Remove/install soft top

AR77.30-P-1002EC

Remove/install soft top

27.2.12

 

Remove/install

 Danger!

Risk of injury caused by moving parts that can pinch, crush or, in extreme cases, even sever extremities

No parts of the body or limbs should be within the operating range of the mechanism when moving components.

AS00.00-Z-0009-01A

 Danger!

Risk of injury to skin or eyes caused by hydraulic fluid spraying out under high pressure. Risk of poisoning caused by swallowing hydraulic fluid

Depressurize the hydraulic system completely before starting any work on the system. Wear protective clothing and safety glasses.

AS00.00-Z-0013-01A

 Danger!

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.

Deburr repair panels.

AS00.00-Z-0017-01A

 Perform assembly work analogously on left and right side of vehicle.

1

Cover vehicle in rear area

 To prevent scratching the paint during assembly work.

2

Remove side paneling in trunk

AR68.30-P-4800EC

3

Connect variable soft top compartment limit switch to wiring harness on vehicle side.

 Connect and actuate soft top compartment limit switch on vehicle side so that the soft top (1) can be moved electrically.
The following document describes removing variable soft top compartment limit switch from retractable cover, actuating striker, securing with cable ties and connecting:

Remove/install soft top hydraulic pump

AR77.37-P-1000EC

4

Remove lower side paneling in rear

AR68.30-P-4780ED

5

Lower soft top (1) toward front

 Leave soft top bow and soft top compartment cover in upright position

6

Disconnect electrical connector (2) from AM amplifier (A104/1)

7

Remove sidebag (8)

Only on vehicles with code (293) right and left rear sidebag.

AR91.60-P-0694EC

8

Remove foam material (7)

9

Unclip belt guide (10)

AR91.40-P-0681ECA

10

Remove bolts (3)

11

Remove connecting panel (4)

12

Remove bolt (5)

13

Unscrew nut (6)

14

Loosen left belt extender (A10) and right belt extender (A11) and lay down to side with electrical line connected

 Installation: Do not twist seat belt.

15

Unscrew bolt (12) from bracket (13)

16

Remove bracket (13)

 Installation: Ensure that bracket (13) is seated correctly in lug (arrow A).

17

Unscrew bolt (15) and lay belt guide bracket (14) down to side

 Installation: Do not twist seat belt.



*BA91.40-P-1014-01P

18

Remove trim strip beltline (17) from side wall paneling starting at front

 Mounting wedge

*110589035900

19

Remove shaped part of sealing rail (16) with retaining clamp and adhesive tape (18) from
B-pillar

 Installation: Clean bonding area on adhesive tape (18) on B-pillar. Observe flash-off time for cleaner of at least 60 s.

Lift shaped part in area of adhesive tape (18) until protective foil can be removed from adhesive tape (18)
Remove protective foil from adhesive tape (18) and press adhesive tape (18) with shaped part to body
Ensure that shaped part is seated correctly on B-pillar
Roll shaped part onto B-pillar with roller in area of adhesive tape (18)

 Roller

*168589056300

Cleaner

*BR00.45-Z-1025-04A

20

Pull pin (19) on shaped part on sealing frame (16) out of B-pillar

 Installation: Moisten pin (19) on shaped part with lubricant and press into B-pillar.
Ensure that pin (19) is seated correctly in opening (arrow B) of B-pillar.

Antifriction agent

*BR00.45-Z-1010-06A

21

Remove sealing rail (16) from side wall inner section

 Mounting wedge

*110589035900

 Installation: Prepare sealing rail (16) for installation:

Prepare sealing profile on roof frame for installation

AR88.85-P-2000-01EC

 Allow primer to flash off for at least 90 s, apply primer only once and do not touch with bare fingers, otherwise the adhesive force of the new adhesive strip (18) is not ensured. Attach new adhesive tape (18) to shaped part within one hour, otherwise the adhesive force of the new adhesive tape (18) on shaped part is not ensured.

Adhesive tape

*BR00.45-Z-1099-02A

4298 UV primer

*BR00.45-Z-1125-02A

Cleaner

*BR00.45-Z-1025-04A

Hot air blower
gotis://E_15/54_12.0

22

Remove rear window heater ground line (20) from left C-pillar ground point (W29/3)

23

Disconnect electrical connector (21) from soft top limit switch electrical line (22)

24

Unscrew bolt (23) on soft top support (1.2) from tolerance compensation element (25)



*BA77.30-P-1001-01A

25

Disconnect electrical connector (26) from rear window heater electrical line (27)

26

Unscrew bolt (28) on soft top support (1.2) from tolerance compensation element (30)



*BA77.30-P-1001-01A

27

Unscrew bolts (31) from inner panel (33)

28

Unscrew nut (32) from inner panel (33)

29

Remove inner panel (33)

 Installation: Remove sealing profile (arrow C) from inner panel (33) and clean inner panel (33) and soft top compartment seal in bonding area. Apply new sealing profile (arrow C) to inner panel (33).

