Remove/install soft top hydraulic pump

AR77.37-P-1000EC

Remove/install soft top hydraulic pump

16.3.11



Removing

Danger!

Risk of injury when performing check and repair work in area of roll bar

Type 207.4

AS91.00-Z-0003-01A

Before working in area of rollbar, completely extend rear head restraints

Keep body parts out of the area where the roll bar extends.

 Danger!

Risk of injury caused by moving parts that can pinch, crush or, in extreme cases, even sever extremities

No parts of the body or limbs should be within the operating range of the mechanism when moving components.

AS00.00-Z-0009-01A

 Danger!

Risk of injury to skin or eyes caused by hydraulic fluid spraying out under high pressure. Risk of poisoning caused by swallowing hydraulic fluid

Depressurize the hydraulic system completely before starting any work on the system. Wear protective clothing and safety glasses.

AS00.00-Z-0013-01A

 Danger!

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.

Deburr repair panels.

AS00.00-Z-0017-01A

1

Remove left side paneling in trunk

AR68.30-P-4800EC

2

Unscrew nuts (1)

With code (810) Sound system

3

Remove bracket (2) with sound system amplifier control unit (N40/3) and lay down to side with electrical lines connected

With code (810) Sound system

 Do not kink optical fiber conductor or route over sharp edges or in radiuses smaller than 25 mm, otherwise they can be damaged and must be replaced.

4

Remove left soft top compartment lid hydraulic cylinder (3) and lay down to side with hydraulic lines (8) connected

AR77.37-P-4175QA

5

Cut cable tie (9) from hydraulic lines (8)

6

Unclip electrical connectors (4, 5) from bracket (6) on soft top control hydraulic unit (A7/5) and disconnect

7

Loosen bolt (12) on soft top control hydraulic unit (A7/5)

 Pressure is relieved from hydraulic system

8

Unscrew nut (7) from bracket (6) on soft top control hydraulic unit (A7/5)

9

Remove oft top control hydraulic unit (A7/5) and lay down on suitable collecting pan (14) with hydraulic lines (8) connected

 Do not kink hydraulic lines (8) and do not route over sharp edges or in small rows smaller than 25 mm, otherwise they can be damaged and must be replaced.

10

Cut cable tie (13) and lay electrical wiring harness (10) down to side

11

Remove hydraulic lines (8) from soft top control hydraulic unit (A7/5)

 Do not allow hydraulic oil to run out and soil insulation (15).

AR77.37-P-1000-04KA



*129589009100

12

Remove soft top control hydraulic unit (A7/5)

13

Cut cable tie (16) and remove insulation (15) from soft top control hydraulic unit (A7/5)

Only when replacing soft top control hydraulic unit (A7/5).



Install

14

Install insulation (15) on soft top control hydraulic unit (A7/5) and fasten with cable tie (16)

Only when replacing soft top control hydraulic unit (A7/5).

15

Lay soft top control hydraulic unit (A7/5) down in area of hydraulic lines (8)

16

Attach hydraulic lines (8) to soft top control hydraulic unit (A7/5)

 Do not allow hydraulic oil to run out and soil insulation (15).

AR77.37-P-1000-04KA

 Provide all hydraulic lines (8) pulled out with new retaining rings and new sealing rings. Moisten new sealing rings with hydraulic oil.



Hydraulic fluids (Specification 343.0)

Sheet 343.0

BB00.40-P-0343-00A



*BA77.37-P-1002-01C



*BA77.37-P-1003-01C



*129589009100



*208589012100

17

Insert soft top control hydraulic unit (A7/5) into pins (11) on longitudinal member

18

Screw nut (7) into bracket (6) on soft top control hydraulic unit (A7/5)

19

Tighten bolt (12) to soft top control hydraulic unit (A7/5)

20

Connect electrical connectors (4, 5) and clip into bracket (6) on soft top control hydraulic unit (A7/5)

21

Fasten hydraulic lines (8) with cable tie (9)

22

Install left soft top compartment lid hydraulic cylinder (3)

AR77.37-P-4175QA

23

Position retractable partition (17) so that the bracket (18) can be removed together with the variable soft top compartment limit switch (S84/9)

24

Turn bracket (18) 270° counterclockwise as shown.

25

Carefully pull bracket (18) out of mount (19)

 Danger of breaking guide pin

(arrow A).

26

Actuate bracket of variable soft top compartment limit switch (S84/9) and fasten with cable tie (20) as shown.

27

Connect variable soft top compartment limit switch (S84/9) to electrical connector (21)

28

Check oil level of hydraulic line, correct if necessary



Hydraulic fluids (Specification 343.0)

Sheet 343.0

BB00.40-P-0343-00A



*BA77.37-P-1003-01C



*230589016300

29

Check soft top control hydraulic unit (A7/5) for leakage and proper function

30

Check oil level of hydraulic line, correct if necessary



Hydraulic fluids (Specification 343.0)

Sheet 343.0

BB00.40-P-0343-00A



*BA77.37-P-1003-01C



*230589016300

31

Disconnect electrical connector (21) from variable soft top compartment limit switch (S84/9)

32

Separate cable tie (20)

33

Carefully guide mount (18) with guide pin (arrow A) into groove (arrow B) of mount (19)

 Danger of breaking guide pin
(arrow A).

34

Turn bracket (18) clockwise to end stop

35

Install bracket (2) with sound system amplifier control unit (N40/3)

With code (810) Sound system

 Do not kink optical fiber conductor or route over sharp edges or in radiuses smaller than 25 mm, otherwise they can be damaged and must be replaced.

36

Screw on nuts (1)

With code (810) Sound system

37

Install left side paneling in trunk

AR68.30-P-4800EC

Number

Designation

Model 207.4

BA77.37-P-1002-01C

Bolt, terminal plate to hydraulic unit

Nm

10

BA77.37-P-1003-01C

Oil filler screw to hydraulic unit reservoir

Nm

2