Convertible Top Audi TT 8J

Scheme 1

1. Front convertible top compartment trim Removing and Installing, refer to «FRONT CONVERTIBLE TOP COMPARTMENT TRIM»(/audi/tt/8j-2006-2010/remont/sun-rooft-topconvertible-top/#convertible-top)
2. Expanding clip Quantity: 9
3. Wind deflector Only the wind deflector support is installed on some vehicles, note corresponding equipment

Note. Only on manual convertible top.

Scheme 2

1. Release cable
2. Cable bracket Clip cable bracket with wind screen support.
3. Clip Clip into upper end plate as shown
4. Front convertible top compartment wall
5. Convertible top latch bracket Height adjustment, refer to «CONVERTIBLE TOP LATCH HEIGHT ADJUSTMENT»(/audi/tt/8j-2006-2010/remont/sun-rooft-topconvertible-top/#convertible-top)
6. Screws 8 Nm
7. Convertible top latch handle

Scheme 3

1. Release cable
2. Convertible top latch The convertible top latch must be adjusted so top is 4 mm below front convertible top compartment trim.
3. Markings To adjust height, adjust latch according to markings.

Scheme 4

When convertible top is adjusted correctly, front rail must engage with dimension -a- = 4 mm in center of vehicle under front convertible top compartment trim.

SAFETY PRECAUTIONS

To avoid personal injury or damage to the convertible top, note the following

1. Always activate parking brake.
2. Switch ignition on and leave on during the opening or closing procedure.
3. Objects in the convertible top compartment must be removed to prevent the convertible top and rear window from being damaged.

Scheme 5

1. Convertible top Removing and installing, refer to «CONVERTIBLE TOP»(/audi/tt/8j-2006-2010/remont/sun-rooft-topconvertible-top/#convertible-top)
2. Tensioning strap Bolted under convertible top compartment from luggage compartment out
3. Hydraulic System Must be removed when installing convertible top.
4. Screws 36 Nm
5. Spring Bracket securing spring.
6. Bracket Must be removed before removing convertible top. Loosen spring and remove bracket sideways from retaining pins.
7. Convertible top frame cover Removing and installing, refer to «CONVERTIBLE TOP FRAME FLAP»(/audi/tt/8j-2006-2010/remont/sun-rooft-topconvertible-top/#convertible-top)
8. Rear convertible top compartment trim When removing the convertible top, only disengage at the rear bracket «BRACKET, DISENGAGING AT MAIN BEARING»(/audi/tt/8j-2006-2010/remont/sun-rooft-topconvertible-top/#convertible-top) .
9. Convertible top release Only on manual convertible top.
10. Clip Quantity: 12

Convertible Top Spring-Back Dimension

Note. For correct convertible top adjustment, a spring-back dimension of 35 +/- 5 mm must be maintained. Close the convertible top from the stored state via switch operation until the hydraulic pump switches off. The front side of the convertible top main bearing must be installed parallel to the front wall of the convertible top compartment. The dimension between the roof frame crossmember and front rail must now be 35 +/- 5 mm. If the dimension 35 +/- 5 mm is not maintained, the position of the main bearing must be checked for parallel alignment with respect to the convertible top front wall and adjusted if necessary. If the spring-back dimension is still not within the tolerance specifications after these measures, it can be corrected via the adjusting screw on the front main bearing CONVERTIBLE TOP, ADJUSTING .

Adjustment Dimensions at Main Bracket

Scheme 6

1. Bolt Before removing the convertible top, screw in the screw for convertible top height adjustment to the stop on convertible top compartment floor «CONVERTIBLE TOP, ADJUSTING»(/audi/tt/8j-2006-2010/remont/sun-rooft-topconvertible-top/#convertible-top) .
2. Convertible top main bearing Before removing the convertible top, measure the distance from the main bearing to the convertible top compartment front wall, distance -a-. When installing the convertible top, the same parallel distance must be set. NOTE: After convertible top installation, the screw for convertible top height adjustment must be turned back approx. 2 revolutions. When installing the convertible top, the parallel distance must be -a- = 30 mm for the preadjustment. When correctly set, the centering pin of the convertible top must retract at the front center end plate. If necessary, the dimension of 30 mm on the main bearing front side can be shifted parallel to the convertible top compartment front wall.
3. Main bearing front side
4. Convertible top compartment front wall

Scheme 7

Note. If the spring-back dimension is not within the tolerance range despite the correct settings at the main bearing, it can additionally be corrected by adjusting the adjusting screw -arrow- at the front main bearing.

