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Home >> Porsche >> 2002 >> Boxster S (986) F6-3.2L >> Repair and Diagnosis >> Body and Frame >> Roof and Associated Components >> Convertible Top >> Convertible Top Frame >> Service and Repair >> Procedures >> Replacing Convertible-Top Frame With Glass Rear Window

Replacing Convertible-Top Frame With Glass Rear Window



Replacing convertible-top frame - for convertible top covering with glass window, - as of MY 2003




6 Convertible-top support
15 B-pillar
20 Main bow
22 Roof frame
23 Convertible top lock
30 Stop
33 Corner bow
34 Connection-piece with joint
35 Connection-piece with joint
36 Tension bow
40 Tension strap
44 Restraining strap


Assembling convertible-top frame




1. Placing the roll-over bar on assembly fixture
- Place the roll-over bar outside the vehicle on a workbench or assembly fixture and secure.




2. Fitting the adjusting piece and strips of adhesive tape
a. Insert the adjusting piece -2- , which is used to brace the tension bow, into the guides of the roll-over bar -1- and fasten the adjusting piece -2- with the fastening screw -3- .
b. Affix two strips of double-sided adhesive tape -4- in the area of the convertible-top support fastening point. See 'Materials and tools'
The strips of tape are used to fasten the water collection tray.




3. Installing water collection tray
- Position the hole pattern of the water collection tray -5- on the hole pattern -Arrows- of the roll-over bar -1- and press the tray onto the two strips of double-sided adhesive tape -4- .




4. Installing convertible-top support
- Position the convertible-top support -6- on the roll-over bar and fasten it with the fastening screws -7- . Make sure that when tightening, the convertible-top support is pressed in the direction of arrows -A and B-. See 'Tightening torques'




5. Install seat belt.
- Position the belt reel at the bottom -8- and the deflector at the top -9- on the roll-over bar -1- and fasten with the fastening screws -10, 11-. See 'Tightening torques'




6. Fitting stop buffer on the roll-over bar
- Position bracket (stop) -12- on the roll-over bar -1- and tighten with the fastening screws -13-. See 'Tightening torques'




7. Joining drive lever to the B-pillar

Note!
- When inserting the push bar -Arrow- of the roof frame into the roof frame, make sure that it is routed through the rubber strap of the B-pillar!
- Use assembly grease when fitting the pins!

a. Press in Teflon bushings -14- in the bores of the push bar and drive lever on both sides.
b. Position the drive lever -16- on the B-pillar -15- and join it with the pin, -18- 8 x 45.
c. Position the push bar -17- on the drive lever -16- and join it with the pin, -18- 8 x 45.
d. Press the retaining clips -19- into the pins -18- .




8. Joining convertible-top support to the B-pillar

Note! Use assembly grease when fitting the pins!

a. Press in Teflon bushings -14- in the bore of the drive lever on both sides.
b. Position the B-pillar -15- on the convertible-top support -5- and join it with the pin -18- 8 x 45.
c. Press the retaining clips -19- into the pins -18- .




9. Installing main bow

Note! Use assembly grease when fitting the pins!

a. Press in Teflon bushings -14- in the bore of the convertible-top support and drive lever on both sides.
b. Position the main bow -20- on the convertible-top support -5- and drive lever -16- . Then join with the pins, -21- 8 x 70 and -18- 8 x 45. Insert pins in -direction of arrow-.
c. Press the retaining clips -19- into the pins -18, 21-.




10. Fitting the roof frame on the B-pillar

Note! Use assembly grease when fitting the pins -18- !

a. Press in Teflon bushings -14- in the bore of the B-pillar and push bar on both sides.
b. Fit the pre-assembled B-pillar -15- in the roof frame -22- and connect with the pins 8 x 45 -18- .
c. Secure the pin -18- with a clip -19- .




11. Fitting convertible-top lock
a. Position convertible-top lock -23- in roof frame -22-
and fasten with the fastening screws -24-. See 'Tightening torques'




12. Fitting centring pins
a. Position centring pins -25- on the roof frame -22- on the left and right and fasten with the fastening screws -26-. See 'Tightening torques'
b. Affix cover cap -27- onto the centring pins with Loctite 270.




13. Fitting the cover on the roof frame
- Insert the cover -28- on the roof frame -22- and tighten the fastening screws -29- .
- The cover is spring-supported and covers the screw and pivot points on the roof frame.




14. Fitting stop on the corner bow
- Position stop -30- on the corner bow and screw down using the fastening screws -31-. See 'Tightening torques'




15. Installing corner bow
a. Press in Teflon bushings -14- in the bore of the corner bow on both sides.
b. Position corner bow -33- on the main bow -20- and join with the pins -18- .
c. Press the retaining clips -19- into the pins -18- .




16. Fitting the connection-piece with joint on the tension bow
a. Press in Teflon bushings -14- in the bore of the joint on both sides.
b. Position joint -34- on the main bow and join with the pins -18-.
c. Secure the pin -18- with a clip -19- .




17. Fitting connection-piece

Note! Before removal, mark the longitudinal adjustment from the connection-piece to the tension bow on the connection piece using a scriber.

- Insert the connection-piece -35- into the tension bow -36- and fasten with the fastening screws -37-. See 'Tightening torques'




18. Installing tension bow

Note! Use assembly grease when fitting the pins!

a. Position the tension bow with the connection-piece -35- on the link -34- and join with the pin 8 x 25 -18- .
b. Press the retaining clips -19- into the pins -18- .




19. Installing the tension cable
- Press the ball socket -38- of the tension cable -39- into the ball head of the adjusting piece -2- on the roll-over bar -1- .

20. Installing tension strap
- See 'Installing tension strap'

21. Measuring roll-over bar with convertible-top frame in the vehicle.
- See 'Test and adjusting values'


Installing tension strap




1. Installing tension strap on the main bow
- Position the strap cover -37- using the holes provided on the tension strap -36- and press into the main bow -26- .




2. Installing tension strap on the corner bow
- Position the strap cover -42- using the holes provided on the tension strap -40- and press into the corner bow -33- .




3. Installing tension strap on the roof frame
- Position the tension strap -40- on the roof frame at the rear -22- and fasten the tension strap -40- with the fastening screws -43-. See 'Tightening torques'




4. Installing tension strap on the corner bow

Note! Use only aluminium rivets listed in the scope of parts

- Position tension strap -44- on corner bow -33- on the holes provided, rivet on the tension strap -44- with the pop rivets -45- (parts scope component of convertible-top covering)




5. Installing tension strap on the tension bow

Note! Use only -yellow galvanized- rivets listed in the scope of parts

- Position tension strap -44- on tension bow -36- on the holes provided, rivet on the tension strap with the pop rivets -45- (parts scope component of convertible-top covering).


Test And Adjusting Values:




Materials And Tools:




Tightening Torques:




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