Disassembly
CONVERTIBLE: SOFT TOP:
COMPONENTS
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 dia3.35mm (0.1319 in.), drill out the heads of the 3 rivets as shown in the illustration below (*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 dia3.35 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 below (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 below.
(c) Using a drill, drill out the heads of the rivet from the hinge link as shown in B below.
(d) Using a drill of less than dia5.1 mm (0.200 in.), drill out the heads of the 2 rivets from the No. 2 bow as shown in C below.
(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 dia10 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.