Disassembling and Assembling Hardtop

610237 Disassembling And Assembling Hardtop






Preliminary work
1. Remove rear window.
2. Remove centering peg.
3. Remove rear hardtop locking mechanism.

Disassembling hardtop
1. Detach cover strips and roof strip clips.
1.1. Lift up the cover strip -1- at left and right using a plastic spatula and pull it off. The roof strip clips are destroyed on removal.






2. Place outer roof panel of hardtop on the assembly fixture.
3. Unclip linings.
3.1. Unclip linings -1- front and rear from hardtop -2-.






4. Detach seal at sides of roof frame.
4.1. The seal at the sides of the roof frame -1- is in two parts. Pull the upper seal -2- out of the profile of the retaining strip -3-.
4.2. Unscrew fastening screws -4- from the retaining strip -3-.
4.3. Remove the seal below together with the retaining strip -5- from the roof frame -1-.






5. Loosen and detach retaining strip and roof frame seal.
5.1. Unscrew tapping screws -1- from retaining strip -2-.
5.2. Unscrew pan-head screw -3- from the roof frame seal, detach the seal at the corners and remove it.






6. Pull off sealing rubber.
6.1. Pull off the surrounding sealing rubber -1- to the rear and pull it out at the ends from the roof frame seal -2-.






7. Detach roof liner at front.
7.1. Lift front retaining strip -1- of roof liner -2- with a plastic spatula and pull it off.






8. Detach roof liner at sides.
8.1. Lift up the roof liner -1- on the left and right sides with a plastic spatula and disengage from the sheetmetal clips -2-.






9. Detach roof liner at rear and transverse struts.
9.1. Pull plastic strip -2- of roof liner to the rear and detach it -1-.
9.2. Pull out transverse struts -3- with plastic sleeves -4- and remove the roof liner -1-.






10. Loosen sound absorber from the hardtop body.
10.1. Loosen the sound absorber -2- of the hardtop body -1- using a spatula.






11. Remove foam strips.
11.1. Carefully pull off foam strips -1- on B-pillar -A- , at rear of roof -B- and at the centering pegs at front -C- and the foam pads -2- on the left and right.






12. Remove locking lever.
12.1. Unscrew and remove fastening screws -1- from the locking lever -2-.






13. Press expander nuts out of the hardtop body.
13.1. Press expander nuts -1- out of the hardtop body -2- at the sides and top.






Assembling hardtop
1. Set the hardtop down on the assembly fixture on the outer roof panel.

NOTE:
- Please observe the coloured installation position of the expander nuts.
- 1A = yellow
- 1B = white
- 1C = green
- 2A = red
- 2B = white

2. Press expander nuts into the hardtop body.
2.1. Beginning in the direction of travel going left
2.2. One red -2A- expander nut
2.3. Three yellow -1A- expander nuts
2.4. One green -1C- expander nut
2.5. One white -1B- expander nut
2.6. Press three green -1C- expander nuts into the hardtop body.
2.7. Beginning in the direction of travel going right
2.8. One white -2B- expander nut
2.9. Three yellow -1A- expander nuts
2.10. One green -1C- expander nut
2.11. One white -1B- expander nut
2.12. Press three green -1C- expander nuts into the hardtop body.
2.13. Press the expander nuts at the front -1B- into the hardtop body in the direction of travel.






3. Stick felt strips on inside of window aperture.
3.1. Stick a felt strip -2- approx. 2 cm wide along the window aperture on the rivet joints of the hardtop body -1-.






4. Stick sound absorber on the hardtop body.
4.1. Position the self-adhesive sound absorber -2- in the hardtop body -1- and press firmly into place.






5. Fit locking lever.
5.1. Position locking lever -2- on hardtop body -1- and secure with fastening screws -3-. Tightening torque - Tightening torque : 10 Nm (7.5 ftlb.)






6. Stick in foam strips and foam pads.
6.1. Position foam strips -1- on B-pillar -A-, at rear of roof -B- and at centering pegs at front -C- and the foam pads -2- on the left and right. Press on firmly.






7. Engage roof liner at rear and transverse struts.
7.1. Insert transverse struts -2- with plastic sleeves -3- into the hardtop body -3-.
7.2. Pull back plastic strip -4- of roof liner -5- and engage in groove of hardtop body -1-.






NOTE: If the hardtop body is new, the sheetmetal clips on the left and right must be bent over to the outside using a plastic hammer.

8. Engage roof liner at sides.
8.1. Engage roof liner -1- at the left and right sides in the sheetmetal clips -2-.






9. Fit roof liner at front.
9.1. Position front retaining strip -2- of roof liner -1- and clip it in.






10. Fit sealing rubber.
10.1. Insert self-adhesive sealing rubber -2- at the ends of the roof frame seal -1-.
10.2. Remove protective film of the sealing rubber and press firmly into place at the rear on all sides.






11. Affix Nito tape to the hardtop body.
11.1. Stick a 2 cm wide strip of Nitto tape -2- on the hardtop body -1- at the front left and right.






12. Fit roof frame seal and retaining strip.
12.1. Engage roof frame seal in the hardtop body at the corners and fasten with the fastening screw -1-. Tightening torque Tightening torque : 10 Nm (7.5 ftlb.)
12.2. Position retaining strip -2- and screw down using the fastening screws -3-.






13. Fit seal at sides of roof frame.
13.1. The seal at the sides of the roof frame -1- is in two parts. Position lower seal with retaining strip -2- on roof frame -1- and fasten with fastening screws -3-.
13.2. Press upper seal -4- into the profile of the retaining strip -5-.






NOTE: Once a trim panel has been clipped in, the old plastic clips are no longer usable and must always be replaced.

14. Fit lining.
14.1. Clip linings -2- front and rear into hardtop -1-.






15. Clip in roof strip clips and cover strips.
15.1. Fit roof strip clips -3-.
15.2. Fit cover strip seal on the cover strip -2-.
15.3. Position cover strips on the hardtop body -1- and press into the roof strip clips.






Subsequent work
1. Install rear hardtop locking mechanism.
2. Install centering peg.
3. Install rear window.