Removal and Installation

CONVERTIBLE TOP ASSEMBLY

REMOVAL

CAUTION: To prevent any scratches to the vehicle, cover the surfaces with a protective material.

Part 1:

Part 2:

Part 1:

Part 2:

Part 1:

Part 2:

1. Remove the parts in the order indicated in the illustration and table.

Item 1: Top Well Sling Interior Trim Cover Removal Note

1. CAUTION: Do not try to disconnect the rear window defrost grid connector from the rear window glass.

Disconnect the rear window grid wire electrical connectors and route them through the well sling.

Item 2: Convertible Top Tack Strip Nuts Removal Note

1. Remove both front headliner screws from the convertible top assembly.

Item 3: Side Tack Strip Trim Removal Note

1. After removing the tack strip trim plates, position the rear of the convertible top upwards for access.

Item 6: Lift Cylinder Bolts Removal Note
1. The convertible top must be in the up position to remove the bolts

Item 7: Lift Cylinder Removal Note
1. The lift cylinders and motor must be removed as an assembly.

2. NOTE: Prior to their removal, mark the upper and lower hydraulic lines to insure correct installation on the new lift cylinder.

Remove the hydraulic lines from the lift cylinder.

Item 11: Hard Top Locator Brackets Removal Note

1. Remove the covers to access the locator brackets.

2. On the RH locator bracket disconnect the electrical connector.

Item 15: Hydraulic Motor And Pump Assembly Removal Note
1. The lift cylinders and motor must be removed as an assembly.

2. NOTE: Prior to removal, mark the hydraulic lines to insure correct installation of the motor assembly.

Remove the hydraulic lines from the motor assembly.

Item 16: Convertible Top Bolts Removal Note
1. Loosen but do not remove the lower bolt from the top.

Item 17: Convertible Top Assembly Removal Note
1. An assistant is required to remove the top assembly.

Item 19: Header Locator Mark Removal Note
1. Mark the convertible top material to the front edge of the convertible top header using a grease pencil.

Item 22: Header Tack Strip Removal Note

1. Remove the staples from the header and loosen the convertible top material from the header.

Item 26: Front Weather Seal Retainer Removal Note

1. Remove both front headliner screws from the convertible top assembly.

Item 27: Rear Weather Seal Removal Note
1. Cycle the convertible top upwards toward the closed position.

Item 30: Assist Strap Rivets Removal Note

1. Disconnect the 2 top assist straps from the convertible top frame. Remove the 2 rivets.

Item 32: Mark Location Removal Note
1. Mark the location of the top to the rear tack strips

Item 33: Staples Removal Note

1. CAUTION: Use caution not to damage the convertible top.

Remove enough staples to free the top cover from the 3 tacking strips.

Item 34: Convertible Top Material Removal Note

1. Mark the winter seal at the top, bottom and the forward edge of the rear tacking strip using a grease pencil.
2. Lift the rear cover assembly over the convertible top exposing the top of the rear window glass assembly shroud.

3. CAUTION: Do not remove staples from the stay pads.

Mark the center of the rear window glass assembly shroud to the number four bow using a grease pencil and remove all of the staples along the number four bow from the top material listing, insulator pad, headliner listing, and corner Velcro(R) pieces.

4. Remove the convertible top material from the vehicle and place on a workbench. Transfer the markings from the old convertible top material to the new convertible top material and mark the holes for the sail panel bracket and screw on each side using a grease pencil.

Item 35: Velcro Strip Removal Note
1. Do not remove the staples from the stay pad.

Item 39: Mark Location Removal Note
1. Mark the location of the center of the rear window glass curtain assembly.

Item 40: Staples Removal Note
1. Do not remove the staples from the stay pad.

Item 41: Rear Window Glass Curtain Assembly Removal Note
1. Place the rear window glass curtain over the new rear window glass curtain and transfer the location markings

Item 42: Rear Stay Pad Removal Note
1. Work on 1 stay pad at a time.

Item 44: Top Stay Pad Removal Note
1. Work on 1 stay pad at a time.

Item 46: Headlining Assembly Removal Note

1. Remove the 2 rear screws from the rear tack strip.

2. Remove the 2 screws at the front of the No.1 bow.
3. Separate the headlining retainer from the No.3 bow.

INSTALLATION
1. To install, reverse the removal procedure.

Item 15: Hydraulic Motor And Pump Assembly Installation Note

1. NOTE: Make sure that each fitting is installed in the correct position on the motor assembly.

Install the hydraulic lines using a thread locker onto the motor assembly.

Item 7: Lift Cylinder Installation Note

1. NOTE:
- Make sure that each fitting is installed in the correct position on the folding top lift cylinder.
- Make sure that the tetra seal is installed in the bottom of each of the folding top lift cylinder ports before attaching the upper and lower hose fittings.

Install the hydraulic lines using a thread locker onto the lift cylinder.

Item 1: Top Well Sling Installation Note
1. Route the rear window defrost grid wire through the hole in the well sling interior trim cover.