The spring-back dimension can be reduced by turning the adjusting screw to the left.

The spring-back dimension can be increased by turning the adjusting screw to the right.

Scheme 8

Prior to convertible top removal, the screw for convertible top height adjustment -1- on lower main bearing -2- must be unscrewed to the convertible top compartment floor.

Height Adjustment at Main Bearing

Scheme 9

During installation, the main bearing must be installed for preadjustment at a distance of -a- = 77 mm from the convertible top compartment front wall with respect to the upper edge of the main bearing front side.

Gap Dimensions on Convertible Top

Note. The gap dimensions are set by adjusting at the main bearing. Measure the dimension -c- from the forward edge of the rear lid outward Dimension -d- must be measured from the side panel starting at the main bearing. Dimension -f- can be adjusted by placing adjustment shims on the upper seal guide rails CONVERTIBLE TOP SEALS .

1. Dimension -a- = 7 mm
2. Dimension -b- = 1.5 mm
3. Dimension -b- can be adjusted by adding or removing shims between the front rail and convertible top lock.
4. Dimension -c- = 14 mm
5. Dimension -d- = 4.5 mm
6. Dimension -e- = 1.5 mm
7. Dimension -f- = 12 mm
8. Adjust the dimension -f- by adding or removing washers from between the guide rail and roof guide, refer to «CONVERTIBLE TOP SEALS»(/audi/tt/8j-2006-2010/remont/sun-rooft-topconvertible-top/#convertible-top)

Scheme 10

1. Body window crossmember
2. Convertible top
3. Body
4. Side panel
5. Door window

HYDRAULIC SYSTEM GENERAL INFORMATION

1. The hydraulic system is self-bleeding and maintenance-free.
2. After all work where the oil circuit was opened or parts of the hydraulic system were replaced, check oil level and fill according to the markings on the oil reservoir if necessary. Refer to «HYDRAULIC PUMP OIL LEVEL, CHECKING»(/audi/tt/8j-2006-2010/remont/sun-rooft-topconvertible-top/#convertible-top__hydraulic-pump-oil-level-checking) .

CLEAN WORKING CONDITIONS

1. Clean connecting points and surrounding areas before loosening.
2. Place removed parts on a clean surface and cover. Use foil and paper. Do not use cloths with lint!
3. Carefully cover or seal opened components if the repair will not be done immediately.
4. Only install clean parts: remove replacement parts from the packaging immediately prior to installation.
5. Place collecting container or foil and cloths under connections to be opened so that hydraulic oil does not come into contact with painted surfaces.
6. Seal open hydraulic lines with cover caps to prevent hydraulic oil from leaking out.

HYDRAULIC SYSTEM, FILLING AND BLEEDING

Note. The electro-hydraulic convertible top operation involves a closed hydraulic system. Generally, filling is necessary after a loss of oil (accident, leaks, etc.). Due to the lift and displacement effect of the pistons in the hydraulic cylinders, the hydraulic system must be filled when the convertible top is stored in the compartment. After filling, convertible top must then be moved several times using the electro-hydraulic operation. Then check the oil level again and correct if necessary.

HYDRAULIC SYSTEM ASSEMBLY OVERVIEW

Scheme 11

1. Hydraulic cylinder Before removal, remove convertible top. Removing, refer to «HYDRAULIC CYLINDER ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/sun-rooft-topconvertible-top/#convertible-top)
2. Hydraulic line Unclip hydraulic line to body -arrows-.
3. Hydraulic pump housing To remove, remove bolts -4- and raise housing out of body.
4. Bolt 10 Nm
5. Electric wire To remove hydraulic pump, disconnect at connector.
6. Body crossmember

Scheme 12

Open hydraulic pump valve by rotating valve bolt 180° counterclockwise using a screwdriver -2- through the opening -3- in the pump housing cover -1-.

