on the DME (DFI) control unit. => 247019 Removing and installing DME (DFI) control unit - section on "Installing"
General information on the hydraulic system
Filling the hydraulic system
Information
- When filling the hydraulic system, proceed with utmost care to ensure dirt does not get into the system.
- Before unscrewing the screw plug, place a cloth underneath the hydraulic unit to catch emerging hydraulic oil.
- The hydraulic hood uses a closed hydraulic system. In general, the hydraulic system will need to be filled only if the hydraulic circuit was opened (after parts replacement). Only Genuine Porsche hydraulic oil => OIL must be used when changing or topping up the hydraulic oil.
1. Fill the hydraulic pump.
Filling the hydraulic system
1.1. Unscrew screw plug -1-.
1.2. Fill hydraulic pump -2- as far as the cross hair marking with Genuine Porsche hydraulic oil -3-.
Information
When screwing in the screw plug -1- , ensure that the seal -4- is touching the screw head.
1.3. Screw in screw plug -1-. => Tightening torque: 1 Nm (0.5 ftlb.)+/-0.3 Nm (+/-0.2 ftlb.)
Bleeding the hydraulic system
NOTICE
Non-synchronous running when bleeding the hydraulic system
- Risk of damage to the hood frame
-> Remove the hydraulic cylinders for the hood support and drive levers on both sides.
1. Bleed the hydraulic system.
1.1. Switch on ignition.
1.2. Open and close the hood electrically 2 to 3 times.
The system has a self-bleeding feature. Several operations will bleed the system. After bleeding the system, check the hydraulic oil level in the hydraulic pump reservoir and correct it if necessary.
1.3. Move hood to service position.
1.4. Switch off ignition and remove ignition key.
Checking hydraulic oil level
1. Check the hydraulic oil level on the reservoir by checking the cross hair marking.
The hydraulic oil level must not fall below the minimum mark.
Checking hydraulic oil level
2. A hydraulic oil level that is too low must be adjusted accordingly.
Access for opening and closing the hydraulic valve (emergency operation)
To open, insert the Allen key -1- through the bore on the roll-over bar module -3- into the hydraulic valve -2- and turn approx. 1 turn to the left -arrow-.
Opening and closing hydraulic valve
To close, insert the Allen key -1- through the bore of the roll-over bar module -3- into the hydraulic valve -2- and turn to the right.
Subsequent work
Install trim panel for hood compartment. => 700819 Removing and installing trim panel for hood compartment - section on "Installing"