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Home >> Saab >> 2010 >> 9-3X Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 49 (Convertible Top) >> Repair Instructions >> Replacing the hydraulic lines and wiring harness, front bow >> To fit

To fit

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  1. Carefully thread the lines through the soft top eyes.
    IMPORTANT: Hydraulic lines must be refitted as they were earlier or there will be a risk of them being damaged when the soft top is operated.
    Fig 1: Locating Soft Top Eyes
    G05566537Courtesy of SAAB-SCANIA OF AMERICA, INC.
  2. Secure the cable duct to the hinge with clips and refit the hinge's metal clips.
    Fig 2: Identifying Hinge Metal Clips
    G05566538Courtesy of SAAB-SCANIA OF AMERICA, INC.
  3. Fit chafe protection tape and secure the lines with new cable ties in the metal clips.
    Fig 3: Identifying Cable Ties
    G05566539Courtesy of SAAB-SCANIA OF AMERICA, INC.
  4. Fit the headlining right-hand corner.
  5. Fit the lines in place and secure them with new cable ties.
    Fig 4: Illustration For Step 5-6
    G05566540Courtesy of SAAB-SCANIA OF AMERICA, INC.
  6. Fit the soft top storage hinge.
  7. Fit sleeve 21 (brown) and sleeve 12 (black) in the connector.
    Fig 5: Illustration For Step 7, 12 And 21
    G05063430Courtesy of SAAB-SCANIA OF AMERICA, INC.
  8. Plug the connector together.
    Fig 6: Plugging Connector
    G05063431Courtesy of SAAB-SCANIA OF AMERICA, INC.
  9. Tape the exposed wires close to the connector.
  10. Plug the connector into the control module.
    Fig 7: Illustration For Step 10-11
    G05566543Courtesy of SAAB-SCANIA OF AMERICA, INC.
    IMPORTANT: Take care when plugging in the connector so as not to damage or press out the pins/sleeves in the connector. For further information regarding connectors, refer to CONNECTORS, HANDLING AND INSPECTION .
  11. Insert the new hydraulic lines in the attaching plate in position no. 65 and 66.
  12. Fit new circlips to the two new hydraulic lines:
    Fig 8: Identifying Circlips
    G05063433Courtesy of SAAB-SCANIA OF AMERICA, INC.
  13. Fit new O-rings on the new hydraulic lines:
    Fig 9: Illustration For Step 13-14
    G05063434Courtesy of SAAB-SCANIA OF AMERICA, INC.
  14. Remove the special tool.
  15. Place the attaching plate together with the hydraulic lines in mounting position.
    Fig 10: Illustration For Step 15-16
    G05063435Courtesy of SAAB-SCANIA OF AMERICA, INC.
  16. Fit and tighten the bolts for the hydraulic line attaching plate.
  17. Wipe away any spilled oil.
  18. Align the hydraulic unit in the fitting position and fit the hydraulic unit's nuts.
    Fig 11: Illustration For Step 18-19
    G05063436Courtesy of SAAB-SCANIA OF AMERICA, INC.
  19. Secure the lines with cable ties.
  20. Fit the soft top storage. See Soft top storage .
  21. Plug in the connector and secure the lines with cable ties.
    Fig 12: Identifying Lines With Cable Ties
    G05566548Courtesy of SAAB-SCANIA OF AMERICA, INC.
  22. Replace the O-rings at the hydraulic cylinder's connections with new ones.
  23. Fit the hydraulic lines on the hydraulic cylinder by pressing them in. Take care so as not to damage the seal.
    Fig 13: Identifying Hydraulic Lines
    G05566549Courtesy of SAAB-SCANIA OF AMERICA, INC.
  24. Fit the chafe protection tape on the line assembly and fit the line assembly clips.
    Fig 14: Identifying Clips
    G05063439Courtesy of SAAB-SCANIA OF AMERICA, INC.
  25. Put the hydraulic cylinder in mounting position. Fit the clip to the hydraulic cylinder piston rod.
    Fig 15: Illustration For Step 25-27
    G05566551Courtesy of SAAB-SCANIA OF AMERICA, INC.
  26. Fit the fastening pin to the hydraulic cylinder.
  27. Fit the cable lock to the fastening pin.
  28. Turn the lock hooks to open them.
  29. Untwist the line assembly and position the two hydraulic lines (grey) closest to the brackets with the electrical cable (white) on the outside of the hydraulic lines. The line assembly must be shaped like a triangle with the electrical cable on the outside, see Fig 16.
    Fig 16: Identifying Hydraulic Lines (Grey) And Electrical Cable (White)
    G05063441Courtesy of SAAB-SCANIA OF AMERICA, INC.
    NOTE: The electrical cable has a smoother surface than the hydraulic lines.
  30. Secure the line assembly in the brackets with cable ties; tighten loosely. Fit the cable ties so that their heads are located uppermost on top of the line assembly.
    Fig 17: Identifying Brackets With Cable Ties
    G05063442Courtesy of SAAB-SCANIA OF AMERICA, INC.
  31. Fit 12 765 358 FITTING TOOL, CV  and position the line assembly on the top of the tool.
    Fig 18: Identifying Fitting Tool (12 765 358)
    G05063443Courtesy of SAAB-SCANIA OF AMERICA, INC.
  32. Tighten the cable ties and cut off any excess.
    Fig 19: Identifying Cable Ties
    G05063444Courtesy of SAAB-SCANIA OF AMERICA, INC.
  33. Remove the fitting tool.
  34. Fit a small cable tie in the position between the center and front rail.
  35. Operate the soft top to its center position; the soft top first bow must point straight up.
    WARNING: Risk of pinching that can result in serious injury if the soft top is released in a semi-raised position (when standing straight up) as it could fall either forward or rearward depending on where the center of gravity is situated.
  36. Fit the outer roof on the right-hand side of the first bow.
    Fig 20: Identifying Outer Roof
    G05063445Courtesy of SAAB-SCANIA OF AMERICA, INC.
  37. Fit the center rail seal.
    Fig 21: Illustration For Step 37-38
    G05063446Courtesy of SAAB-SCANIA OF AMERICA, INC.
  38. Fit the screw and the seal to the front rail.
  39. Open the soft top and leave the soft top cover open.
  40. Fit the headlining plastic plugs and hook in the outer roof attachment eye on the right-hand side of the first bow.
    Fig 22: Illustration For Step 40-41
    G05063447Courtesy of SAAB-SCANIA OF AMERICA, INC.
  41. Fit the headlining attachment eyes to the first bow on the right-hand side.
  42. Operate the soft top to check that the line assembly does not get trapped or twist.
    Fig 23: Identifying Cable Tie
    G05063448Courtesy of SAAB-SCANIA OF AMERICA, INC.
  43. Operate the soft top for 5 complete cycles in order to bleed the system and check the function. Check that the lines are positioned correctly and that there is no risk of them becoming trapped in the hinges.
  44. After hydraulic line replacement:  Fill oil in the reservoir up to the MAX mark. See CHECKING/FILLING OIL .
  45. After hydraulic line replacement:  Check that there is no leakage of oil at any point.
  46. Open the soft top and leave the soft top cover open.
  47. Fit the trim.
    Fig 24: Illustration For Step 47-49
    G05063449Courtesy of SAAB-SCANIA OF AMERICA, INC.
  48. Fit the mounting plate with the clips.
  49. Fit the clips' center pins to the mounting plate.
  50. Raise the soft top fully.
  51. Connect the diagnostics tool and erase any diagnostic trouble code.
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