Sealing cord

*BR00.45-Z-1086-01A

Cleaner

*BR00.45-Z-1025-04A

30

Unscrew bolt (34) from soft top support (1.2)

 Intermediate layers are located between the body and the soft top support (1.2).

 Installation: Reuse intermediate layers.

31

Loosen soft top actuation hydraulic cylinder (35) and lay down to side with hydraulic lines connected

AR77.37-P-4171QA

32

Loosen soft top bow hydraulic cylinder (36) and lay down to side with hydraulic lines connected

AR77.37-P-4190QA

33

Disconnect electrical connector (37) from soft top bow up/down limit switch (S84/15)

34

Unscrew bolts (38) from soft top support (1.2)



*BA77.30-P-1001-01A

35

Unclip cable (39) from soft top support (1.2) at rear

 Relieve pressure by slightly pressing onto cable side flap (39).

36

Loosen electrical line on antenna (40) from attachment points (arrows D)

37

Disconnect electrical connector (41) from AM amplifier with selection switch (A104/2)

38

Remove soft top control hydraulic unit (A7/5)

AR77.37-P-1000EC

39

Expose hydraulic line set (42)

40

Cut cable tie (arrows E) and expose hydraulic lines on locking unit hydraulic cylinder

 The hydraulic lines on the locking unit hydraulic cylinder are marked on the connection plate (43) with item numbers "65" and "66".

41

Remove hydraulic lines on locking unit hydraulic cylinder from connection plate (43)

Mark hydraulic lines for locking unit hydraulic cylinder.

42

Plug hydraulic lines for locking unit hydraulic cylinder

 Set of stop plugs

*129589009100

43

Remove soft top (1)

 Aid of helper required.

 Installation:To allow tolerance compensation on both sides, screw expansion nuts (24, 29) counterclockwise into tolerance compensation elements (25, 30).

44

Prepare sealing rail (16) for installation

When reinstalling old sealing rail (16).

AR88.85-P-2000-01EC

 Allow primer to flash off for at least 90 s, apply primer only once and do not touch with bare fingers, otherwise the adhesive force of the new adhesive strip (18) is not ensured. Attach new adhesive tape (18) to shaped part within one hour, otherwise the adhesive force of the new adhesive tape (18) on shaped part is not ensured.

Adhesive tape

*BR00.45-Z-1099-02A

4298 UV primer

*BR00.45-Z-1125-02A

Cleaner

*BR00.45-Z-1025-04A

Hot air blower
gotis://E_15/54_12.0

45

Check soft top support with locating tool, adjust if necessary

 After checking or adjusting remove  locating tool.

AR77.30-P-1002-02QA

 Locating tool

*207589032300

46

Install in the reverse order

47

Check gaps on hoods, door and cover, adjust if necessary

 Gap dimension "R" and "S".

*BE60.00-P-1006-01W

Feeler gauge

*129589032100

Number

Designation

Model 207.4

BE60.00-P-1006-01W

Gap dimension

Soft top to windshield frame

Dimension "R"

mm

11 (1.5)

Soft top to soft top compartment cover

Dimension "S"

mm

3 (+2)

See picture

AR60.00-P-0700-01EC

Number

Designation

Model 207.4

BA77.30-P-1001-01A

Bolt, soft top support on body

Nm

20 (2)

Number

Designation

Model
207

BA91.40-P-1014-01P

Screw/bolt, rear belt guide bracket to rear panel

Nm

35

Number

Designation

Order number

BR00.45-Z-1086-01A

Soft top frame sealing profile with metal core 35 m, SEALANT/butyl Bostik 1127

A 005 989 12 71 10

BR00.45-Z-1099-02A

Adhesive tape/Acrylic Plus PT 1100

A 008 989 20 85

BR00.45-Z-1125-02A

4298 UV primer

A 007 989 96 71 10

BR00.45-Z-1025-04A

Cleaner

A 005 989 19 71

BR00.45-Z-1010-06A

Lubricant, rubber assembly 1 l

A 000 989 03 67