Part 1
DISASSEMBLY
1. REMOVE FRONT ROOF SIDE RAIL GARNISH
a. Remove the clip from the front side rail garnish.
b. Using a screwdriver, pry out the 4 claws by pushing the claws in the directions shown in the illustration.
HINT: Tape the screwdriver tip before use.
2. REMOVE ROOF SIDE RAIL GARNISH NO.2
a. Using a screwdriver, pry out the 2 claws by pushing the claws in the directions shown in the illustration.
HINT: Tape the screwdriver tip before use.
3. REMOVE ROOF HEADER GARNISH
a. Using a torx wrench (T25), remove the 6 screws from the LH side as shown in the illustration. Then remove the 6 screws from the other side.
b. Remove the 3 claws and header panel patch from the header garnish.
c. Remove the roof header garnish.
HINT: Pull the tarpaulin latch from the circled area in the illustration.
4. REMOVE TARPAULIN HEADLINING
a. Using a clip remover, remove the 5 clips from the tarpaulin rail.
b. Using a torx wrench (T25), remove the screw.
c. Using a clip remover, remove the clip.
d. Using a torx wrench (T25), remove the 4 screws from the LH side. Then remove the 4 screws from the other side.
e. Peel the tarpaulin headlining from the adhesive tape of the No. 1 tarpaulin bow.
f. Using a screwdriver, pry out the tarpaulin bows (No. 2, No. 3 and No. 4).
HINT: Tape the screwdriver tip before use.
5. REMOVE BACK WINDOW GLASS WIRE COVER
a. Using a clip remover, remove the 2 clips. Then remove the defogger connector from the back window glass side.
b. Using a screwdriver, pry out the back window glass wire cover.
HINT: Tape the screwdriver tip before use.
6. REMOVE CONVERTIBLE ROOF MOTOR ASSEMBLY LH
a. Using a clip remover, remove the convertible roof motor's connector clip.
b. Using a 6 mm hexagon wrench, remove the 3 bolts and convertible roof motor.
7. REMOVE TARPAULIN COVER
a. Using a torx wrench (T25), remove the 6 screws.
b. 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.
c. Using a torx wrench (T25), remove the screw under the tarpaulin rail (*1).
d. Using a drill of less than approximately Dia. 3.35mm (0.1319 in.), drill out the heads of the 3 rivets as shown in the illustration (*2).
e. Hold the nylon strip in place with pliers or a similar tool.
CAUTION: Do not use your hand to hold the nylon strip in place.
f. Using a drill of less than approximately Dia. 3.35 mm (0.1319 in.), drill out the head of the rivet as shown in the illustration.
g. Peel the tarpaulin cover from the adhesive tape of tarpaulin bows (No. 1, No. 2, No. 3 and No. 4) as shown in the illustration.
h. Using a torx wrench (T25), remove the screw.
i. Using a clip remover, remove the staples from the tarpaulin cover and No. 5 bow.
HINT: Tape the screwdriver tip before use.
j. Using a screwdriver, remove the staple and the sound pad from the tarpaulin bows (No. 2, No. 3 and No. 4).
HINT: Tape the screwdriver tip before use.
8. REVERSE TARPAULIN RAIL ASSEMBLY
a. Reverse the tarpaulin rail on the top of the tarpaulin cover.
NOTE: When placing a removed tarpaulin on the ground, prevent damage to its rail by placing cushions beneath the tarpaulin.
CAUTION: Do not reverse the tarpaulin with less than 3 people.
9. REMOVE SIDE STAY PAD
a. From the center hole, remove the side stay pad.
b. Align the matchmarks on the tarpaulin bows (No. 2, No. 3 and No. 4) and No. 5 bow.
c. Using a screwdriver, remove the staples from the side stay pad, tarpaulin bows (No. 2, No. 3 and No. 4) and No. 5 bow.
HINT: Tape the screwdriver tip before use.
10. REMOVE TARPAULIN REAR RAIL BOW DRAIN TROUGH
a. Using a screwdriver, remove the staples and drain trough from the No. 5 bow.
HINT: Tape the screwdriver tip before use.
11. REMOVE TARPAULIN BOW
a. Align the matchmarks on the bolts and tarpaulin bows.
b. Using a torx wrench (T40), remove the 12 bolts (LH and RH) from the tarpaulin bows (No. 3 and No. 4) and No. 5 bow as shown in A and B in the illustration (RH bolts are not shown in the illustration).
