Section C
Section C - Headlining Tensioning System RepairTO BETTER UNDERSTAND THE FOLLOWING WORK SEQUENCE, PLEASE REFER TO THE PICTURES WHICH IDENTIFY THE ASSEMBLED HEADLINING TENSIONING CABLE ROUTING AND DESCRIPTIONS:
NOTE: All illustrations in this section are showing right side of vehicle unless identified as a left side illustration
- Long upper cable -2- is attached to outer part of convertible top frame -arrow C-
- Long upper cable -2- is then routed behind cross rail and over extended element and through highest and rearmost cable guide (when observing frame from outside of vehicle)
- Long upper cable -2- will be routed through convertible top fabric loops, if present -arrow D-, then attached to a retaining plate
- If fabric loops are not present, the upper long cable will be routed from cable guide directly to the retaining plate
- Left side Illustration
- Short lower cable -1- is attached to upper convertible top frame -arrow C-
- Short lower cable -1- is then routed through cable guides -arrows A & B-
NOTE: Lower cable guide -arrow A- is partially shown
- Short lower cable -1- is then routed in front of convertible top frame and is attached to retaining plate
- Position convertible top to vertical position approximately half way between up and down)
NOTE:
- Convertible top position may need to be adjusted throughout repair to have access to components
- Work on one side of vehicle at a time
- Remove 3 rivets -arrows A & B- and remove guide rail from convertible top frame
NOTE: The rivet -arrow A- may not have an eyelet with cable as shown in the illustration
- Remove guide rail -2- from slider -4-
- Remove rivet -1- securing eyelet on the short lower cable
- Remove rivet -2- securing eyelet on the long upper cable
NOTE:
- On some vehicles, the rivet -2- is securing a small bracket
- Remove rivet and small bracket
- Using cutters -S-, cut off eyelet from the short lower cable
- Remove short lower cable from cable guides -A- & -B- in direction of arrow
- Check cable guides -A- & -B- for wear or damage and remove as necessary
NOTE: If cable guide -B- is being removed, a bushing will also come off
- Move headlining aside and remove rivet -arrow- attaching cable guide (with bushing) or elastic strap to the frame
NOTE: If there is no cable guide, elastic strap or hole in the frame, to which cable guide can be attached, see Additional Repair Information in Section D for instructions to drill hole
IMPORTANT: Make note of cable guide position and complete cable routing for installation of new cable and cable guide
NOTE: Illustration shows rivet and cable guide as seen from inside the vehicle
- On some vehicles, remove long upper cable with cable guide through fabric loops arrows-
NOTE: Fabric loops are not on all vehicles
- Remove slider -1- from retaining plate -2- (inside headlining) by starting at bottom -arrow- and prying away from clips -3-
NOTE:
- Retaining plate inside headlining is attached to an elastic cable that is under tension
- Illustration shows an upper cable attached to the slider
- Some vehicles may have an elastic strap and no cable
- Remove slider with cable(s) or elastic strap from vehicle
- Push retaining plate clips -1- into the headlining to allow retaining plate to be removed
- On convertible top, remove screw securing elastic cable eyelet
CAUTION:
- ELASTIC CABLE MAY BE UNDER TENSION
- DO NOT ALLOW ELASTIC CABLE TO RETRACT INTO THE HEADLINING
- Carefully remove elastic cable with retaining plate in direction of the arrow
- Tie a strong one meter (3 ft) piece of string from the cable kit (1YM 898 001B) to the eyelet on a new elastic cable with retaining plate (1Y0 871 955A or 1Y0 871 956A)
- Attach the cable guide tool JC 4200 to the end clip on the retaining plate and fully insert the retaining plate and elastic cable into headlining -arrow- and remove the JC 4200 guide tool
IMPORTANT: When using the JC 4200 cable guide tool, pull elastic cable to keep tension against clip, otherwise tool will come off retaining plate
NOTE:
- Clips on retaining plate must face outwards when inserted