When closing, tighten hydraulic pump valve bolt to 2 Nm.

HYDRAULIC PUMP OIL LEVEL, CHECKING

Hydraulic pump removed and placed on a level surface in luggage compartment.

Oil level must be between both markings -4-, fill oil if necessary.

Remove filler plug -5

Scheme 13

Fill with oil until the level is between >>Min<< and >>Max<< markings.

Install filler plug and tighten to 5 Nm.

Operate convertible top electrically several times and check oil level again.

Scheme 14

1. Spring Connecting piece securing spring
2. Hydraulic line Supply
3. Convertible top cylinder
4. Spring Connecting piece securing spring
5. Hydraulic line Return

Scheme 15

1. Pump housing Remove pump housing from body crossmember -3-. Remove pump housing as shown upward out of opening in convertible top compartment base. Pump housing, installing, refer to «HYDRAULIC SYSTEM ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/sun-rooft-topconvertible-top/#convertible-top__hydraulic-system-assembly-overview)
2. Convertible top compartment floor
3. Body crossmember

Scheme 16

1. Convertible top frame
2. Bracket tensioning strap Before removing convertible, remove bolts -6-, release tensioning strap at retaining tabs and pull strap into convertible top compartment. If tensioning strap must be replaced, also remove bolts on bracket and remove retaining strip -4- with tensioning strap from bracket. When installing, first slide into convertible top compartment from below and engage at rear on retaining tabs.
3. Bracket Removal «BRACKET, DISENGAGING AT MAIN BEARING»(/audi/tt/8j-2006-2010/remont/sun-rooft-topconvertible-top/#convertible-top)
4. Retaining strip
5. Bolt 2 Nm
6. Bolt 2 Nm

Note. On the electro-hydraulic convertible top, convertible top movements are performed electrically during removal work. Therefore, connectors to cover motors and hydraulics should only be disconnected after the convertible top is stored in the compartment.

Removing

Remove all luggage compartment trim. Refer to Removal and Installation .

Remove rear panel trim behind seat. Refer to Removal and Installation .

Remove hydraulic pump reservoir cover from body (quantity: 6) and remove housing with hydraulic pump. PUMP HOUSING

Close convertible top.

Remove tensioning straps under convertible top compartment and pull through compartment BRACKET TENSIONING STRAP .

Remove the front convertible top compartment trim.

Store convertible top approximately halfway in compartment.

Completely disengage convertible top compartment trim from bracket. Refer to CONVERTIBLE TOP COMPARTMENT TRIM .

Unclip hydraulic lines from rear wall of convertible top compartment. Refer to HYDRAULIC SYSTEM ASSEMBLY OVERVIEW .

Note. When storing convertible top in compartment, press bracket down so that it doesn't get stuck on the compartment seal.

Store convertible top in compartment completely.

Remove left and right convertible top covers and disconnect motor. Refer to CONVERTIBLE TOP FRAME FLAP .

Disengage left and right bracket. Refer to BRACKET, DISENGAGING AT MAIN BEARING .

Disconnect electrical connector to hydraulic pump

Note. Before main bearing bolts are loosened, height adjusting bolt must be unscrewed as far as convertible top compartment base and the distance of the main bearing to the rear wall of the compartment must be measured. Refer to CONVERTIBLE TOP, ADJUSTING .

Remove bolts on left and right of main bearing

Raise the convertible top at an angle toward the front up out of compartment while another person pulls the hydraulic pump through the floor in the convertible top compartment.

Remove convertible top back from vehicle.

Installing

Install in reverse order of removal.

Special tools and workshop equipment required

1. Pry lever 80 - 200

Removing

Remove rear wall cover.

Position convertible top or linkage removal flaps so that expanding clips -A- can be unclipped with 80 - 200.

Scheme 17

Note. Secure expanding clips -A- against falling.

Unclip remaining expanding clips and remove front convertible top compartment trim -B-.

Installation

Install in reverse order of removal.

Scheme 18

1. Main bearing
2. Bracket To remove, press securing spring sideways off pins and remove bracket sideways.
3. Securing spring To install, slide on sideways as far as stop.

