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2004 CLK 240 Coupe
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Discussion Starter #1 (Edited)
If you suspect that you have a limit switch problem that is affecting the opening/closing operation of your soft top, what can you do?

You can pay a specialist to use diagnostic equipment to read your fault codes - or you can use a basic test meter and the circuit diagram of the power soft top control module (N52) to locate the problem.

[This thread can also be read in conjunction with the following post from the W209 stickies, which also shows the location of the limit switches discussed below. A circuit diagram of module N52 is also there, showing these external connections]

http://www.benzworld.org/forums/w209-clk-class/1677185-convertible-top-does-not-open.html#post5527380

List of limit switches that can be checked.

Soft Top group.

Soft Top UP is S84/3, Soft Top in CATCH position is S84/18, Soft Top LOCKED is S84/11.

Compartment Cover group.

Compartment Cover OPEN is S84/13s1, Compartment Cover CLOSED is S84/13s2, Compartment Cover in CATCH position is S84/22. Compartment Cover CLOSED is S84/23 (added post 06/2004)

Bow group

Bow UP is S84/15a, Bow DOWN is S84/15b, Bow LOCKED is S84/19.

Luggage Cover (Well)

Well CLOSED is S84/9, Ski Bag CLOSED is S84/20. (if fitted)

8 limit switches are connected to Power Soft Top control module N52.
2 limit switches are connected to CanBus.

A. Prepare for testing as follows: With roof closed, ignition off and key removed :

1. Open the trunk and locate module N52 behind covers. See WIS drawing below for location.

2. Remove connector 1. The checks will be done using the pins on the cable loom plug now visible.

3. Take a digital voltmeter and set the mode to Resistance and a low ohms range.

4. Connect (or just touch) the test meter's black lead to a good chassis earth, and use the red lead for the limit switch tests, checking for either short circuit (zero ohms), or open circuit (infinity ohms).Unless stated otherwise, it must be one or the other, as there should be minimal resistance in the path.

B. Do the limit switch checks as follows, where o/c = open circuit. s/c = short circuit.

Note: MB use 'mixed terminology' here.
Soft Top OPEN = Soft Top Down. Soft Top CLOSED = Soft Top Up.

*S84/3 Soft Top UP l/s.
Red test lead to pin 41 (gray/black wire)
Switch is o/c when ST is DOWN. Switch is s/c when ST is UP, ( i.e., fully closed.)

(S84/18 Soft Top in CATCH position l/s & S84/11 Soft Top LOCKED are routed to CanBus)


* S84/13s1 ST Compartment Cover CLOSED l/s
Red test lead to pin 44 (gray/green wire)
Switch is s/c when the Soft Top is closed & when the Compartment Cover is also closed.
This switch operates in series with S84/23 below.

*S84/23 ST Compartment Cover in CLOSED position l/s. (switch added after 06/2004)
This switch operates in series with S84/13s1 above.

Red test lead to pin 44 (gray/green wire)
Switch is s/c when the Soft Top is closed & when the Compartment Cover is also closed.

*S84/13s2 ST Compartment Cover OPEN l/s
Red test lead to pin 43 (gray/orange wire)
Switch is s/c when the Compartment Cover is open.

*S84/22 ST Compartment Cover in CATCH position l/s
Red test lead to pin 30 (gray/pink wire)
Switch is s/c when the Compartment Cover is in the catch position.

*S84/15s1 ST Bow UP l/s
Red test lead to pin 36 (red/brown wire)
Switch is s/c when the bow is vertical (approx)

*S84/15s2 ST Bow DOWN l/s
Red test lead to pin 49 (red/yellow wire)
Switch is s/c when the bow is fully down

Note: Between bow vertical and down the switch will be o/c.

*S84/19 ST Bow LOCKED l/s
Red test lead to pin 45 (grey/violet wire)
Switch is s/c when the bow is locked.

*S84/9 ST Well CLOSED l/s
Red test lead to pin 47 (red/grey wire)
Switch is s/c when the well is closed. (also referred to as Luggage Cover)

*S84/20 Ski Bag CLOSED l/s
Red test lead to pin 46 (red/white wire)
Switch is s/c when the Ski Bag is closed

Switch functions, locations and add/remove details are shown on the WIS drawings below. Please advise any errors or improvements in this post.

(continued on page 2 with more drawings)
 

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Coupe/Convertible Forums Moderator
CURRENT: 2011 SL550, 2011 C300 FORMER: ML350, CLK550 Cabriolet, C240, ML320, 300TD
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Great info - thanks Keyhole!
 

