Diesel Data: Automotive Repair
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Part 2




35. REMOVE RUBBER BUMPER
a. Using a clip remover, remove the rubber bumper and clip.

36. INSTALL RUBBER BUMPER
a. Install the rubber bumper with the clip.

37. INSTALL TARPAULIN STORAGE COVER ASSY
a. Install the tarpaulin storage cover with the 20 clips.




38. INSTALL TARPAULIN RAIL ASSY

CAUTION: The tarpaulin may separate if the tops of the clips are not securely hooked into the grooves of their respective shafts.

NOTE:
- If clips are damaged during removal, replace them.




- Do not prize the riveter. The riveter will be damaged and the mandrel will bend.




- Do not till the riveter when fastening the rivet to the tarpaulin hinge link as this will cause the rivet to be loose.
- Do not have any space between the rivet head and the tarpaulin hinge link. The rivet head must be completely flat against the tarpaulin hinge link.




- Do not have any space between the No.2 bow and tarpaulin hinge link. Firmly hold together the 2 items while installing the rivet.




a. Connect the rear tarpaulin rail and center tarpaulin rail.
1. Install the shaft (length: 45 mm (1.77 in.)) to the tarpaulin rails. Then connect the clip into the groove of the shaft.

HINT: Install the shaft to the interior side of the tarpaulin rail.

NOTE: The tarpaulin assy may separate if the top of the clip is not securely hooked into the groove of its respective shaft.

2. Using a torx wrench (T40), install the 2 bolts to the rear tarpaulin rail with the link.

Torque: 30 Nm (306 kgf.cm, 22 ft.lbf)

HINT: Partially tighten bolts A and B. Then fully tighten bolt B first and fully tighten bolt A.




b. Connect the center tarpaulin rail assy and front tarpaulin rail.
. Install the 3 shafts (length A: 24 mm (0.94 in.); length B: 45 mm (1.77 in.)) to the tarpaulin rails. Then connect the 3 clips into the grooves of the 3 shafts.

HINT: Install the shaft to the interior side of the tarpaulin rail.

NOTE: The tarpaulin may separate if the tops of the clips are not securely hooked into the grooves of their respective shaft.




39. INSTALL RECLINING CONTROL LINK AND TARPAULIN RAIL PIVOT BRACKET
a. Apply MP grease to the neck and gear of the reclining control link as shown in the illustration.

HINT: Apply a thin coat of grease to the neck and gear of the link.

NOTE: Do not allow grease to come in contact with the cover. Doing so will damage or cause color damage to the cover.

b. Install the shaft (length: 45 mm (1.77 in.)) to the tarpaulin rail pivot bracket with the reclining control link.

HINT: Install the shaft to the interior side of the tarpaulin rail.

c. Insert a clip into the groove of the shaft.

CAUTION: The tarpaulin may separate if the top of the clip is not securely hooked into the groove of the shaft.

d. Install the tarpaulin rear bow bracket with the 2 nuts.

Torque: 26 Nm (265 kgf.cm, 19 ft.lbf)




40. INSTALL TARPAULIN RAIL PIVOT BRACKET AND TARPAULIN RAIL ASSY
a. Install the 4 shafts (A and B) to the tarpaulin rail pivot bracket and tarpaulin rail, as shown in the illustration.

HINT: Install the shaft to the interior side of the tarpaulin rail.

b. Insert the 4 clips into the grooves of the 4 shafts.

CAUTION: The tarpaulin may separate if the tops of the clips are not securely hooked into the grooves of their respective shafts.




c. Install the tarpaulin rail balance link to the tarpaulin pivot bracket.
1. Apply adhesive on the thread of the bolt.
Adhesive:
Part No. 08833-00100, THREE BOND 1360 K or equivalent

2. Align the lock plate with the matchmark.
3. Using a torx wrench (T40), install the bolt, spacer, lock plate and nut to the tarpaulin pivot bracket.