Scheme 19

1. Washers May be used if necessary for side adjustment of seals.
2. Bolt 3 Nm
3. Rear guide hinge
4. Rear seal
5. Center roof guide seal >>2<<
6. Front roof guide seal >>1<<
7. Center guide rail for roof guide >>2<<
8. Front guide rail for roof guide >>1<<

Seal, Removing

Scheme 20

Seals are slid into guide rails.

To remove, remove from guide rails.

For easier assembly, coat seal -1- with soapy solution if necessary and slide onto seal guide -2-.

Scheme 21

For side adjustment, slide in shims -3- between guide rails and convertible top guide -2- appropriate to the door window.

Tighten bolts -1- on guide rails to the specification.

Scheme 22

1. Trim Is clipped to flap. Flap, releasing, refer to «CONVERTIBLE TOP FRAME FLAP»(/audi/tt/8j-2006-2010/remont/sun-rooft-topconvertible-top/#convertible-top)
2. Convertible top frame cover To adjust, loosen bolts -4- on body and adjust flap so it is flush with convertible top. Height adjustment to side panel «CONVERTIBLE TOP FRAME FLAP»(/audi/tt/8j-2006-2010/remont/sun-rooft-topconvertible-top/#convertible-top) Panel gap dimensions «CONVERTIBLE TOP FRAME FLAP»(/audi/tt/8j-2006-2010/remont/sun-rooft-topconvertible-top/#convertible-top)
3. Push rod CAUTION: During convertible top emergency operation, push rod must first be disconnected at upper ball stud -arrow- and valve bolt on hydraulic pump «HYDRAULIC SYSTEM ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/sun-rooft-topconvertible-top/#convertible-top__hydraulic-system-assembly-overview) must be opened.
4. Bolt 5 Nm
5. Window
6. Body flange

Scheme 23

Using a small screwdriver, for example, press retainer -arrow- down and slide trim -2- back away from flap -1-.

For side adjustment to flap, loosen bolts -3- and slide flap carrier -1- according to gap dimensions.

Scheme 24

1. Dimension >>a<< = 3.6 mm
2. Dimension >>b<< = 3.6 mm
3. Dimension >>c<< = 3.6 mm

Scheme 25

Height to side panel is adjusted using adjusting screws -arrows-.

Scheme 26

1. Rear convertible top compartment trim To remove, first disengage upward all around from the bracket and insert between the outer wall and plastic strip. CAUTION: If the trim is not inserted, damage can occur when the convertible top is stored.
2. Clip Quantity: 12
3. Body flange
4. Bracket

Scheme 27

1. Right roof guide rear trim >>2<<
2. Right roof guide front trim >>1<<
3. Bolt 2.5 Nm
4. Front cover Remove bolts -8- on front cover. Only on manual convertible top. Remove latch handle «LATCH HANDLE»(/audi/tt/8j-2006-2010/remont/sun-rooft-topconvertible-top/#convertible-top) . Unclip cover -9-. Remove cover forward out of latches.
5. Left roof guide front trim >>1<<
6. Left roof guide rear trim >>2<<
7. Bolt 2.5 Nm
8. Bolt 2.5 Nm
9. Cover Only on manual convertible top.
10. Handle Only on manual convertible top latch.

Special tools and workshop equipment required

Scheme 28

1. Convertible top bracket VAS 6586
2. Scissor lift table VAS 6131 A

Note. The VAS 6586 can be secured via the bore holes in the crossmember to the VAS 6131 A or a workbench. For the convertible top to be in the installation position, it must be secured to the main bearing via threaded holes >>A; B; C; D and E<< of the mounting plates. INSTALLING CONVERTIBLE TOP TO VAS 6586 First, screw the mounting plates slightly onto the main bearing. Insert the convertible top with the mounting plates into the VAS 6586 and tighten the screws on the main bearing. For proper functioning, the hydraulic pump must be placed with the oil reservoir and hydraulic pump motor in the half shells on the crossmember.