2. Connect the rear window defrost grid electrical connector and attach the locator to the body.

3. Install the rear window defrost grid ground bolt.

Item 17: Convertible Top Assembly - The Convertible Top Dowel Pins Fall Forward Of The Receiver Cups (Overshoot) Inspection Note

NOTE: The following adjustments are listed in the order of fine to coarse adjustment. Make the adjustments on the side that coordinates with the overshoot condition.

1. Fully raise the convertible top until the hydraulic pump motor stalls for 3 seconds.
2. Examine the position of the dowel pins relative to the receiver cups. Note the side that has the condition (right or left).

3. CAUTION: Do not over-adjust. Test for normal operation and water performance following adjustment.

NOTE: This adjustment may affect the fit of the weatherstrips to the door glass.

Adjust the B-hinge set screw by turning in the screw about one half-turn (fine adjustment).

5. CAUTION: Do not over-adjust. Test for normal operation and water performance following adjustment.

NOTE: This adjustment may affect the fit of the weatherstrips to the door glass.

Adjust the position of the No.1 bow to the side arm (move the No.1 bow rearward) as follows:
- Lower the convertible top about one-quarter of the way down. Locate the 2 bolts under the cloth material that fasten the No.1 bow to the side arm.
- Loosen the bolts and slide the No.1 bow rearward and tighten the bolts.

Item 17: Convertible Top Assembly - Convertible Top Dowel Pins Fall Rearward Of The Receiver Cups (Undershoot) Inspection Note

NOTE: The following adjustments are listed in the order of fine to coarse adjustment. Make the adjustments on the side that coordinates with the undershoot condition.

1. Fully raise the convertible top until the hydraulic pump motor stalls for three seconds.
2. Examine the position of the dowel pins relative to the receiver cups. Note the side that has the condition (right or left).

3. CAUTION: Do not over-adjust. Test for normal operation and water performance following adjustment.

NOTE: This adjustment may affect the fit of the weatherstrips to the door glass.

Adjust the B-hinge set screw by turning out the screw about one half-turn (fine adjustment).

4. CAUTION: Do not over-adjust. Test for normal operation and water performance following adjustment.

NOTE: This adjustment may affect the fit of the weatherstrips to the door glass.

Adjust the position of the No.1 bow to the side arm (move the No.1 bow forward) as follows:
- Lower the top about one-quarter of the way down. Locate the 2 bolts under the cloth material that fasten the No.1 bow to the side arm.
- Loosen the bolts and slide the No.1 bow forward and tighten the bolts.

Item 17: Convertible Top Assembly - Difficult To Engage Convertible Top J-Hooks Into The Receivers (Pull-Down Effort) Inspection Note

NOTE:
- Pull down effort is defined as the effort necessary to engage the J-hooks into the receivers after running the top motor to the full up position and stalling the motor for three seconds.
- Latch effort is defined as the effort necessary to fully close the center latch handle after the J-hooks are engaged into the receivers.
- If the convertible top has been in the stowed/down position for a long period of time, or if the removable top has been on for a long period of time, the first time to latch the convertible top may be difficult, occasionally requiring two people. Often, keeping the top latched will relieve effort. It is recommended that the convertible top remains latched over night and during long periods of non vehicle usage.
- A new convertible top installed by the dealer will typically experience high-pull down effort.

1. Allow the top to remain latched continuously for 24-48 hours. Allow the top to receive direct sunlight if the external temperature is above 10°C (50°F).

2. CAUTION: Do not exceed 88°C (190°F) on the outer surface, or heat the surface for longer then four hours. The use of a concentrated heating device (hair dryer or other) is not recommended.

Latch the top and apply heat to the outer surface of the cloth (using a paint booth or heat lamps).

Item 17: Convertible Top Assembly - Convertible Top Does Not "Lock-Up" When Raised Inspection Note

1. NOTE:
- Examine condition of the convertible top during cycle, adjust if necessary.
- The B-hinge joint is defined as the first pivot joint from the front of the convertible top.
- If the B-hinge joint is locked at the end of travel (full up), this is a normal condition and adjustment is not necessary.

Cycle the convertible top from down to up. View the condition of the B-hinge joint. If the joint does not come together or lock at end of travel (full up), adjustment is necessary.

2. With the folding top in the down/folded condition, access the lower attachment bolt of the balance link to the main pivot bracket. Loosen the joint and adjust the balance link down approximately 1-2 mm (0.04-0.08 in).
3. Retest for condition. If condition still exists, proceed to the next step.
4. Raise the top and access the main control link adjustment from inside the vehicle by slightly lifting the headliner.

5. Loosen the bolts in the main control link adjustment bracket and move the link forward 1 mm (0.04 in).
6. Retest for condition. If condition still exists, repeat the adjustment procedure.

Item 17: Convertible Top Assembly - Convertible Top No.1 Bow Is Not Flush To The Header Chrome Molding Inspection Note

1. Remove the J-hook set screw.
2. Turn the J-hook in (clockwise) by 1 turn.

3. Install the set screw.
- Add blue threadlock and sealer to the set screw.