Torque: 30 Nm (306 kgf.cm, 22 ft.lbf)




41. INSTALL TARPAULIN LATCH
a. Using a torx wrench (T40), install the tarpaulin latch with the 2 bolts.

Torque: 30 Nm (306 kgf.cm, 22 ft.lbf)




42. INSTALL NO.1 BOW LOCATING PIN
a. Apply adhesive on the thread of the pin.
Adhesive:
Part No. 08833-00100, THREE BOND 1360 K or equivalent

b. Using a 13 mm socket wrench and 8 mm open end wrench, install the bow locating pin with the nut.

Torque: 30 Nm (306 kgf.cm, 22 ft.lbf)




43. PARTIALLY TIGHTEN NO.1 TARPAULIN BOW AND TARPAULIN RAIL ASSY

NOTE: When placing a removed tarpaulin on the ground, prevent damage to its rail by placing cushions beneath the tarpaulin.

a. Using a torx wrench (T40), install the 2 spacers and 4 bushings, and partially tightening the 2 bolts to the No.1 bow as shown in the illustration.




44. PARTIALLY TIGHTEN NO.5 TARPAULIN BOW AND TARPAULIN RAIL ASSY
a. Align the bow with the matchmarks.
b. Using a torx wrench (T40), install the tarpaulin bow by partially tightening the 2 bolts.




45. PARTIALLY TIGHTEN NO.3 TARPAULIN BOW AND TARPAULIN RAIL ASSY
a. Align the bow with the matchmarks.
b. Using a torx wrench (T40), install the No.3 bow by partially tightening the 2 bolts.

HINT: The torx wrench will not be able to reach the bolts unless the tarpaulin bow is tilted as shown in the illustration.

c. Using an air riveter equipped with a nose piece, install the strap into the hinge link with the rivet.




46. INSTALL NO.2 TARPAULIN BOW AND TARPAULIN RAIL ASSY
a. Using an air riveter equipped with a nose piece, strike 2 rivets into the base of the tarpaulin hinge link.




47. PARTIALLY TIGHTEN NO.4 TARPAULIN BOW AND TARPAULIN RAIL ASSY
a. Align the bow with the matchmarks.
b. Using a torx wrench (T40), install the No.4 bow by partially tightening the 2 bolts.




48. MEASURE FITTING OF TARPAULIN ASSY
a. Fully open the tarpaulin.
b. Using a 6 mm hexagon wrench, install the roof motor with the 3 bolts.

Torque: 30 Nm (306 kgf.cm, 22 in.lbf)

c. On the rear rail bow bracket, uniformly loosen nuts A and B. Then remove nut A.
d. Retighten nut B a distance of 65 mm (2.56 in.) as shown in the illustration.

HINT: Performing procedures c.and d.will make the No.5 bow operational.

e. Close the tarpaulin.
f. Install the tarpaulin to the vehicle with the 2 bolts and 4 nuts.

Torque:
30 Nm (306 kgf.cm, 22 ft.lbf) for bolt
26 Nm (265 kgf.cm, 19 ft.lbf) for nut

CAUTION: During installation/removal of the tarpaulin, do not lift the assy with less than 3 people.

NOTE: Be careful not to deform the courtesy lamp switch base.

g. Install the rear rail bow bracket with the 2 nuts (A and B).

Torque: 26 Nm (265 kgf.cm, 19 ft.lbf)







h. Close the tarpaulin and lock to the tarpaulin latch.
i. Check the alignment of the tarpaulin rail's parts by taking the measurements indicated in A, B, C and D in the illustration. Check that the measurements are within the standard values.

HINT:
- The standard values are for reference only. Measurements do not have to be exactly as shown in the illustration.
- Using the values listed under "Measurement" as a reference, adjust the marked areas as necessary.







j. Check the alignment of the tarpaulin rail's parts by taking the measurements indicated in A, B, C, and D in the illustration. Check that the measurements are within the standard values.




49. FULLY TIGHTEN NO.1 TARPAULIN BOW
a. Using a torx wrench (T40), tighten tarpaulin bow with the 2 bolts.

Torque: 30 Nm (306 kgf.cm, 22 ft.lbf)

HINT: Tighten bolt B first, then tighten bolt A.