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03 SL Kleemann, 97 SL320, 95 E320 cab, Tesla X, Ferrari 360, etc
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Excellent - I know that this info will be helping many CLK owners out there!

Future readers, please post your success stories or other useful comments... :thumbsup:

Klaus

www.tophydraulicsinc.com
 

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Corrections/Variations I found...

On my 2009 CLK 550 there were a couple corrections/variations from the suggestions above:

S84/3 is o/c when the top is up and s/c when the top is down. I removed the switch and confirmed this is the way it functions based on the cams in it.

Also, S84/19 is on pin 35, not 45.
 

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2004 CLK 240 Coupe
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11,367 Posts
Discussion Starter #6
On my 2009 CLK 550 there were a couple corrections/variations from the suggestions above:

S84/3 is o/c when the top is up and s/c when the top is down. I removed the switch and confirmed this is the way it functions based on the cams in it.
You could well be right here. It is logical that 'soft top OPEN limit switch' is True, ie., closed when the top is down.

Also, S84/19 is on pin 35, not 45.
You are quite correct, sir. My error here.

Many thanks for the feedback!
 

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2008 AMG CLK63 Conv., 2012 R350 4-Matic, Wife's 2015 C300 sedan
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9,376 Posts
Both our CLK convertibles are having trouble right now due to the microswitches onn the little fold-down thing in the trunk (boot) saying it's up when it's really down.

Bloody typical this should happen when it's about the only time of year you'd want to use them in Houston!

Is there any way to adjust these rather than flat out replace them? Can I put duct tape over them and risk the consequences?
 

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2008 AMG CLK63 Conv., 2012 R350 4-Matic, Wife's 2015 C300 sedan
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9,376 Posts
PS How can I persuade my wife to climb into the trunk (boot) and close the lid while I fold the soft-tops down on her? Is there an "iron maiden" accessory I can buy to add to the (my) fun?
 

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Coupe/Convertible Forums Moderator
CURRENT: 2011 SL550, 2011 C300 FORMER: ML350, CLK550 Cabriolet, C240, ML320, 300TD
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Replace the Lift-O-Mat struts on the trunk partition. RMEuropean as them for about $22 each. With good struts, the partition will hold tightly in the open or closed position. With weak struts, it doesn't hold strongly and won't engage the switch.
 

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2008 AMG CLK63 Conv., 2012 R350 4-Matic, Wife's 2015 C300 sedan
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9,376 Posts
Our partitions are manual. Does this still apply?
 

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2008 AMG CLK63 Conv., 2012 R350 4-Matic, Wife's 2015 C300 sedan
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9,376 Posts
Okay. Thanks. I shall check prices and if I can fit them myself.
 

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2008 AMG CLK63 Conv., 2012 R350 4-Matic, Wife's 2015 C300 sedan
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9,376 Posts
Do you think I can still get away with the iron Maiden thing on the wife? ;-)
 

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Many Thanks Klaus! My soft top is working again

After testing every limit switch in the soft top and determining they were working, I sent my pump to Klaus Witte at Top Hydraulics. Let me say this, it is great that there's someone like Klaus out there to help with this stuff. 1 day after he got it, it was on its way back completely rebuilt. I reinstalled it and followed his recommendations for start up. It is now working fine, and I'm pretty proud I "almost" did it myself; were it not for Klaus' help, I'd still have a hardtop. I give my highest recommendation for Klaus Witte & Top Hydraulics. Great resource for these over-engineered marvels.
 

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03 SL Kleemann, 97 SL320, 95 E320 cab, Tesla X, Ferrari 360, etc
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gssmith1986, you're a trooper! It is very kind of you to follow up with such a glowing recommendation, after you had already contributed to this forum by correcting some details in keyhole's original, very helpful post.

I just looked at the rebuild log on your pump, and it turns out that you had a fried motor on the pump. It was seriously melted inside, and we replaced it with one of ours. One of our pump rebuilders actually used to do nothing but rewind electrical motors for a living, and we have learned a lot from him. We rewind the motors with heavier gauge copper wire and more wire loops, which results in less current drawn for the same output power and much less heat developed. In practical terms, this means the following:
1) You can cycle the top continuously for more cycles before the motor overheats,
2) the temperature sensor inside the pump has more time to signal overheating to the soft top controller, and
3) less current drawn by the motor makes a future relay failure less likely (of course, we install new high-current relays on each pump rebuild that we ship back).

There are many ways that the CLK convertible top motors can fail, and of course we go through the whole pump with a fine-tooth comb.

