Drive clutch, hydraulic unit
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Drive clutch, hydraulic unit
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1.
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Operate the hood to the open position to increase the light and make working easier.
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Note
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This task can be performed with the hood closed.
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If it is not possible to operate the soft top via the electric controls proceed as follows:
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1.a.
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Release the rear seat backrest and fold it forward.
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1.b.
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Remove the cover over the emergency valve and open the valve approx. one half turn
(A)
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1.c.
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Unlock the soft top from the windscreen frame.
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1.d.
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Activate the fifth bow lock using the diagnostic tool set to UNLOCK and fold up the fifth bow.
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1.e.
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Push the wheel bolt tool through the hole in the covering on the right-hand side of the luggage compartment and into the link arm of the operating mechanism
(B)
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1.f.
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Unlock the soft top cover by pulling the tool backwards until the soft top cover lifts up a few centimetres
(C)
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1.g.
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Remove the tool, close the boot lid and open the soft top cover.
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1.h.
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Carefully fold down the soft top.
Warning
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There is a pinch hazard and danger of crushing if you let go of the soft top in the half-open position (when vertical). It will fall backwards or forwards, depending on its centre of gravity.
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1.i.
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Close the soft top cover.
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2.
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Release the rear seat backrest and fold it forward.
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3.
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Remove the cover from the hydraulic unit.
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4.
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Fold aside the luggage compartment mat and unscrew the hydraulic unit mounting bolts.
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5.
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Lift up the hydraulic unit and unplug the connectors. Loosen the holders for the hydraulic hoses to make it easier to lift the unit.
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6.
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Open the emergency valve. Unscrew the reservoir oil plug and then retighten it to even out the pressure.
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Note
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This prevents unnecessary oil spill when hydraulic unit components are replaced.
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7.
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Place rags under the hydraulic unit it turn it so that the oil reservoir points down and the electric motor points up.
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Important
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It is very important that the unit remains in this position throughout the replacement operation.
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8.
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Remove the two screws of the electric motor.
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Note
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Screws should always be replaced.
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9.
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Remove the electric motor from the hydraulic unit by lifting it out. Oil may be spilled when the electric motor is removed.
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10.
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Remove the drive clutch from the electric motor.
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11.
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Remove the metal clip if it is still on the pump housing. The metal clip will not be used again.
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Important
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The hydraulic unit can be damaged if the metal clip is left in place.
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1.
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Fit the new drive clutch to the electric motor. The drive clutch only fits in one position. Press the drive clutch down on the electric motor shaft.
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2.
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Fit the pump housing with a new O-ring. Lubricate the O-ring with hydraulic oil.
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3.
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Fit the electric motor. The pin in the pump housing should pass between the drive clutch flanges.
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4.
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Fit new screws on the electric motor.
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5.
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Turn the unit horizontal with the filler hole up and check the oil level. If needed, top up with new oil to the MAX mark.
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7.
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Plug in the connectors to the hydraulic unit. Lift the hydraulic unit back into place.
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8.
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Close the emergency valve. Operate the soft top with the ROOF button a few times.
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9.
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Manoeuvre the soft-top to the up (closed) position.
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10.
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Check the oil level by turning the hydraulic unit until the oil plug is pointing straight upwards.
Check that the oil level is between the two marks.
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11.
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Clean up any oil spills.
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12.
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Fit the hydraulic hose holders. Fit the hydraulic unit in the torsion box.
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13.
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Re-position the luggage compartment mat and fit the cover.
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Important
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Check that the emergency operation valve is completely closed.
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15.
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Manoeuvre the soft-top up and down through 5 complete cycles. Check for correct operation and any DTCs.
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16.
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Fold back the rear seat backrest.
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