50. FULLY TIGHTEN NO.4 TARPAULIN BOW
a. Using a torx wrench (T40), tighten the tarpaulin bow with the 2 bolts.

Torque: 30 Nm (306 kgf.cm, 22 ft.lbf)




51. FULLY TIGHTEN NO.5 TARPAULIN BOW
a. Using a torx wrench (T40), tighten the No.5 bow with 2 bolts.

Torque: 30 Nm (306 kgf.cm, 22 ft.lbf)




52. FULLY TIGHTEN NO.3 TARPAULIN BOW
a. Replace the tarpaulin latch and bend the tarpaulin rail.
b. Using a torx wrench (T40), tighten the tarpaulin bow with the 2 bolts.

Torque: 30 Nm (306 kgf.cm, 22 ft.lbf)

HINT: The torx wrench will not be able to reach the bolts unless the tarpaulin bow is tilted as shown in the illustration.




53. CHECK NO.1 BOW LOCATING PIN POSITION

HINT: Check that when the bow control link is closed, the No.1 bow locating pin and pin hole are aligned.




54. CHECK POSITION OF BOW CONTROL LINK UP STOP
a. Replace the tarpaulin latch.
b. Measure the distance (A) between the bottom surface of the No.1 tarpaulin bow and the top surface of the header weather seal, as shown in the illustration.
Standard (A):
w/ Tarpaulin cover: 55 to 70 mm ( 2.17 to 2.76 in.)
w/o Tarpaulin cover: 5.0 to 25 mm (0.20 to 0.98 in.)

c. When performing adjustments, refer to the "Adjustment" section's up stop procedures.




55. CHECK POSITION OF BOW CONTROL LINK DOWN STOP
a. Fully open the soft top.
b. Place a straight edge across the top of the No.1 tarpaulin bow. Using a scale, measure the distance (A) between the bottom of the straight edge and top of the quarter belt moulding as shown in the illustration.
Standard (A): 39.5 to 45.5 mm ( 1.56 to 1.79 in.)

c. When performing adjustments, refer to the "Adjustment" section's down stop procedures.




56. CHECK TARPAULIN LATCH
a. Move the tarpaulin latch by hand and check that it moves in the direction of the arrow marks in the illustration. If there is clearance or level difference between the windshield and the front edge of the tarpaulin cover when the tarpaulin cover is fully closed, turn the convertible roof hook to adjust it.
b. When performing adjustments, refer to the "Adjustment" section's tarpaulin latch procedures.

57. CHECK TARPAULIN ASSY OPERATES
a. Connect the battery negative terminal.
b. Connect the convertible roof motor's connector.
c. Check that the tarpaulin opens/closes through operation of the convertible roof switch. If a malfunction occurs, confirm that steps (38) to (52) were completed properly.
d. Turn the ignition switch OFF and wait for approximately 43 seconds. Use your hands to move the soft top and check that it can open and close smoothly.
e. Disconnect the battery negative terminal.

58. REMOVE TARPAULIN ASSY
a. Fully open the tarpaulin.
b. Disconnect the convertible roof motor's connecter.
c. On the rear rail bow bracket, uniformly loosen nuts A and B. Then remove nut A.




d. Retighten nut B a distance of 65 mm (2.56 in.) as shown in the illustration.

HINT: Performing procedures c.and d.will make the No.5 bow operational.

e. Close the tarpaulin.
f. Remove the 2 bolts, 4 nuts and tarpaulin.

CAUTION: During installation/removal of the tarpaulin, do not lift the tarpaulin with less than 3 people.

NOTE:
- When placing a removed tarpaulin on the ground, prevent damage to its rail by placing cushions beneath the tarpaulin.
- Be careful not to deform the base of the courtesy lamp switch.
- The motor should not be removed when installing the stay pad.

g. Install the rear rail bow bracket with the 2 nuts (A and B).

Torque: 26 Nm (265 kgf.cm, 19 ft.lbf)




59. INSTALL TARPAULIN REAR RAIL BOW DRAIN TROUGH

HINT:
- The drain trough should be installed so that its strap is on the outer side.
- Before performing work on the tarpaulin, it should be turned upside down.