Scheme 29

1. Convertible top cover
2. Rail tensioning strap
3. Bolt 2.5 Nm
4. Bracket
5. Retaining strip
6. Bolt 3 Nm
7. Front rail
8. Bolt 1.5 Nm

Clamping

Note. Lightly secure both mounting plates with mounting points -B- and -E- on the main bearing. The arrows must point forward in the direction of travel.

Lightly secure the main bearing on the left and right with the bore holes shown in the figure -arrows- to the mounting plates via mounting points -B- and -E-.

Scheme 30

Insert the convertible top with the mounting plates into the mounts on the VAS 6586 from above.

Tighten the screws on the main bearing.

Note. These parts designations are used in the description

Scheme 31

1. Rail >>1<< Fixed rail
2. Rail >>2<< Rotatable rail
3. Rail >>3<< Guided rail
4. Rear window guide
5. Rail tensioning strap
6. Bracket tensioning strap
7. Bracket
8. Hydraulic pump housing
9. Main bearing
10. Angle bracket for rear guide rail
11. Roof guide >>2<<
12. Roof guide >>1<<
13. Front rail

Scheme 32

Secure stop -2- with bolts -3- to roof guide -1- and tighten to 2 Nm.

Scheme 33

1. Front rail
2. Tension cable First disengage tension cable at spring. Disengage tension cable at front rail and remove back from convertible top cover.
3. Convertible top cover
4. Adhesive tape After installing the tension cable, tape it over with adhesive tape as shown for noise insulation.
5. Main guide
6. Spring

TENSION CABLE, TIGHTENING

Note. Make a hook from welding wire to help tighten the tension cable.

With manual convertible top cover, slide hook -1- up into pocket, or with automatic convertible top, in direction of arrow between cover and insulation.

Scheme 34

Engage the tension cable in the hook as shown and pull forward.

Scheme 35

Engage tension cable nipple -1- in front rail

Scheme 36

Engage spring -3- in eyes -arrow- on main guide -1- and rear tension cable -2-.

Scheme 37

Removing

Convertible top compartment cover trim disengaged from bracket. Refer to CONVERTIBLE TOP COMPARTMENT TRIM

Front cover removed CONVERTIBLE TOP LATCH

Convertible top headliner removed HEADLINER

Remove bolts -arrows- on front rail -2- and remove front rail retaining strip -1-.

Scheme 38

Note. Only on vehicles with electro-hydraulic convertible top. On vehicles with manual convertible top, plastic retaining rails must be removed from rails.

Scheme 39

1. Guide cable To remove cover, remove guide cable on both sides from roof guide >>2<< «GUIDE CABLE MOUNT ON ROOF GUIDE»(/audi/tt/8j-2006-2010/remont/sun-rooft-topconvertible-top/#convertible-top) .
2. Bolt 2.5 Nm
3. Guide retaining strip >>1<< Retaining strips for rails 1, 2 and 3 are removed to remove cover.
4. Guide retaining strip >>2<<
5. Guide retaining strip >>3<<
6. Bolt 2 Nm

Scheme 40

To remove cover, remove bolt -2- for guide cable -3- on roof guide >>2<< -1-.

Loosen all tension cable threaded connections and tensioning straps for securing cover.

Remove cover retaining strips at rails.

On angle bracket -1-, drill out rivet heads -arrows- for securing the cover and drive out rivet shafts.

Scheme 41

Remove rear window securing screw -1

Scheme 42

Tighten to 6 Nm when installing

Loosen the screw on the upper release cable on the rear window and detach the release cable.

Disconnect window defroster wire at connection -arrow-.

Scheme 43

Removing

Scheme 44

1. Retaining strip No replacement part, part of the convertible top headliner delivery package.
2. Convertible top headliner Removed
3. Bracket Disengage convertible top cover assembly bracket on convertible top frame.
4. Bolt 2.5 Nm
5. Convertible top cover Drill out rivet heads on the angle bracket and pull out the main guide with cover. Remove bolts on retaining strip -6- and remove from convertible top frame.
6. Retaining strip No replacement part, part of the convertible top cover delivery package.
7. Bolt 3 Nm

Installing

Install in reverse order of removal.

HEADLINER

Note. The headliner is removed with the convertible top installed.

