Removal And Installation

HYDRAULIC SYSTEM

Removal and Installation


CAUTION:
It is prohibited to disassemble the hydraulic unit assembly components. Never remove cylinders and oil pressure hoses.

REMOVAL

1.Remove soft top assembly from the vehicle. Exploded View.
2.Remove soft top control unit. Exploded View.
3.Remove bolt. Remove hydraulic pump bracket and hydraulic pump case.
4.Remove front rail weather-strip (LH and RH). Exploded View.
5.Remove front rail weather-strip retainer (LH and RH). Exploded View.





6.Remove soft top cover outer front retainer mounting screws (A).





7.Lift up soft top cover outer front retainer (1), and then pull up soft top cover outer (2) portion (A) to outside (both LH and RH).
8.Pull out soft top cover outer wire (2) from soft top linkage assembly (1) (both LH and RH).










9.Pull up front end of soft top cover outer.





10.Remove mounting rivet (A) of soft top outer bungee cord (1)
from soft top linkage assembly (2) (LH and RH).

CAUTION:
Cover the surrounding area because iron powder is spread when using a drill.
NOTE:
Removal and Installation of Rivet





- Grind the head of rivet (1) with a drill (A) [bit of dia. 4.0 mm (dia. 0.157 in)].
- Securely crimp the bungee cord with the soft top linkage assembly using a hand riveter (B).










11.Remove soft top cover inner mounting screws (A) from 1st bow (1) (LH and RH).





12.Remove mounting screws (A) of soft top cover inner retainer (2)
from 1st bow (1).
NOTE:
Soft top cover inner strap (B) and soft top cover inner are tightened together to 1st bow.
13.Remove 2nd bow mounting bolts.





14.Remove soft top linkage assembly bungee cord (A) from 2nd bow (1) (LH and RH).





15.Pull out wire (2) from soft top cover outer (1) (LH and RH).
16.Remove rear rail weather-strip. Exploded View.
17.Remove rear rail weather-strip retainer (LH and RH). Exploded View.





18.Remove rear end of soft top cover outer (2) from 5th bow (1).





19.Pull up soft top cover outer lateral side to outside from upper to lower. Remove double-sided tape (A) (LH and RH).





20.Remove E-clips (A). Disengage connection of soft top cover outer wire (2) from soft top linkage assembly pin (1) (LH and RH).

White arrow indicates : Vehicle front






21.Slide soft top cover outer (1) in the direction shown by the arrow.
Simultaneously pull out retainer (3) and wire (4) from soft top linkage assembly (2) (LH and RH).

CAUTION:
Write a short note to describe the wire locations and the retainer mounting positions.





22.Manually operate soft top linkage assembly to the open position.





23.Pull up soft top cover outer lateral side to outside. Remove rivet (A) and screw (B) that secure soft top cover outer bungee cord (1) (LH and RH).

CAUTION:
Cover the surrounding area because iron powder is spread when using a drill.

White arrow indicates : Vehicle front

NOTE:
Removal and Installation of Rivet





- Grind the head of rivet (1) with a drill (A) [bit of dia. 4.0 mm dia. 0.157 in)].
- Securely crimp the bungee cord with the soft top linkage assembly using a hand riveter (B).





24.Remove rear defogger connector. Pull out rear defogger harness from soft top inner (LH and RH).
25.Remove roof latch lock sensor harness connector. Exploded View.





26.Remove spring lock (A). Pull out cylinder mounting pin (1)
toward upper side of vehicle.
27.Remove TORX bolts (B). Remove 1st bow latch assembly center bracket (2).

White arrow indicates : Vehicle front







28.Lift up center portion of 1st bow latch assembly (1). Remove retaining plate (A) of roof latch cylinder (2).
29.Remove band and screw that fix oil pressure hose to soft top linkage assembly.
NOTE:
Write a short note to describe the band and screw locations.

CAUTION:
Never sharply bend, twist or strongly pull oil pressure hose.
30.Remove E-clips (A) of 5th bow drive cylinder (1). Remove cylinder mounting pins (2) (LH and RH).






White arrow indicates : Vehicle front






31.Remove E-clip (A) and pin (1).
32.Lift up linkage (2). Pull out roof latch cylinder and oil pressure hose.

White arrow indicates : Vehicle front






33.Place soft top assembly as shown in the figure. Maintain clearance (a).
NOTE:
Do not allow soft top assembly to apply its own weight to installation portion of the vehicle body.

CAUTION:
Be careful not to turn over soft top assembly.





34.Remove E-clip (A). Remove mounting pin (2) of roof drive cylinder (1) (LH and RH).

White arrow indicates : Vehicle front






35.Remove push on nut (A). Remove mounting pin (2) of roof drive cylinder (1) (LH and RH).

CAUTION:
Be careful not to allow excessive twisting of rotating axis portion (b).

White arrow indicates : Vehicle front

36.Remove hydraulic unit assembly from soft top linkage assembly.

CAUTION:
Never sharply bend, twist or strongly pull oil pressure hose.

INSTALLATION

Note the following items, and install in the reverse order of removal.

CAUTION:





- Tighten soft top cover inner front end and bungee cord (2)
together to soft top linkage assembly using screw (A), when installing soft top cover inner (1).

White arrow indicates : Vehicle front

- After installing hydraulic unit assembly, manually operate soft top linkage assembly and check that oil pressure hose is not pinched.
- Manually operate and check that soft top assembly operates without interfering with other portions of the vehicle body.
- Before manually operating each cylinder of the hydraulic system, turn ignition switch OFF or disconnect battery cable from the negative terminal, then wait for 4 minutes or more. (Each cylinder maintains oil pressure and therefore it takes a period of time to lower oil pressure.)
- Perform fitting adjustment after installing soft top assembly. Adjustment.
- Perform door glass fitting adjustment after soft top assembly fitting adjustment. Adjustments.
- Perform leakage test.
NOTE:





- When installing push on nut (1), crimp it using water pump pliers (A) and socket (B).