NOTE: When placing a removed tarpaulin on the ground, prevent damage to its rail by placing cushions beneath the tarpaulin.

a. Using a staple gun, install the drain trough to the No.5 bow.
1. With the frame extended, align the center of the cover to the frame. Use the staple gun to affix the rear top cover tarpaulin bow to the frame.
2. Pull one side of the cover's rear away from the center of the cover. Use the staple gun to affix the side of the cover's rear to the frame, as shown in the illustration. Repeat for the other side.




60. INSTALL SIDE STAY PAD

NOTE: When placing a removed tarpaulin on the ground, prevent damage to its rail by placing cushions beneath the tarpaulin.

HINT:
- Turn the tarpaulin over so that it's right side up.
- Install the longer side of the interior side (A) to the interior of the No.5 bow.
- Straighten the tarpaulin so that the tarpaulin is fully extended.

NOTE: Keep the side stay pad straight from the No.1 bow to the No.5 bow.




a. Install the pad to the No.1 bow.




b. Using a staple gun, staple the pad to the No.5 bow.
1. Fully open the tarpaulin.
2. Measure the outer surface length of are A (indicated in the illustration) of the No.5 bow.
3. Place a reference mark on the middle point of are A.
4. Place the stay pad onto the No.5 bow, leaving a distance of dimension B between the reference mark (placed in step 3) and the stay pad.
Dimension B: 555 to 565 mm (21.85 to 22.24 in.)

HINT:
- The stay pad must not be loose between the No.4 and No.5 bows.
- The stay pad must be lined up to the outboard end of the bow detail.

5. Staple the stay pad across the No.5 bow in 8 places.

HINT:
- Attach 2 staples for every 25.4 mm (1 in.).
- Staples must be fully seated.




c. Using a staple gun, staple the pad to the No.4 bow.
1. Align the stay pad to the No.4 bow.

HINT:
- The stay pad must not be loose between the No.3 and No.4 bows.
- The stay pad must be aligned to the lower edge of the lower hole on the No.4 bow.

2. Staple the pad across the No.4 bow in 8 places.

HINT:
- Staples must be fully seated.
- Attach 2 staples for every 25.4 mm (1 in.).




d. Using a staple gun, staple the pad to the No.2 bow.
1. Align the stay pad assembly to the lower edge on the No.2 bow.

HINT:
- Align the pad so that it is flush to the No.2 bow edge.
- The stay pad must not be loose between the No.1 and No.2 bows.

2. Staple the pad to across the No.2 bow in 4 places.

HINT:
- Staple the inner side of the No.2 bow.
- Staples must be fully seated.




e. Using a staple gun, staple the pad to the No.3 bow.
1. Align the stay pad assembly to the No.3 bow.

HINT: The stay pad must be set 25 mm (0.98 in.) from the edge of the No.3 bow.

2. Staple stay pad to the No.3 bow in 4 places.

HINT:
- Staple the inner side of the No.3 bow.
- Staples must be fully seated.




f. Check that the stay pad is not loose.

HINT: The stay pad must be pulled taut between the No.1 and No.2 bows, the No.3 and No.4 bows and the No.4 and No.5 bows. If the stay pad is slack in any location, the stay pad should be re-stapled to the bow.

61. INSTALL TARPAULIN COVER

NOTE: When placing a removed tarpaulin on the ground, prevent damage to its rail by placing cushions beneath the tarpaulin.




a. Remove the adhesive tape from the tarpaulin bows (No.1, No.2, No.3 and No.4). Clean off any residual adhesive.
b. Apply new adhesive tape to the tarpaulin bows (No.1, No.2, No.3 and No.4) as shown in the illustration.




c. Using a torx wrench (T25), install the tarpaulin rail damper and rear rail with the 2 screws.

Torque: 8.0 Nm (82 kgf.cm, 71 in.lbf)




d. Using a staple gun, staple the stay pad to the No.2, No.3 and No.4 bows, as shown in the illustration.
e. Using a 6 mm hexagon wrench, remove the 3 bolts and convertible roof motor.




f. Fold the tarpaulin rail as shown in the illustration.