Front Headliner

Scheme 45

1. Front convertible top headliner Front trim removed. Front cover removed «CONVERTIBLE TOP LATCH»(/audi/tt/8j-2006-2010/remont/sun-rooft-topconvertible-top/#convertible-top) To remove, remove bolts -4-.
2. Retaining strip Removed
3. Convertible top front rail
4. Bolt 1.5 Nm

Rear Headliner

Note. In the case of a new convertible top headliner, missing outer holes must be replaced by the retaining strip.

1. Retaining strip Retaining strip with tensioning strap removed. No replacement part, part of the convertible top headliner delivery package.
2. Rear convertible top headliner The convertible top headliner is secured all around to the rear window with Velcro strip. To remove, pull from the rear window.
3. Bracket
4. Bolt 2.5 Nm

HEADLINER RETAINING STRIP ON BRACKET

Installing

Scheme 46

Rear window heater cable -4- must be routed in the upper groove -arrow- on bracket -5- as shown.

Secure retaining strip -2- for convertible top headliner -3- with screws -1- in the lower groove.

BRACKET TENSIONING STRAP

Removing

Scheme 47

1. Convertible top
2. Bracket tensioning strap Remove bolts -3- and pull tensioning strap through into convertible top compartment.
3. Bolt 2 Nm
4. Convertible top compartment

HEADLINER TENSIONING STRAPS

Removing

Scheme 48

Remove bolts -1- on front rail -3-.

Pull tensioning strap -2- forward out of retainer and remove upward from front rail.

Remove retainer bolts on tensioning strap from rail >>1<< as shown.

Scheme 49

Remove retainer bolts on tensioning strap from rail >>2<<.

Scheme 50

Remove retainer bolts on tensioning strap from rail >>3<<.

Scheme 51

Remove bolt -3- on guide strap -1- as shown on roof guide >>2<<.

Scheme 52

REAR WINDOW RELEASE CABLE

Removing

Scheme 53

1. Rear Window No replacement part
2. Rear window release -- When removing convertible top cover, disconnect release at upper rear window. NOTE: Reinstall the same number of cable ties and in the same places as before removal. On vehicles where threaded cable clips are used, the wiring and the release should be routed accordingly in the clips.
3. Bolt 2 Nm
4. Main bearing

Headliner, installing

Install in reverse order of removal.

WATER TRAY

Removing

Scheme 54

1. Water tray
2. Clip
3. Bolt 2 Nm
4. Expanding clip

Removing

Front cover removed.

Scheme 55

1. End plate
2. Nut 9 Nm
3. Convertible top lock The locks on the convertible top are preset above the locking rods and do not need to be adjusted.
4. Convertible top
5. Bolt 9 Nm
6. Convertible top latch
7. Convertible top latch motor Removal «CONVERTIBLE TOP LATCH MOTOR»(/audi/tt/8j-2006-2010/remont/sun-rooft-topconvertible-top/#convertible-top)
8. Bolt 10 Nm

Removing

Note. Shims with different inner diameters are located between the convertible top lock and front rail. The first shim for the front rail must have the largest inner diameter.

Front trim removed.

Scheme 56

Remove nuts and remove convertible top lock with linkage.

Scheme 57

Roof crossmember trim removed.

Remove bolts -1- and nuts -3- on convertible top latch -2-.

Removing

Scheme 58

1. End plate
2. Nut 9 Nm
3. Convertible top lock
4. Convertible top
5. Bolt 9 Nm
6. Convertible top latch Front cover removed.

Scheme 59

Fold up the handle, turn it approx. 90°, and unscrew the screw.

Slide bolt -3- sideways out of handle -2- using a thin wire -2-.

Tighten bolt to 2 Nm when installing.

Scheme 60

Unclip collar -1- in direction of -arrow-.

Scheme 61

Unclip cover -2- at front trim -1- -arrow-.

Scheme 62

Removing

Scheme 63

Tighten handle -2- with bolts -1- to 8 Nm.

Clip -3- clipped in.

END PLATE

Removing

Scheme 64

1. End plate Window crossmember cover, removing, refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/exteriorinterior-trim/#interior-trim-roadster) To remove, disconnect the electrical connector and unscrew the screws.
2. Bolt 15 Nm.
3. End plate cover To remove, unclip.

