Remove/install soft top

AR77.30-P-1002QA

Remove/install soft top

15.3.10

 

Remove/install

Danger!

Risk of injury when performing check and repair work in area of roll bar

Before working in the area of the roll bar, pull out the rear head restraints by hand.

Keep body parts out of the area where the roll bar extends.

AS91.00-Z-0003-01QA

 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

1

Cover vehicle in rear area

 To prevent scratching the paint during assembly work.

2

Open soft top

 Lower soft top and leave soft top compartment cover upright.

3

Remove rear seat and rear seat cushion

AR91.12-P-1700QA

4

Remove side panelings in left and right rear

AR68.30-P-4780QA

5

Remove seat belt extender

AR91.45-P-1000Q

6

Close soft top

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

7

Remove retractable trunk partition

AR68.50-P-3000QA

8

Remove trim in trunk

 Remove only left side wall paneling and left soft top compartment paneling.

AR68.30-P-4600QA

9

Pull out expansion rivet (2) and remove cover (1).

10

Remove clip (4) and remove soft top support covering (3).

11

Remove screws (6) and remove cover (5)

12

Remove seal (7).

 Lift with mounting wedge.

 Mounting wedge

*110589035900

13

Remove bolts (9) and remove cross strut (8).

 Bolt, cross strut to B-pillar strut to soft top support

*BA77.30-P-1004-01A

14

Remove bolt (11)

 Bolt on B-pillar strut

*BA77.30-P-1005-01A

15

Loosen nut (12)

 Nut on B-pillar strut

*BA77.30-P-1006-01A

16

Remove B-pillar strut (10).

17.1

Remove sidebag (33)

With code (293) Left rear and right sidebag

AR91.60-P-0694QA

18

Separate connector (13)

19

Separate connector (14)

20

Unscrew nut (15) and remove rear window heater ground cable (16).

21

Separate connector (17)

22

Remove soft top bow hydraulic cylinder (19).

 Lay soft top bow hydraulic cylinder (19) down to side with lines connected.

AR77.37-P-4190QA

23

Remove soft top frame hydraulic cylinder.

 Lay soft top frame hydraulic cylinder down to side with lines connected

AR77.37-P-4171QA

24

Remove soft top compartment lid of hydraulic cylinder

 Lay soft top compartment lid hydraulic cylinder down to side with lines connected.

AR77.37-P-4175QA

25

Separate cable tie (27) and expose hydraulic lines (29) for lock unit hydraulic cylinder

26

Remove screw (28)

27

Remove hydraulic lines (29) from hydraulic pump (31).

28

Remove circlips (30) from hydraulic lines (29).

29

Pull hydraulic lines (29) out of connection plate (32).

30

Remove cable (20) from ball head (22).

31

Remove screw/bolt (34) from bracket (21)

32

Remove bracket (21)

33

Remove bolt (25) and lay seat belt (26) down to side.

 Screw in rear upper belt guide fitting

*BA91.40-P-1005-01A

34

Remove bolts (35)

35

Remove support (36)

36

Remove bolts (24) from soft top support (23).

 Bolt, soft top main bearing to body bearing plate

*BA77.30-P-1001-01A

37

Remove soft top.

38

Check soft top support with fastening gauge.

AR77.30-P-1002-02QA

 Locating tool

*209589016300

39

Install in the reverse order

40

Adjust gap dimensions on hoods, doors and lids

AR60.00-P-0700-01QA

Soft top to windshield frame

*BE60.00-P-1006-01G

Soft top to soft top compartment cover

*BE60.00-P-1006-01G

Feeler gauge

*129589032100

Number

Designation

Model
209.4

BE60.00-P-1006-01G

Gap dimension

Soft top to windshield frame

Dimension "M"

mm

10 (2)

Soft top to soft top compartment cover

Dimension "N"

mm

3 (0.5)

See picture

AR60.00-P-0700-01QA

Number

Designation

Model 209.4

BA77.30-P-1001-01A

Bolt, soft top support on body

Nm

20 (2)

BA77.30-P-1004-01A

Bolt, cross strut on B-pillar strut to soft top bearing

Nm

10 (2)

BA77.30-P-1005-01A

Bolt on B-pillar strut

M616

Nm

10 (2)

M816

Nm

20 (2)

BA77.30-P-1006-01A

Nut on B-pillar strut

Nm

20 (2)

Number

Designation

Model
209.4

BA91.40-P-1005-01A

Screw in rear upper belt guide fitting

Nm

30