AR77.30-P-1002QA Remove/Install Soft Top

AR77.30-P-1002QA Remove/Install Soft Top






















DANGER!
- Injury hazard from roll bar extending
- Before working in the area of the roll bar pull rear head restraints out by hand.
- Risk of injury. Moving parts can pinch, crush or, in extreme cases even sever extremities.
- Keep body parts and limbs well clear of moving parts.
- Risk of injury to skin or eyes from hydraulic fluid spraying out under pressure. Risk of poisoning from swallowing hydraulic fluid.
- Release the pressure in the hydraulic system completely before starting any work on the system. Wear protective clothing and safety glasses.

1 Cover vehicle in rear area

NOTE: To prevent scratching the paint during assembly work.

2 Open soft top

NOTE: Lower soft top and leave soft top compartment cover upright.

3 Remove rear seat and rear seat cushion
4 Remove side paneling in left and right rear
5 Remove seat belt extender
6 Close soft top

NOTE: Leave soft top bow and soft top compartment cover in upright position

7 Remove retractable trunk partition
8 Remove coverings in trunk

NOTE: Remove only left side wall paneling and left soft top compartment paneling.

9 Pull out body-bound rivet (2) and remove cover(1).
10 Remove clip (4) and remove soft top support cover (3).
11 Unscrew bolts (6) and remove cover (5)
12 Remove gasket (7).

NOTE: Lift with assembly wedge.

Assembly wedge - See Special Tools below

13 Unscrew bolts (9) and remove cross strut (8)
- Screw for lateral strut on B-pillar strut to soft top bearing = 10 ± 2 Nm
14 Remove bolts (11).
- Screw on B-pillar strut M6 x 16 10 ± 2 Nm
M8 x 16 20 ± 2 Nm
15 Slacken nut (12)
- Nut on B-pillar strut = 20 ± 2 Nm
16 Remove B-pillar strut (10).
17 Undo connector (13)
18 Undo connector (14)
19 Unscrew nut (15) and remove heated rear window ground cable (16).
20 Undo connector (17)
21 Remove/install hydraulic cylinder for soft top bow

NOTE: Lay hydraulic cylinder for soft top bow down to side with leads connected

22 Remove/install hydraulic cylinder for soft top frame

NOTE: Lay hydraulic cylinder for soft top frame down to side with leads connected

23 Remove/install hydraulic cylinder for soft top compartment cover

NOTE: Lay hydraulic cylinder for soft top compartment cover down to side with leads connected

24 Separate tie strap (27) and expose hydraulic lines (29) for hydraulic cylinder lock unit
25 Remove bolt (28)
26 Remove hydraulic lines (29) from hydraulic pump (31).
27 Pull circlip (30) out of hydraulic lines (29).
28 Pull hydraulic lines (29) out of terminal plate (32).
29 Remove control cable (20) from ball head (22).
30 Remove bracket (21)
31 Unscrew bolt (25) and lay seat belt (26) down to side.
- Screw in rear upper belt guide fitting = 30 Nm
32 Unscrew bolts (24) from soft top support (23).
- Screw for soft top main bearing on body bearing plate = 20 ± 2 Nm
33 Remove soft top
34 Install in reverse order
35 Adjust gap dimensions on hoods, doors and lids
- Soft top to windshield frame - Dimension "M" 10 ± 2 mm
- Soft top to soft top compartment cover - Dimension "7" 3 ± 0.5 mm
Feeler gauge - See Special Tools below


Special Tools

Special Tools: