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Thread: Manual Closing of the Audi TT (8J) Convertible Top and VCDS Related Issues

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    Verified VCDS User SwissJetPilot's Avatar
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    Manual Closing of the Audi TT (8J) Convertible Top and VCDS Related Issues

    Here's some additional help for anyone with a failed top:
    http://www.ttforum.co.uk/forum/viewt...f=43&t=1347177

    Further soft top assitance is available here:
    http://www.ttforum.co.uk/forum/viewt...?f=19&t=622842

    If you're a roadster owner, you should also be aware of SSP 391 which can be found here...
    https://www.google.com/url?sa=t&rct=...OsNA8_HocxVTsQ

    Typical roof error codes -

    02000 Switch Position 008 - Implausible Signal
    03246 - Sensor for Canopy Flap; Left (G596)E
    03247 - Sensor for Canopy Flap; Right (G597)
    00446 - Function Limitation due to Under - Voltage

    These are typically found when you get the "Soft top not secure" message in the DIS and/or if the roof warning light (E137) is flashing. In either case, these warnings will let you know the convertible control switch in the center console will no longer function. Is possible to have an implausible signal error and still get the top to work without having to scan and clear this error with the VCDS as the controller is simply waiting for the implausible signal to be cleared. This can be done by manually opening and closing the top with the ignition in the first position so the controller receives the correct sequence of events as noted below.

    One of the most common causes of roof failure is opening the roof while in motion. While the TT is designed to be able to do this under 50kph, it's bad practice. Any significant shift in the alignment of the frame (side to side, or fore to aft) can cause the sensors to trigger a fault. If you open the top while moving, a sudden gust of wind, pothole or sudden swerve can trigger a fault and generate an "Implausible Signal" fault.

    This usually happens if the top pushes sideways against the roof flaps while the top and/or flaps are in motion. The pressure against the flaps may generate an unexpected potentiometer reading, triggering the fault. When this happens, the system may generate canopy flap error and render the center console switch unuseable and bring up the DIS message "soft top not secure" even when the flap motors are perfectly fine. This same situation can also happen if you open the top while the TT is parked sideways on a steep incline which may causing the top to "lean" right or left during operation. Again, the top may "lean" just enough to push against the roof flaps and trigger an error.

    In cases where you suspect the flap motors are actually okay, and the errors were probably due to the top getting out of alignment (as mentioned above) you may want to put the ignition into the first position and manually cycle the top (open and close). This way the sensors and switches will be cycled and provide the controler with the correct sequence it expects. This often clears the faults and the top will function normally.
    Last edited by SwissJetPilot; 09-25-2017 at 02:54 AM.

  2. #2
    Verified VCDS User SwissJetPilot's Avatar
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    Convertible Top Flap Servo R&R

    Overview –

    The Convertible Top Flap Servo has two primary components; the Motor (V381/V383) and the Potentiometer (G596/G597). When energized, the motor drives the potentiometer gears which move the servo arm and ball link to raise and lower the flaps. The potentiometer sends a real-time position signal to the J256 Convertible Top Operational Control Unit so it knows if the flap is open or closed. If the potentiometer value is outside the expected range, it will generate an implausible signal error and stop the top from further operation.

    Further investigation of this topic on other Audi TT sites revealed that excessive grease on the Servo Potentiometer contacts is very common. This may be causing a fault error (implausible signal) during VCDS scans. Simply replacing it with a new Servo may not make the problem go away if the new Servo has the same problem. The only way to know for sure is to open up the Servo case and perform an inspection. If excessive grease is noted on the contacts, clean them as described in this post. If, after reassembly, the fault still exists, at least you’ve eliminated one possible cause. If the fault does goes away, you just saved yourself the cost of a new Servo.

    Getting Started –

    The Servo Flap Motors can be removed without having to remove the Flap Assembly. By doing it this way you won't have to worry about Flap Assembly misalignment issues. But if you're having trouble getting to the three Torx screws, then you can remove the four bolts that hold the Flap Assembly in place and then remove the Servo from the Flap Assembly. See page 8 of this link - viewtopic.php?f=19&t=622842&start=105

    CAUTION - It's a good idea to place a towel around this area to prevent anything from falling into the "abyss" as recovering a dropped part will be more of challenge than R&R of the Servo.

    Tools –
    1. Torx driver
    2. Plastic card (old credit card will work)
    3. Isopropyl alcohol or electrical contact cleaner
    4. Clean cloth, cotton swabs or soft brush

    Removal of the Servo –
    1. Open the convertible top.
    2. Disconnect the ball-link from the flap.
    3. Unscrew and remove the three Torx screws holding the Servo Motor to the Flap Assembly.
    4. Disconnect the plug.

    Opening the Servo Case –
    1. Use an old credit card, similar plastic card, and cut it into 1/2” wide strips. Insert one strip into each of the seven (7) clips to disengage them. This will minimize the risk of breaking the clips with a screwdriver. Note - it may be necessary to peel away the Audi product sticker.

    Servo Case Opened –
    1. Once the Servo Case is open, you will see the two major components; the Motor and the Potentiometer. The potentiometer has two parts, the Contact Gear and the circuit board traces.
    2. Use a permanent marker and draw a line on the Contact Gear and the worm gear that drives it as a reference point for reassembly.
    3. Remove the Contact Gear to access the fixed circuit board traces by applying a light pressure on the Servo Axel and gently remove the Contact Gear. NOTE - Use caution as there are three very small contacts on the other side of the Contact Gear.
    4. De-grease and clean the Contact Gear contacts and the circuit traces. Note - you can reused the grease anywhere it’s missing, but a little goes a long way.
    5. Once clean, reinstall the Contact Gear and Servo Axel. Remember to install the Servo Axel so that the Actuator Rod is in the same position when it was disassembled, otherwise it may not be possible to attach it to the flap.

    Reinstallation of the Servo -
    1. Connect the plug.
    2. Attach the Servo Motor to the Flap Assembly with the three Torx screws. (No torque value is given in the Workshop Manual, but don’t over tighten!)
    3. Connect the ball-link to the flap.

    Cycle the Convertible Top -
    1. After everything is back together, start the car and cycle the top open and closed a few times using the Convertible Top Switch (E137) in the center console. This should clear any error codes.
    2. If this fails to clear error codes, then a VCDS Adaption is required.

    VCDS Adaption of the Flap Motors -

    When performing repairs/replacement of the Flap Motors it will be necessary to perform the Adaption of the Flap Motors.

    [Select]
    [26 - Auto Roof]
    [Output Tests - 03]
    [Select] Selective Output Tests
    [Choose]Convertible Top Flap Initialisation
    [Start]
    Operate the Convertible Top throughout a complete Open/Close sequence BEFORE exiting the Output Test function.
    [Done, Go Back]
    [Close Controller, Go Back - 06]


    For additional information on VCDS codes, please refer to the Ross-Tech website -
    http://wiki.ross-tech.com/wiki/index.ph ... Procedures

    For additional information on Convertible Top issues, please visit the UK Audi TT Forum - http://www.ttforum.co.uk/forum/viewforum.php?f=19

    For more information on the operation of the convertible top and all the system components, refer to Audi TT Roadster, Self Study Program 391. It can be found in the Knowledge Base section under FAQ - Audi Owners Manuals & Technical Documents -
    Last edited by SwissJetPilot; 03-24-2018 at 12:30 AM.

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