Rebuild/upgrade includes:
- Two new relays
- Service of electric motor and solenoids
- Upgrade of internal components in motor's electronics
- Replacement of electric motor if needed
- Upgrade of pump seals
- Thorough check of pump pistons (and replacement if necessary)
- Service and upgrade of internal valves
- Extensive final testing for output pressure, output flow, valve function, thermal behaviour, etc.

Pump part numbers for reference, depending on W209 model:

2098000148 aka A 209 800 01 48
2098000248 aka A 209 800 02 48
2098000548 aka A 209 800 05 48
2098000648 aka A 209 800 06 48

Part numbers displayed on the pump's sticker:
2098000030 or A 209 800 00 30
2098000330 or A 209 800 03 30
2098000130 or A 209 800 01 30
2098000530 or A 209 800 05 30
2098000630 or A 209 800 06 30

See Rebuild Service for '03-'09 Mercedes W209 CLK-Class Hydraulic Pump - Top Hydraulics, Inc

Klaus

 

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CLK 2003 (early W209)
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31 Posts
Soft top won't go up

Hi guys,

A year ago, I bought a 2003 Clk 200 and since than the thing has caused me trouble. The latest problem is again with the soft top (I had to replace the struts of the luggage compartment after I bought it). The problem started a few months ago with the top unwilling to go up again when I was at the railway station heading for work 😡 (had to drive back home,clean out the garage and head back to the station).

After getting the top manually up again (2003, so manual = pain in the ass), it worked fine again. This has happened a couple of times but now the problem no longer intermittent. When the top is up there is no problem getting it down, but if it's down, it gives the message "visit workshop".

Thanks to this thread I've able to test the switches, but so far I see nothing strange. Measurements:
Top up:
S84/13s1 s/c
S84/13s2 o/c
S84/22 o/c
S84/19 s/c
S84/3 o/c
S84/9 s/c
S84/20 o/c
S84/15s1 o/c
S84/15s2 s/c

Top down
S84/13s1 s/c
S84/13s2 o/c
S84/22 o/c
S84/19 o/c
S84/3 s/c
S84/9 s/c
S84/20 o/c
S84/15s1 o/c
S84/15s2 s/c

So only switches S84/3 and S84/19 change in both positions.

Anybody any clue. Thanks guys
 

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You have a W208, so the info in this thread does not apply to it. You might want to check that forum for better help as those guys will be more familiar with your model.
 

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CLK 2003 (early W209)
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Thanks rudeney for your reply. I have an early W209, the ones without bypass valve on the cylinders of the top cover ... A lot of "fun" to open and close manually.
 

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CURRENT: 2011 SL550, 2011 C300 FORMER: ML350, CLK550 Cabriolet, C240, ML320, 300TD
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Oh, I see now you are in Belgium, so you are referring to "plate year" which has really nothing to do with model year. I know, it's confusing, but you can blame the 1960's auto industry for all that! So anyhow...

First, to make the soft top cover easier to operate manually, you can unhook the hydraulic cylinders from it. They have clips on top where they attach. They unsnap and then rotate out of the way to allow the strut to be removed - no tools required (well, maybe a screwdriver to keep from hurting your fingers).

Now, exactly what does the top do when you try to close it? Does anything move and then stop, or do you immediately get the "visit workshop" message? I can tell you this has nothing to do with the luggage partition (or ski bag, if you have that option); those will never give a "visit workshop" message, but instead will say "close partition". The "visit workshop" message only occurs when an implausible reading of the top position (based on reports from the microswitches) occurs. Or, if the Soft Top Controller itself is malfunctioning.

The best way to find out what's going on is to scan the Soft Top Controller for error codes. A generic OBDII tool won't do that. You need SDS, or a cheaper/simpler tool like iCarsoft i980.

Regarding your readings, I don't understand the s1/s2 on A84/13. That's the "Cover Opened Limit Switch" and there's only one, at the top of the left-side cylinder that raises the cover. But there are two of the S84/22 "Cover Closed" switches, behind each headrest. Those should be in sync - if not, you may have a bad one.
 

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CLK 2003 (early W209)
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Sorry my fault, I hadn't filled in my any details before my first post. So you couldn't know my country ...

My interpretation of the schematic is that on pin44 I find the switch S84/13s1 with in series the switch S84/23 "cover closed". And I've unmounted the switches S84/13 as they are easily accessible and it's 3 wire and 2 micro switches (no errors in them).

When the roof is down and I push the button, nothing moves and I immediately get the message "visit workshop "

Thanks for the suggestion around the 980i. I was going to ask if it would read these switch problems. I start to think it is in the 2 switches that are connected through CAN-bus.
 
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