Test Notes

! CAUTION!
Injury hazard from pinching and crushing, in extreme cases extremities can even be severed when caught in the mechanism.

Do not allow any body pants to be in the general area of the moving components.


Notes for Hydraulic Test:

The following lobs are the same for all test steps:
A. Connection of test equipment to hydraulic unit (Figure 1, below).
Torque check valve 129 589 08 63 00 to 5 Nm.
B. Build up and release test pressure.
C. Test hydraulic cylinder only at end position of piston (Observe soft top positions).
D. If hydraulic lines need to be disconnected from the valve blocks during pressure tests, the appropriate soft top position (end position of the hydraulic cylinder) must first be ensured.

Preparation for Test:
1. Review entire section, especially "Preparation for Test", prior to performing any of the following tests on the soft top.

Disconnected hydraulic lines should be held in a container (connect a transparent hose such as windshield washer hose).

Hydraulic components that leak should be replaced. During pressure tests, the valve block connections must be plugged with plug 129 589 00 91 01.

If hydraulic components need to be replaced, the disconnected hydraulic lines must be plugged with plug 129 589 00 91 07, while the connections of valve blocks, hydraulic cylinders and hydraulic manifolds must be plugged immediately using plug 129 589 00 91 11 to prevent the possible entry of dint.

Example: Building up and releasing test pressure.

Soft top

Ignition ON:
Activate power soft top switch (toward lower if the soft top is down, toward raise if the soft top is up) for 5 seconds. Have a second technician disconnect relay (A7/5k1, Figure 1).

Hold power soft top switch for 5 additional seconds. Read and record test pressure.

Release test pressure:
Briefly activate power soft top switch several more times.


! CAUTION!
Release established test pressure before beginning the next test step.


Roll bar

Ignition ON:
Activate RB switch (toward lower if the roll bar is lowered, toward raise if it is raised) for 5 seconds. Have a second technician disconnect relay (A7/5k1, Figure 1). Hold roll bar switch for 5 additional seconds. Read and record test pressure.

Release test pressure:
Briefly activate power soft top switch several more times.

Connection Diagram - Check valve and Pressure Gauge to Hydraulic Unit

Figure 1:

1 Check valve 129 589 08 63 00
Adaptor kit 129 589 14 21 00
2 Test pressure line
3 Connector piece
4 Pressure gauge
10 Roll bar operation hydraulic line
11 Test connection
12 Soft top operation hydraulic line
13 Return line
A7/5 Hydraulic unit
A7/5k1 Relay
A7/5y1 Main valve (deleted as of VIN 1F-083891)


Y55 Left RST valve block (4 connections)



Y55 Left RST valve block (4 connections)
y6 Soft top "open" valve
y7 Soft top "close" valve
y5 fabric bow "raise" valve
Y6 Fabric bow "lower" valve

Y56 Right RST Valve Block (4 connections)
and
Y57 Roll bar Valve Block (2 connections)



Y56 Left RST valve block (4 connections)
y2 Rear locks valve
y3 Center locks valve
y4 Front locks valve
y5 Soft top compartment cover valve

Y57 Roll Bar valve block (2 connections)
y10 Roll bar "Lower" valve
y11 Roll bar "raise" valve