Installing hardtop — AUDI

Lower side windows as far as they will go.
Retract (if necessary unscrew) radio aerial.
Switch off ignition.
If necessary, remove wind deflector.

Open flaps for convertible top compartment lid catch on left and right.
Guide seat belt around flap as shown.

Vehicles ä 07.96:

Remove rear seat bench.

=> General Body Repairs, Interior; Repair Group 72; Rear seat; Removing and installing rear seat bench
General Body Repairs, Interior
Rear seat
Removing and installing rear seat bench

Remove rear seat backrest.

=> General Body Repairs, Interior; Repair Group 72; Rear seat; Removing and installing rear seat backrest
General Body Repairs, Interior
Rear seat
Removing and installing rear seat backrest

Remove rear left side padding.

=> General Body Repairs, Interior; Repair Group 72; Rear seat; Removing and installing side padding
General Body Repairs, Interior
Rear seat
Removing and installing side padding

Remove rear left side trim.

=> General Body Repairs, Interior; Repair Group 70; Side Trim; Removing and installing rear side trim
General Body Repairs, Interior
Side Trim
Removing and installing rear side trim

Unplug connector -1- at blower for rear window -2-.
Remove blower for rear window with bracket.

=> Electrical System; Repair Group 96; Servicing blower for rear window
Electrical System
Servicing blower for rear window

Unfasten cable ties from bitumen mat.
Unscrew self-tapping hexagon nuts for securing bitumen mat.
Detach bitumen mat.

Move convertible top manually to centre position.
Lay summer/winter wiring harness.

Attach wiring-harness connector with adhesive strip to welding wire.
Lift bottom trim in convertible top compartment on left.

With the aid of the welding wire, guide wiring harness -1- at water hose through body opening on left -arrow-.

Note:

Any other routing could lead to damage caused by convertible top linkage or window lifter mechanism.

Clip wiring harness -1- into rubber grommet -2-.

Attach connector of wiring harness -2- to connector -1- of wire for rear window blower -arrow-.

Vehicles with electrohydraulic convertible top actuator mechanism:

Unplug connector -arrow- to convertible top control unit.

Attach connectors of new wiring harness -1- for convertible top control unit to existing connectors -2-.

Vehicles ä 07.96:

Fit bitumen mat.

Lay new summer/winter wiring harness in front of bitumen mat.
Re-attach cable ties at same locations.
Install blower for rear window.

=> Electrical System; Repair Group 96; Servicing blower for rear window
Electrical System
Servicing blower for rear window

Attach connector -1- to blower for rear window -2-.

Vehicles with manual convertible top actuator mechanism:

Stow convertible top in compartment.

Close convertible top compartment lid and open luggage compartment.
Remove left luggage compartment trim.

=> General Body Repairs, Interior; Repair Group 70; Trim; Removing and installing luggage compartment trim
General Body Repairs, Interior
Trim
Removing and installing luggage compartment trim

Unplug connector of convertible top micro-switch -arrow- in area of rear left wheel housing.

Attach adapter lead -1- between unplugged connectors -2- of convertible top micro-switch.
Route adapter lead through opening in body towards convertible top compartment.
Close luggage compartment.

Open convertible top compartment.
Move convertible top manually to centre position.
Lift bottom trim in convertible top compartment on left.

Pull wiring harness with adapter lead for convertible top micro-switch -1- with connector -2- into convertible top compartment.
Stow convertible top in compartment.
Close convertible top compartment lid and open luggage compartment.
Install left luggage compartment trim.

=> General Body Repairs, Interior; Repair Group 70; Trim; Removing and installing luggage compartment trim
General Body Repairs, Interior
Trim
Removing and installing luggage compartment trim

Close luggage compartment.

Vehicles ä 07.96:

Open convertible top compartment.
Move convertible top manually to centre position.
Lift bottom trim in convertible top compartment on left.

Attach connector to short wire of summer/winter wiring harness using cable tie -arrow-.
Route connector with long wire of summer/winter wiring harness out over left wing.

Note:

Do not connect heated rear window until hardtop has been installed.

Install rear left side trim.

=> General Body Repairs, Interior; Repair Group 70; Side Trim; Removing and installing rear side trim
General Body Repairs, Interior
Side Trim
Removing and installing rear side trim

Install rear left side padding.

=> General Body Repairs, Interior; Repair Group 72; Rear seat; Removing and installing side padding
General Body Repairs, Interior
Rear seat
Removing and installing side padding

Install rear seat backrest.

=> General Body Repairs, Interior; Repair Group 72; Rear seat; Removing and installing rear seat backrest
General Body Repairs, Interior
Rear seat
Removing and installing rear seat backrest

Install rear seat bench.

=> General Body Repairs, Interior; Repair Group 72; Rear seat; Removing and installing rear seat bench
General Body Repairs, Interior
Rear seat
Removing and installing rear seat bench

All models:

Replace pushbutton switch of rear window blower by pushbutton switch with time function for heated rear window.

=> Electrical System; Repair Group 96; Servicing switches in centre console
Electrical System
Servicing switches in centre console

Pull trim cap -1- off stud -2-.