HINT: The torx wrench will not be able to reach the bolts unless the tarpaulin bow is tilted as shown in B.
c. Using a drill, drill out the heads of the rivet from the hinge link as shown in B.
d. Using a drill of less than Dia. 5.1 mm (0.200 in.), drill out the heads of the 2 rivets from the No. 2 bow as shown in C.
e. Using a torx wrench (T40), remove the 2 bolts and 2 bushings from the No. 1 bow and remove the 2 bushings and 2 spacers between the No. 1 bow and tarpaulin rail.
12. REMOVE TARPAULIN LATCH
a. Using a torx wrench (T40), remove the 2 bolts from the No. 1 bow.
13. REMOVE NO.1 BOW LOCATING PIN
a. Using a 13 mm socket wrench and 8 mm open end wrench, remove the nut and bow locating pin from the No. 1 bow.
14. REMOVE TARPAULIN STORAGE COVER ASSEMBLY
a. Using a clip remover, remove the 20 clips and storage cover.
15. REMOVE TARPAULIN RAIL PIVOT BRACKET
a. Using a torx wrench (T25), remove the 2 screws and tarpaulin rail damper from the tarpaulin rear rail.
b. Align the matchmark of the lock plate.
c. Pull up and pry off the 3 clips (*1).
d. Strike the area of the 3 shafts where the 3 clips were installed (*2).
e. Pull up and pry off the clip (*3).
f. Strike the area of the shaft where the clip were installed (*4).
HINT: Using a hammer and thin pole that is less than the diameter of the shaft (Approximately Dia, 10 mm (0.39 in.)), strike the shaft and remove it from the other side.
g. Using a torx wrench (T40), remove the bolt, spacer, lock plate and nut (*5).
16. REMOVE RECLINING CONTROL LINK AND TARPAULIN REAR RAIL BOW BRACKET
a. Pull up and pry off the clip (*1).
b. Strike the area of the shaft where the clip were installed (*2).
c. Remove the 2 nuts and rear rail bow bracket (*3).
17. SEPARATE TARPAULIN RAIL ASSEMBLY
HINT: The disassembly of the 2 circled areas are shown below.
a. Separate the rear tarpaulin rail and the center tarpaulin rail.
1. Using a torx wrench (T40), remove the 2 bolts from the rear tarpaulin rail (*1).
2. Pull up and pry off the clip (*2).
3. Remove the shaft between the rear tarpaulin rail assembly and center tarpaulin rail (*3).
b. Separate the center rail and front tarpaulin rail.
1. Pull up and pry off the 3 clips.
2. Remove the 3 shafts between the center tarpaulin rail and front tarpaulin rail.
18. REMOVE RUBBER BUMPER
a. Using a clip remover, remove the rubber and clip.
REASSEMBLY
1. INSTALL RUBBER BUMPER
a. Install the rubber bumper with the clip.
2. INSTALL TARPAULIN STORAGE COVER ASSEMBLY
a. Install the tarpaulin storage cover with the 20 clips.
3. INSTALL TARPAULIN RAIL ASSEMBLY
a. Install the tarpaulin rail assembly.
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.
b. 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 (*1).
HINT: Install the shaft to the interior side of the tarpaulin rail.
NOTE: The tarpaulin 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 (*2).
Torque: 30 N.m (306 kgf.cm, 22 in.lbf)
HINT: Partially tighten bolts A and B. Then fully tighten bolt B first and fully tighten bolt A.
c. Connect the center tarpaulin rail and front tarpaulin rail.
1. 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.
4. INSTALL RECLINING CONTROL LINK AND TARPAULIN REAR RAIL BOW BRACKET
a. Apply MP grease to the neck and gear of the reclining control link as shown in the illustration (*1).
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(*2).
HINT: Install the shaft to the interior side of the tarpaulin rail.
c. Insert a clip into the groove of the shaft (*3).
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 N.m (265 kgf.cm, 19 ft.lbf)
5. INSTALL TARPAULIN RAIL PIVOT BRACKET AND TARPAULIN RAIL ASSEMBLY
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 N.m (306 kgf.cm, 22 ft.lbf)
6. INSTALL TARPAULIN LATCH
a. Using a torx wrench (T40), install the tarpaulin latch with the 2 bolts.
Torque: 30 N.m (306 kgf.cm, 22 ft.lbf)
7. 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 N.m (306 kgf.cm, 22 ft.lbf)