- When retaining plate and elastic cable are fully inserted, only the string will be visible outside headlining
- Push clips on retaining plate through holes in headlining
- Obtain new slider (1Y0 871 341/A or 1Y0 871 342/A) from cable kit
- Untie only knot -1- in the short lower cable
IMPORTANT:
- Do not cut knot off new cable
- Cable length must be maintained
- Remove two cable guides -A- and -B- from short lower cable -1-
NOTE:
- If lower cable guides (-A- & -B-) on vehicle were previously inspected and found worn or damaged, then the short lower cable on new slider does not have to be untied
- Install new guides on cable.(See Section D - Additional Repair Information )
- Rotate cable guide -B- to a position that is forward of it s securing rivet
- Insert untied short lower cable down through cable guide -B- then through cable guide -A-
- Reinsert short lower cable into previously installed hole in slider and retie knot arrow 1- in the same position as untied
IMPORTANT: Cable length must be same as it was prior to untying knot
- Attach slider -1- to retaining plate -2- inside headlining
- Carefully press parts together with pliers to ensure clips -3- are properly seated
NOTE: Make certain lower short and upper long cables are not between the slider and retaining plate when assembling
- Insert guide rail -3- into slider -4- making certain that long upper cable -2- is behind guide rail -3- and short lower cable -1- is in front of guide rail -3-
IMPORTANT: If guide rail is worn, defective or is missing the molded in stop at the top, install new guide rail (1Y0 871 371/407) from the cable kit
NOTE: Assembled parts should look like illustration to the left (viewed from outside the vehicle)
- Using rivets (1Y0 871 996 A) attach guide rail to frame at two lower points -arrows-
NOTE: Do not install upper rivet at this time
- Use a rivet (1Y0 871 996 A) and attach short lower cable eyelet -arrow-
NOTE: Short lower cable must be in front of guide rail as shown in previous illustration
- If vehicle has a headlining with loops, route long upper cable with cable guide through loops
- Insert new rivet (1Y0 871 996 C) into cable guide on long upper cable, as shown
- Place a new bushing (1Y0 871 180) over rivet and into cable guide hole
CAUTION: MAKE CERTAIN THAT RIVET IS POSITIONED INTO CABLE GUIDE AS SHOWN, OTHERWISE LONG UPPER CABLE WILL NOT FUNCTION PROPERLY
- Position cable guide rearward of rivet arrow- and secure to frame
NOTE: If there is no hole in the frame to which cable guide can be attached, see Additional Repair Information in Section D for instructions to drill hole
CAUTION: FOR CORRECT CABLE ROUTING, ROUNDED PORTION OF CABLE GUIDE MUST BE REARWARD OF THE ATTACHING RIVET
- Route long upper cable -2- behind cross rail -1- and over extend element -3-
- Route long upper cable -2- between the short lower cable -1- and the frame -3-
- Position sliding cable eyelet -4- at a 45° angle to guide rail, and using a rivet (1Y0 871 996 A) attach sliding cable socket -4- along with guide rail to the frame
NOTE: Flat side of the sliding cable eyelet must face guide rail
- Using a rivet (1Y0 871 996 A) secure cable eyelet -1- to upper hole -arrow- in frame
NOTE: Flat side of the cable eyelet must face frame
CAUTION: MAKE SURE UPPER HOLE IS USED, OTHERWISE LONG UPPER CABLE WILL NOT FUNCTION PROPERLY
- Pull cord -arrow- tied to elastic cable until eyelet is outside the headlining
- Partially secure eyelet on elastic cable with screw, remove string, and finish tightening screw
CAUTION: DO NOT ALLOW ELASTIC CABLE TO RETRACT INTO THE HEADLINING
- Repeat procedure on opposite side of the vehicle
- Close and fully open convertible top to make certain new cables are functioning correctly
- Reinstall roof frame trim panel
- Close convertible top, pull down the handle for locking the top, turn the handle counterclockwise as far as the stop, pull the top down and turn the handle clockwise
- Push the handle up into the recess
- Destroy and properly dispose of removed parts, as well as the extra part from the repair kit
- Proceed to Section E