Soft Top Cover

Component Parts Drawing Part 1:

Component Parts Drawing Part 2:

SOFT TOP

Removal and Installation of Soft Top Cover

REMOVAL

CAUTION:
- Do not reuse used double-faced adhesive tape, nonwoven fabric, EPT seal, pad, etc.
- Be careful not to damage soft top assembly during removal. Do not place it upside-down so as to prevent cover from compression scars.

1. Remove soft top assembly from the vehicle. Refer to "Removal and Installation of Soft Top Assembly".




2. Set up the soft top assembly on the table.
3. Remove roof actuator (RH/LH). Refer to "Removal and Installation of Roof Actuator".







4. Remove holder of 5th bow operation strut rods, and then remove 5th bow operation strut rods.

CAUTION:
- When 5th bow operating strut rods are removed, 5th bow drops suddenly.
Perform operation while holding 5th bow.
- Temporarily fix 5th bow operating strut rods on 5th bow finisher




5. Open soft top assembly.




6. Protect the limit switch contact around the rotation axis of the 5th bow on the left side of soft top with tape.




7. Remove welt on the rear end of front lock finisher.




8. Remove left/right clips on the front end of front lock finisher.




9. Pull up front lock lever, and then disengage clips to remove front lock finisher.




10. Remove clip, and then A link weatherstrip.




11. Peel a link sealing out.




12. Remove screws, and then remove front center retainer.
13. Put matching marks to installation position of A link retainer.




14. Remove screws, and then remove A link retainer.




15. Open soft top about 90 degrees.




16. Remove clips on the top of C link and 5th bow weatherstrip.
17. Fully open soft top.
18. Put matching marks to installation position on C link retainer.




19. Remove screws, and then remove C link retainer.




20. Remove clips on the bottom edge of C link and 5th bow weatherstrip.




21. Remove C link and 5th bow weatherstrip from 5th bow.




22. Remove screws, and then remove 5th bow retainer.







23. Shave rivets head of soft top cover 5th bow by using a drill.
[Drill bit diameter: 5.5 mm (0.22 in)]

CAUTION: Do not attempt to remove rivets completely.




24. Close soft top, and then Shave rivets head and of C link by using a drill.
[Drill bit diameter: 5.5 mm (0.22 in)]

CAUTION: Do not attempt to remove rivets completely.




25. Cut EPT seal and remove screws on the bottom of C link.

NOTE: Check the position when cutting EPT seal.

26. Pull up soft top cover from 5th bow finisher.




27. Shave rivets head of 5th bow finisher upper surface, and then remove rivets head and remove retainer.
[Drill bit diameter: 5.5 mm (0.22 in)]

CAUTION:
- Do not attempt to remove rivets completely.
- Be careful not to damage soft top when using a drill.




28. Pull up cover from the bottom of C link.




29. Open harness connector cover, and then disconnect defogger harness connector from terminal.




30. Open soft top about 90 degrees.




31. Remove soft top wire from A link.




32. Remove soft top cover wire rear bracket from C link.
33. Remove spring from C link.




34. Pull out soft top cover forward from 1st bow.




35. Pull up 2nd bow retainer by using a screwdriver, and then remove soft top cover from 2nd bow.
36. Pull up 3rd bow retainer by using a screwdriver, and then remove soft top cover from 3rd bow.




37. Pull out glass stay and defogger harness from sleeve on rear window glass side.




38. Pull out soft top cover from 4th bow and remove soft top cover completely from frame.

INSTALLATION






CAUTION: 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.

Preparation Work




1. Remove 5th bow finisher pads.

NOTE: Put matching marks so as to check the position when installing.




2. Remove screws, and then remove 5th bow side finisher (RH/LH).




3. Remove clips, and then remove 5th bow finisher.




4. Remove rivets head of 5th bow finisher retainer.

CAUTION: Do not attempt to remove rivets completely.




5. Replace retainers under 5th bow finisher with a new part.
- Put new retainers under 5th bow finisher with rivet.
- Apply nonwoven fabric to retainer lower edge.

6. Remove remains of soft top cover mounting rivet from 5th bow and C link.






NOTE: Put a steel plate between a rivet and harnesses on 5th bow for harness protection, when removing the remaining rivets by drill.

