Service installation of hardtop Installing hardtop â Lower side windows as far as they will go. â Retract (if necessary unscrew) radio aerial. â Switch off ignition. â If necessary, remove wind deflector. â â Open flaps for convertible top compartment lid catch on left and right. â Guide seat belt around flap as shown. Vehicles à 07.96: â Remove rear seat bench. => General Body Repairs, Interior; Repair Group 72; Rear seat; Removing and installing rear seat bench â Remove rear seat backrest. => General Body Repairs, Interior; Repair Group 72; Rear seat; Removing and installing rear seat backrest â Remove rear left side padding. => General Body Repairs, Interior; Repair Group 72; Rear seat; Removing and installing side padding Page 1 of 24
â Remove rear left side trim. => General Body Repairs, Interior; Repair Group 70; Side Trim; Removing and installing rear side trim â â Unplug connector -1- at blower for rear window -2-. â Remove blower for rear window with bracket. => Electrical System; Repair Group 96; Servicing blower for rear window â Unfasten cable ties from bitumen mat. â Unscrew self-tapping hexagon nuts for securing bitumen mat. â Detach bitumen mat. â â Move convertible top manually to centre position. â Lay summer/winter wiring harness. Page 2 of 24
â â Attach wiring-harness connector with adhesive strip to welding wire. â Lift bottom trim in convertible top compartment on left. â â With the aid of the welding wire, guide wiring harness -1- at water hose through body opening on left - arrow-. Any other routing could lead to damage caused by convertible top linkage or window lifter mechanism. Page 3 of 24
â â Clip wiring harness -1- into rubber grommet -2-. â â Attach connector of wiring harness -2- to connector -1- of wire for rear window blower -arrow-. Vehicles with electrohydraulic convertible top actuator mechanism: Page 4 of 24
â â Unplug connector - arrow- to convertible top control unit. â â Attach connectors of new wiring harness -1- for convertible top control unit to existing connectors -2-. Vehicles à 07.96: â Fit bitumen mat. Page 5 of 24
â Lay new summer/winter wiring harness in front of bitumen mat. â Re-attach cable ties at same locations. â Install blower for rear window. => Electrical System; Repair Group 96; Servicing blower for rear window â â Attach connector -1- to blower for rear window -2-. Vehicles with manual convertible top actuator mechanism: â Stow convertible top in compartment. â Close convertible top compartment lid and open luggage compartment. â Remove left luggage compartment trim. => General Body Repairs, Interior; Repair Group 70; Trim; Removing and installing luggage compartment trim â â Unplug connector of convertible top micro-switch - arrow- in area of rear left wheel housing. Page 6 of 24
â â Attach adapter lead -1- between unplugged connectors -2- of convertible top micro-switch. â Route adapter lead through opening in body towards convertible top compartment. â Close luggage compartment. â â Open convertible top compartment. â Move convertible top manually to centre position. â Lift bottom trim in convertible top compartment on left. Page 7 of 24
â â Pull wiring harness with adapter lead for convertible top micro-switch -1- with connector -2- into convertible top compartment. â Stow convertible top in compartment. â Close convertible top compartment lid and open luggage compartment. â Install left luggage compartment trim. => General Body Repairs, Interior; Repair Group 70; Trim; Removing and installing luggage compartment trim â Close luggage compartment. Vehicles à 07.96: â â Open convertible top compartment. â Move convertible top manually to centre position. â Lift bottom trim in convertible top compartment on left. Page 8 of 24
â â Attach connector to short wire of summer/winter wiring harness using cable tie -arrow-. â Route connector with long wire of summer/winter wiring harness out over left wing. Do not connect heated rear window until hardtop has been installed. â Install rear left side trim. => General Body Repairs, Interior; Repair Group 70; Side Trim; Removing and installing rear side trim â Install rear left side padding. => General Body Repairs, Interior; Repair Group 72; Rear seat; Removing and installing side padding â Install rear seat backrest. => General Body Repairs, Interior; Repair Group 72; Rear seat; Removing and installing rear seat backrest â Install rear seat bench. => General Body Repairs, Interior; Repair Group 72; Rear seat; Removing and installing rear seat bench All models: â Replace pushbutton switch of rear window blower by pushbutton switch with time function for heated rear window. Page 9 of 24
=> Electrical System; Repair Group 96; Servicing switches in centre console â â Pull trim cap -1- off stud -2-. Trim cap is no longer fitted. â â Check projection -a- of self-locking stud at fitting surface and adjust if necessary. â Dimension a = 33 mm Vehicles à 04.92 Page 10 of 24
â â Screw hexagon bolt - arrow- out of mounting bracket. â Screw in self-locking stud in place of hexagon bolt such that projection is 33 mm => Fig. A61-0044. All models: The following operations are illustrated with mounting bracket removed. â â Determine dimension between top edges of mounting bracket and stop bolt and note down value. â Value determined = 20 mm Page 11 of 24
â â Screw stop bolt -1- out of mounting bracket. â Screw on lock nut as far as bolt head. â â Attach washers to stop bolt until value noted down is attained with allowance for material thickness (4 mm) of reinforcement. Example: + Value determined with washers Thickness of reinforcement = Value noted down 16.0 mm 4.0 mm 20.0 mm Page 12 of 24
â â With convertible top open, fit reinforcement -1- for mounting bracket on left and right. â Screw in stop bolt -2-. â Tightening torque: 15 Nm â Re-measure height of stop bolt between top edges of mounting bracket and stop bolt and compare to value previously noted down. Adjust if necessary. â â Move convertible top manually to centre position. Page 13 of 24
â â Position collared nut -1- for securing reinforcement -2- on inside of mounting bracket and tighten. â Tightening torque: 20 Nm â â Position lower part of left and right mount -1- on mounting bracket. Lower part is marked L for left and R for right. â Hand-tighten special collared nut -3- on stud -4-. â Tighten hexagon nut -2- for clamping wedge. â Tightening torque: 9 Nm Page 14 of 24
â â Tighten special collared nut whilst providing support at stud with Allen key -1-. â Tightening torque: 20 Nm Attention: Always adhere to torque, as higher torque could cause thread in mounting bracket to tear. â â Lubricate mounting hole in lower part of mounting bracket with lubricating paste G 000 150. Page 15 of 24
â â Remove upper scuttle trim at windscreen frame => Page 66-10. â Cut 2 x 10 mm wide strips out of protective sheeting AKL 448 300 04. â Bond protective sheeting strip onto scuttle in area of openings for convertible top locking mechanism -arrow-. Bonding surface must be free from dust and grease. â Fit scuttle trim => Page 66-10. â Stow convertible top in compartment. â â Cut two 15 x 20 mm strips out of protective sheeting AKL 448 300 04. â Bond strips of protective sheeting -arrow- on left and right onto hold-down resting surface at front of convertible top. Bonding surface must be free from dust and grease. â Close convertible top compartment lid and make sure it locks properly. Page 16 of 24
â â Unfasten hexagon nuts - 1- (M6) and -2- (M8) at upper part of left and right mounting bracket at hardtop. Hexagon nuts are not to be screwed off. â â Grease claws of locking mechanism -arrow- at front of hardtop with lubricating paste G 000 150. Page 17 of 24
â â Fit hardtop with the help of a second mechanic. â Insert locking pin of upper part of mounting bracket at hardtop in lower part -arrow-. â Set down hardtop on scuttle. â â Lock front left and right of hardtop by turning T-handle key in direction of arrow as far as stop. Always make sure hardtop is properly locked => General Instructions, Page 61-139. Page 18 of 24
â â Lock rear left and right of hardtop by turning upper hexagon nut in direction of arrow as far as stop using open-ended spanner. â â Tighten hexagon nuts (M8) -arrows-. â Tightening torque: 20 Nm Page 19 of 24
â â Align hardtop with sides of vehicle. â Measure distance on left and right between hardtop and trim strip of convertible top compartment lid. â Align hardtop by way of lateral adjustment. â â Tighten hexagon nuts (M6) -arrows-. â Tightening torque: 9 Nm Page 20 of 24
â â Check height adjustment of hardtop. Hardtop must be locked when checking height adjustment. â Measure distance on left and right between trim strip of convertible top compartment lid and underside of hardtop. â Gap: 4 + 1 mm If reading exceeds or drops below specification: â â Slacken off lock nut -1- by one turn. Hardtop must be locked when adjusting height. â Adjust height of hardtop by turning hexagon nut -2-. â Clockwise = higher â Anti-clockwise = lower Page 21 of 24
â â After adjusting, hold hexagon -2- with open-ended spanner and lock hexagon nut -1- with special tool T40003. â â Attach connector -2- to connector -1-. â Slip foam sheath -3- over connector. â Stow connector in opening beneath flap for convertible top compartment catch. Page 22 of 24
â â Insert trim for hardtop catch on left and right between flap and hardtop - arrow-. â Close side windows. â â Spray water from bottle onto seals. If water ingresses into vehicle: â Adjust seals. Adjustment is always to be made at aluminium strips of hardtop, never at side windows. â Perform height adjustment. Page 23 of 24
â â Slacken off hexagon bolts -1-. â Alter height of compensating rail -2- in line with door window/rear side window. Adjustment is only possible as far as B-pillar. â Tighten hexagon bolts. â Tightening torque: 3 Nm â Perform lateral adjustment. â â Slacken off hexagon socket-head bolts -1-. â Move seal -2- sideways with reinforcing rail. â Tighten hexagon sockethead bolts. â Tightening torque: 3 Nm â Perform leak test again and repeat adjustment if necessary. â Perform final inspection in washing bay. Conversion to folding convertible top can be carried out by customer. => Audi Convertible Owner's Manual => Additional instructions for hardtop Page 24 of 24