Operation CHARM: Car repair manuals for everyone.

5th Bow Drive Unit

Component Parts Drawing Part 1:




Component Parts Drawing Part 2:




SOFT TOP

Removal and Installation of 5th Bow Drive Unit

REMOVAL
1. Un-install soft top assembly from the vehicle.




2. Remove roof actuator (RH/LH) from the soft top.

NOTE: If removal is difficult, rotate motor axis to remove them.




3. Disconnect 5th bow operating rod (RH/LH) at the frame side by pulling out the holder.

NOTE: This step will make the 5th bow up and down motion easier.

4. Make sure that the limit switch contact around the rotation axis of the 5th bow on the left side of soft top is protected with tape.
5. Open the soft top manually, and put a stand under the 1st bow. Then fix the soft top not to move during this procedure.

NOTE: Put a waste cloth between the front lock and the stand not to make any scratches to the soft top.

6. Remove the C link and 5th bow weatherstrip.




7. Remove the soft top cover retainer (5th bow retainer) from 5th bow by taking out screws.
8. Drilling rivets attaching the soft top cover to 5th bow, then pull up the soft top cover bottom edge.

NOTE: Use 4 mm (0.16 in) diameter drill bit to remove the rivet head. When drilling rivets, be careful not to damage the soft top cover.




9. Drilling rivets with retainers attaching with tags from the soft top cover, 5th bow finisher and the 5th bow.

NOTE: Use 4 mm (0.16 in) diameter drill bit to remove the rivet head. The soft top cover is separated from 5th bow.




10. Drilling rivets under retainers by using 4 mm (0.16 in) diameter drill bit.




11. Remove pads from 5th bow finisher.




12. Roll the soft top cover bottom edge up, and disconnect defogger harness connector from the rear window glass.
13. Pull out glass stays from sleeves on each side of the rear window glass.




14. Remove 5th bow side finisher (RH/LH) by removing screws.




15. Remove 5th bow finisher by pulling the finisher up.




16. Remove glass stays from 5th bow by removing screws from the bottom of the 5th bow.

NOTE:
- When removing glass stays, support 5th bow to avoid a bend of glass stay. This bend may happen by the weight of the 5th bow and the tensile force of the tether from the soft top cover.
- Be careful not to damage the 5th bow nor to be hurt by the falling 5th bow, because the 5th bow is heavy and moves freely after removing glass stays.




17. Disconnect 5th bow drive unit harness connector.




18. Remove 5th bow drive unit and rails together from 5th bow by removing screws.

NOTE:
- After removing drive unit and rails, not to pull rails. Otherwise, the wire in the rail may be damaged.
- The screws are not reusable.

INSTALLATION

Preparation Work




1. Blow remains of rivet toward both ends of 5th bow with compressed air if they are entering into 5th bow.




2. Remove the remains drawn to both ends by the air blow from the gap.













3. For fixing harness to 5th bow and Soft top frame, see the figure.




4. Replace rivet retainer on back of 5th bow finisher with a new one.
5. Secure 5th bow finisher with rivet, and then apply nonwoven fabric.
6. Install 5th bow finisher and 5th bow finisher (RH/LH).
7. Apply pad on 5th bow finisher.

NOTE: Apply pad to the original position.

Installation
Install in the reverse order of removal.