NOTE: When placing a removed tarpaulin on the ground, prevent damage to its rail by placing cushions beneath the tarpaulin.

g. Using an air riveter equipped with a nose piece, install the 2 rivets to the No.1 bow.

HINT: Fasten the 2 rivets in the order shown in the illustration A.

h. Using a torx wrench (T25), install the cable end and rear rail with the screw.

Torque: 8.0 Nm (82 kgf.cm, 71 in.lbf)

HINT: Install the screw to the tarpaulin rail but do not fully tighten it. Attach the tarpaulin cover's wire hook to the screw and then fully tighten the screw.




i. Using an air riveter equipped with a nose piece, install the P clip and the rear rail with the rivet.

NOTE: The P clip's round edge must be outboard.




j. Align the front end of the tarpaulin cover with the No.1 bow.

HINT: Align the slit of the tarpaulin cover with center of the No.1 bow.




k. Using a torx wrench (T25), install the cover and rear rail with the 6 screws.

Torque: 6.0 Nm (61 kgf.cm, 53 in.lbf)

HINT: Tighten the center screws first. Then tighten screws toward the right and left side in sequence.




l. Apply the tarpaulin cover to the tarpaulin bows (No.2, No.3 and No.4) as shown in the illustration.

HINT: Cut excess cover at the edge of the bow.




m. Straighten the tarpaulin so that the tarpaulin is fully extended.

NOTE: Do not allow grease to come in contact with the cover. Doing so will damage or cause color damage to the cover.

n. Apply MP grease to the pinion gear of the motor.
o. Using a 6 mm hexagon wrench, install the convertible roof motor with the 3 bolts.

Torque: 30 Nm (306 kgf.cm, 22 ft.lbf)

p. Install the convertible roof motor's connecter clip to the pivot bracket.
q. Using a staple gun, install the tarpaulin cover and down stop strap to the No.5 bow.
1. With the frame extended, align the center of the cover to the frame. Use the staple gun to affix the cover to the No.5 bow.
2. Using a staple gun, staple the down stop strap to the No.5 bow, as shown in the illustration.

HINT: The drain trough should be installed so that its strap is on the outer side.




3. Affix the tips of the No.5 bow to the frame as shown in the illustration A.
4. Pull one side of the cover's rear away from the center of the cover. Use the staple gun to affix the side of the cover's rear to the frame, as shown in the illustration. Repeat for the other side.

HINT:
- Staples must be fully seated.
- Attach 2 staples for every 25.4 mm (1 in.).

5. Using a torx wrench(T25), install a screw to the tarpaulin cover.

HINT: The screw must be fully seated.




r. Remove the adhesive tape from the No.1 tarpaulin bow.
s. Apply new adhesive tape to the No.1 tarpaulin bow as shown in the illustration.




t. Using an air riveter equipped with a nose piece, strike rivets into the nylon strip.




62. INSTALL BACK WINDOW GLASS WIRE COVER
a. Install the back window wire cover.
b. Connect the defogger wire's 2 clips to the tarpaulin rail pivot bracket. Also connect the 2 connectors to the rear window.




63. INSTALL TARPAULIN HEADLINING
a. Push the tarpaulin headlining into the No.2 bow.
b. Attach the tarpaulin headlining into the No.1 bow.
c. Push the tarpaulin headlining into the No.3 bow.
d. Push the tarpaulin headlining into the No.4 bow.
e. Install the tarpaulin headlining to the rear tarpaulin rail with the 5 clips.
f. Using a torx wrench (T25), install the 8 screws (4 screws to LH side and 4 screws to RH side) to the No.1 bow.

Torque: 6.0 Nm (61 kgf.cm, 53 in.lbf)

g. Using a torx wrench (T25), install the screw, clip and tarpaulin headlining into the No.5 bow.

HINT: The screw must be fully seated.

h. Install the tarpaulin headlining to the pivot bracket with the clip.




64. INSTALL ROOF HEADER GARNISH
a. Partially tighten the LH and RH screws (RH screw is not shown in illustration).
b. Install the roof header garnish.
c. Using a torx wrench (T25), install the 10 screws to the roof header garnish (5 screws to LH side and 5 screws to RH side). Then tighten the 12 screws.

Torque: 6.0 Nm (61 kgf.cm, 53 in.lbf)

d. Install the header panel patch to the garnish.




65. INSTALL FRONT ROOF SIDE RAIL GARNISH
a. Install the front garnish to the front rail with the 4 claws.
b. Install the headlining to the front rail with the headlining clip.




66. INSTALL ROOF SIDE RAIL GARNISH NO.2
a. Install the garnish to the center rail with the 2 claws.




67. INSTALL TARPAULIN ASSY
a. Fully open the tarpaulin.
b. On the rear rail bow bracket, uniformly loosen nuts A and B. Then remove nut A.
c. Retighten nut B a distance of 65 mm (2.56 in.) as shown in the illustration.

HINT: Performing procedures b.and c.will make the No.5 bow operational.

d. Close the tarpaulin.
e. Install the tarpaulin with the 2 bolts and 4 nuts.

Torque:
30 Nm (306 kgf.cm, 22 ft.lbf) for bolt
26 Nm (265 kgf.cm, 19 ft.lbf) for nut

CAUTION: During installation/removal of the tarpaulin, do not lift the assy with less than 3 people.

NOTE: Be careful not to deform the base of the courtesy lamp switch.

f. Install the rear rail bracket with the 2 nuts (A and B).

Torque: 26 Nm (265 kgf.cm, 19 ft.lbf)

g. Connect the connector of the convertible roof motor.
h. Connect the connecter of the courtesy lamp switch and defogger connector.




i. Connect the convertible roof motor connector.
j. Install the courtesy lamp switch with the 2 screws.

Torque: 7.0 Nm (71 kgf.cm, 62 in.lbf)

k. Connect the courtesy lamp switch connector.
l. Connect the defogger connector.




m. Install the tarpaulin rear rail bow drain trough's stay.
1. Install the drain trough to the body panel as shown in the illustration.
2. Install the drain trough's stay with the 4 nuts.

Torque: 8.5 Nm (87 kgf.cm, 75 in.lbf)




68. INSTALL QUARTER PANEL EXTENSION REINFORCEMENT LH
a. Install the reinforcement with the 3 bolts.




69. INSTALL TARPAULIN RAIL PIVOT BRACKET COVER
a. Install the pivot bracket cover with the screw.

Torque: 5.5 Nm (56 kgf.cm, 49 in.lbf)

70. INSTALL ROOF SIDE RAIL RETAINER

HINT: See the illustration.

a. Install the tarpaulin front rail retainer and 4 shims with the 4 screws.
b. Install the tarpaulin center rail retainer and 2 shims with the 2 screws.
c. Install the tarpaulin rear rail retainer and 4 shims with with the 4 screws.

Torque: 10 Nm (102 kgf.cm, 7 in.lbf)

NOTE:
- Be careful not to drop shims between the tarpaulin rail retainer and the tarpaulin rail.
- Removed shims must be installed to the location it was installed previously. Depending on the location, each shim's thickness is different.




71. INSTALL TARPAULIN RAIL WEATHERSTRIP

HINT: See the illustration.

a. Install the tarpaulin front rail weatherstrip with the 2 clips.
b. Install the tarpaulin center rail weatherstrip with the 2 clips.
c. Install the tarpaulin rear rail weatherstrip with the 3 clips.

72. CONNECT BATTERY NEGATIVE TERMINAL
a. Connect the battery negative terminal.






NOTE: When disconnecting the negative (-) battery terminal, initialize the systems shown in the table after the terminal is reconnected.

b. Check the SRS warning lamp.

73. CHECK FOR TARPAULIN OPERATE
74. CHECK FOR WATER LEAKS
a. Check that the tarpaulin has no water leaks.
If a leak is found, determine where the leak is occurring. Then, confirm that the relevant procedures between steps (38) to (71) have been completed properly.
If there is leak between the tarpaulin and the front/quarter window glass, refer to the adjustment procedures for the front/quarter widow glass to correct the water leak.
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