HYDRAULIC CYLINDER

Removing

Convertible top completely removed.

Scheme 65

1. Convertible top main bearing
2. Hydraulic cylinder Remove securing spring -4- from pins -3- on piston rod and cylinder. Remove pins sideways from main bearing and remove cylinder. Remove supply and return line from cylinder. After installing, check oil level at hydraulic pump, add hydraulic oil if necessary.
3. Securing pins
4. Securing spring Release and slide sideways off securing pins

HYDRAULIC LINE FROM CYLINDER

Removing

Slide securing spring -1- sideways under connecting piece -3- out of cylinder using a screwdriver.

Scheme 66

Remove connecting piece -1- from cylinder using sealing ring -2-.

Scheme 67

Carefully remove sealing ring -1- using a small hook -2- if necessary without damaging -3- cylinder.

Scheme 68

Slide new sealing ring -2- onto connecting piece -1-.

Insert connecting piece -3- vertically in cylinder, no resistance must be felt.

Do not press connecting piece in with force, otherwise damage to the O-ring and leaks could result.

Scheme 69

Lock securing spring -2- in direction of -arrow

After performing work, check oil level and add oil if necessary.

HYDRAULIC PUMP

Hydraulic Line, Removing from Pump HYDRAULIC PUMP

Scheme 70

1. Hydraulic pump housing Removed from body.
2. Noise Insulation
3. Housing cover Removed.
4. Screws 4 Nm
5. ABS Hydraulic Pump To remove, remove bolts -4- and remove cover with noise insulation.

Hydraulic Line, Removing from Pump

Scheme 71

1. Bolt 6 Nm
2. Hydraulic line Raise hydraulic pump out of housing. To remove, remove securing bolt -1- and remove connector pieces with hydraulic line from pump block -4-. Before installing, slide new O-ring seals onto connecting pieces. CAUTION: When inserting, connecting pieces must lie flush before bolts are tightened. To install, slide connecting pieces completely into pump block and tighten securing bolts -1- to 6 Nm.
3. Oil reservoir With >>Min<< and >>Max<< markings. Oil level must be between markings.
4. Pump block
5. Motor for hydraulic pump
6. Noise Insulation
7. Hydraulic pump housing

Oil Reservoir, Replacing

Scheme 72

1. Oil reservoir Before removing, first loosen filler plug -2- to bleed. To remove, loosen bolt -7- on clamp until oil reservoir can be removed from pump block. Then pull oil reservoir off of pump block, alternating sides. Always replace O-ring seals. Before install, first loosen filler plug -2- to bleed. When installing, slide oil reservoir on to the first retainer. Then slide oil reservoir in the correct position completely onto pump block. The oil reservoir then engages in the pump block. O-ring seal must lie cleanly in the intended groove. After checking, slide on clamp -6- and tighten bolt -7- to the specification.
2. Oil filler screw NOTE: When removing or pressing on oil reservoir, loosen bolt to ventilate or bleed. 5 Nm
3. Emergency operation valve 2 Nm
4. Pump block
5. Motor for hydraulic pump
6. Clamp
7. Bolt 4 Nm
8. Oil level marking

Oil Reservoir Installation Location

For correct installation, >>Max<< marking must be at a distance of -a- = 27 mm from upper edge of pump block, measured outward.

With locking bolt loosened, oil reservoir can be turned far enough for this.

After aligning correctly, tighten locking bolt to the specification and fill oil.

PUMP MOTOR

Removing

Pump removed.

Scheme 73

Remove bolts -2- and remove motor from pump block -1-.

Replace seal and insert new motor -3- in pump block.

Tighten bolts to 6 Nm.

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 74

1. Convertible top bracket VAS 6586
2. Scissor lift table VAS 6131 A
3. Pry lever 80 - 200

See also:
• Removal and Installation
• FRONT CONVERTIBLE TOP COMPARTMENT TRIM
• HYDRAULIC PUMP OIL LEVEL, CHECKING
• HYDRAULIC SYSTEM ASSEMBLY OVERVIEW
• BRACKET TENSIONING STRAP
• HEADLINER
• HYDRAULIC PUMP