Note:

Trim cap is no longer fitted.

Check projection -a- of self-locking stud at fitting surface and adjust if necessary.
Dimension a = 33 mm

Vehicles ä 04.92

Screw hexagon bolt -arrow- out of mounting bracket.
Screw in self-locking stud in place of hexagon bolt such that projection is 33 mm => Fig. A61-0044.

All models:

Note:

The following operations are illustrated with mounting bracket removed.

Determine dimension between top edges of mounting bracket and stop bolt and note down value.
Value determined = 20 mm

Screw stop bolt -1- out of mounting bracket.
Screw on lock nut as far as bolt head.

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 · 16.0 mm
+ · Thickness of reinforcement · 4.0 mm
= · Value noted down · 20.0 mm

With convertible top open, fit reinforcement -1- for mounting bracket on left and right.
Screw in stop bolt -2-.
Tightening torque: 15 Nm

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.

Move convertible top manually to centre position.

Position collared nut -1- for securing reinforcement -2- on inside of mounting bracket and tighten.
Tightening torque: 20 Nm

Position lower part of left and right mount -1- on mounting bracket.

Note:

Lower part is marked L for left and R for right.

Hand-tighten special collared nut -3- on stud -4-.
Tighten hexagon nut -2- for clamping wedge.
Tightening torque: 9 Nm

Tighten special collared nut whilst providing support at stud with Allen key -1-.
Tightening torque: 20 Nm

Attention:
Always adhere to torque, as higher torque could cause thread in mounting bracket to tear.
Lubricate mounting hole in lower part of mounting bracket with lubricating paste G 000 150.

Remove upper scuttle trim at windscreen frame => Page
66-10
.
Cut 2 x 10 mm wide strips out of protective sheeting AKL 448 300 04.
Bond protective sheeting strip onto scuttle in area of openings for convertible top locking mechanism -arrow-.

Note:

Bonding surface must be free from dust and grease.

Fit scuttle trim => Page
66-10
.

Stow convertible top in compartment.

Cut two 15 x 20 mm strips out of protective sheeting AKL 448 300 04.
Bond strips of protective sheeting -arrow- on left and right onto hold-down resting surface at front of convertible top.

Note:

Bonding surface must be free from dust and grease.

Close convertible top compartment lid and make sure it locks properly.

Unfasten hexagon nuts -1- (M6) and -2- (M8) at upper part of left and right mounting bracket at hardtop.

Note:

Hexagon nuts are not to be screwed off.

Grease claws of locking mechanism -arrow- at front of hardtop with lubricating paste G 000 150.

Fit hardtop with the help of a second mechanic.
Insert locking pin of upper part of mounting bracket at hardtop in lower part -arrow-.
Set down hardtop on scuttle.

Lock front left and right of hardtop by turning T-handle key in direction of arrow as far as stop.

Note:

Always make sure hardtop is properly locked => General Instructions, Page
61-153
.

Lock rear left and right of hardtop by turning upper hexagon nut in direction of arrow as far as stop using open-ended spanner.

Tighten hexagon nuts (M8) -arrows-.
Tightening torque: 20 Nm

Align hardtop with sides of vehicle.
Measure distance on left and right between hardtop and trim strip of convertible top compartment lid.
Align hardtop by way of lateral adjustment.

Tighten hexagon nuts (M6) -arrows-.
Tightening torque: 9 Nm

Check height adjustment of hardtop.

Note:

Hardtop must be locked when checking height adjustment.

Measure distance on left and right between trim strip of convertible top compartment lid and underside of hardtop.
Gap: 4 + 1 mm

If reading exceeds or drops below specification:

Slacken off lock nut -1- by one turn.

Note:

Hardtop must be locked when adjusting height.

Adjust height of hardtop by turning hexagon nut -2-.
Clockwise = higher
Anti-clockwise = lower

After adjusting, hold hexagon -2- with open-ended spanner and lock hexagon nut -1- with special tool T40003.

Attach connector -2- to connector -1-.
Slip foam sheath -3- over connector.
Stow connector in opening beneath flap for convertible top compartment catch.

Insert trim for hardtop catch on left and right between flap and hardtop -arrow-.

Close side windows.
Spray water from bottle onto seals.

If water ingresses into vehicle:

Adjust seals.

Note:

Adjustment is always to be made at aluminium strips of hardtop, never at side windows.

Perform height adjustment.

Slacken off hexagon bolts -1-.
Alter height of compensating rail -2- in line with door window/rear side window.

Note:

Adjustment is only possible as far as B-pillar.

Tighten hexagon bolts.
Tightening torque: 3 Nm

Perform lateral adjustment.

Slacken off hexagon socket-head bolts -1-.
Move seal -2- sideways with reinforcing rail.
Tighten hexagon socket-head bolts.
Tightening torque: 3 Nm

Perform leak test again and repeat adjustment if necessary.
Perform final inspection in washing bay.

Note:

Conversion to folding convertible top can be carried out by customer.

=> Audi Convertible Owner's Manual

=> Additional instructions for hardtop