CAUTION: Take out the remains of rivets completely from 5th bow, other wise the remains cause noise.

NOTE:




- Blow remains of rivet toward both ends of 5th bow with compressed air if they are in 5th bow.




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




7. Install 5th bow finisher to 5th bow.




8. Install 5th bow side finisher (RH/LH) to 5th bow.




9. Install new pads and fabric tapes.
10. Secure 5th bow finisher harness with new nonwoven fabric if necessary.

Installation




1. Apply double faced adhesive tape for frame.
2. Put soft top cover on frame.
3. Put glass stays and defogger harnesses into sleeves on both side of rear window.
- Out side bag is for glass stay.
- Inside bag is for harness.




4. Hook soft top cover inner fabric edge to 3rd bow retainer and press retainer to hold securely.
5. Hook soft top cover inner fabric edge to 2nd bow retainer and press retainer to hold securely.




6. Wrap soft top cover around 4th bow and fix soft top cover by velcro fastener.




7. Insert soft top cover wire to A link.




8. Tighten soft top cover wire rear bracket to C link with screw. (Face tension wire outside.)
9. Hook soft top cover wire spring on C link and bend the hook of wire spring to prevent unhooking the hook.




10. Put soft top cover on 1st bow.
11. Align soft top cover hole and grommet hole at the 1st bow.




12. Tighten screws on 1st bow with front center retainer.




13. Apply EPT seal to A link installation position.

CAUTION: Install EPT seal to the original position.




14. Put soft top cover on C link lower.

NOTE:
- Make sure that vinyl tube is on C link bottom end bracket.
- Be careful not to pull soft top cover with too much tension.




15. Open 5th bow then secure soft top cover to 5th bow finisher upper surface with rivet.




16. Close 5th bow then wrap soft top cover around 5th bow.
17. Secure soft top cover to 5th bow with rivet.




18. Secure soft top cover to C link with rivet.




19. Align screw hole on soft top cover and the bottom of C link, and then tighten with screw.

NOTE:
- During tighten up the screw, insert a thin metal rod such as a nail [diameter: 4mm (0.16in)] to a clip hole near the screw to align holes of soft top cloth and its backing plastic plate, and C link frame.
- Tighten screw while holding soft top at certain angle for easy screw installation.




20. Close 5th bow then install 5th bow retainer with screws.

CAUTION: Apply it to the original position.

NOTE: During tighten up the screw, insert a thin metal rod such as a nail [diameter: 4mm (0.16 in)] to a clip hole near the each end of 5th bow retainer to align holes of the retainer, soft top cloth and its backing plastic plate, and 5th bow.




21. Install C link retainer with screws.

NOTE: Align matching marks on the retainer to screw heads, when installing the retainer.




22. Apply seal to C link lower installation position.

CAUTION: Make sure not to cover clip hole and screw head.

23. Install A link retainer with screws.

NOTE: Align matching marks on the retainer to screw heads, when installing the retainer.




24. Apply seal E to A link installation position.




25. Recheck seals for A link and C link.




26. Install C link and 5th bow weatherstrip to 5th bow and C link.




27. Remove protection tape on the limit switch.




28. Install A link weatherstrip.
29. Install front lock finisher and welt after closing soft top.
30. Connect defogger harnesses at rear window.
31. Install 5th bow operating strut rods (RH/LH).
32. Install roof actuator (RH/LH). Refer to "Removal and Installation of Roof Actuator".
33. Install soft top assembly to vehicle. Refer to "Removal and Installation of Soft Top Assembly".
34. Check soft top open/close operation.
35. Check door glass contact. Refer to "FITTING INSPECTION".
36. Check for water leakage. Refer to "Repairing Method for Water Leakage Around Doors".

NOTE: If there are wrinkles on the soft top cover, use a hair dryer to warm up the wrinkled area. Apply warm air from the hair dryer keeping the distance by 150 - 200 mm (5.9 - 7.8 in) and move the dryer to gently warm up soft top cover, for about 5 - 10 minutes until the wrinkle seems to be gone. Not to heat up soft top cover to much.