Remove/install soft top canvas

AR77.31-P-1001QA

Remove/install soft top canvas

15.11.11

 

Remove/install

Danger!

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

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

Keep body parts out of area where 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



General information on riveting

AH60.00-P-0003-01N

1

Cover vehicle in rear area

 To prevent scratching the paint during assembly work.

2

Release soft top at front

 Set up soft top frame at front

3

Lay soft top down in soft top compartment

4

Remove bolts (1) from terminal strip at roof peak (2).

 Installation: Replace bolts removed with new ones.

5

Remove terminal strip from roof peak (2)

6

Remove rubber seal (3)

7

Remove soft top canvas (4) from roof peak (2).

 First remove old soft top canvas (4) on left side and install new soft top canvas (4) on left side. Then, perform same work on right side.

8

Unhook tension cable (5) from roof peak (2).

9

Set up soft top

 Position roof peak (2) vertically

10

Lay soft top canvas (4) down at rear

11

Cut clip (8) on zipper (7)

 With side cutting pliers.

12

Open zipper (7)

 Installation: Close zipper (7) and secure at ends with clip (8).

 Closing pliers

*208589007700

 Tacking pliers

*208589003700

Cap

*BR00.45-Z-1017-13A

13

Knock off rivet (6)

 Remove rivet residues.

Hand riveter

Rivet

*BR00.45-Z-1006-13A

14

Remove fabric tape (49)

 Facilitates correct positioning of zipper (9) when installing.

15

Cut clip (10) on zipper (9)

 With side cutting pliers.

16

Open zipper (9)

 Installation: Close zipper (9) and secure at ends with clips (10).

 Closing pliers

*208589007700

 Tacking pliers

*208589003700

Cap

*BR00.45-Z-1017-13A

17

Knock off rivet (11)

 Remove rivet residues.

Hand riveter

Rivet

*BR00.45-Z-1006-13A

18

Remove fabric tape (12) with tension cable (45)

19

Cut clip (14) on zipper (13)

 With side cutting pliers.

20

Open zipper (13)

 Installation: Close zipper (13) and secure at ends with clip (14).

 Closing pliers

*208589007700

 Tacking pliers

*208589003700

Cap

*BR00.45-Z-1017-13A

21

Pull tension cable (5) out of soft top canvas (4)

 Installation: Pull tension cable (5) through soft top canvas (4) with bent wire.

22

Pull rubber seal (15) out of roof frame

23

Put rubber seal (15) down at side

24

Pull soft top canvas (4) off of roof frame

 Installation: Fasten new mounting clips to new soft top canvas (4).

25

Remove first three bolts (16) from retaining rail (17).

 Bolt for retaining rail on soft top bow

*BA77.30-P-1007-01A

26

Loosen bolts (17) from retaining rail (59).

 Bolt for retaining rail on soft top bow

*BA77.30-P-1007-01A

27

Lift retaining rail (17).

28

Pull out rubber seal (15)

29

Lift retaining rail (17).

30

Pull out soft top canvas (4)

 Loosen soft top canvas (4) before pulling out.

31

Fold soft top canvas (4) up at side

32

Knock off rivet (18)

 Remove rivet residues.

Hand riveter

Rivet

*BR00.45-Z-1007-13A

33

Detach plastic textile strap (19) with fabric strap (20)

 Installation: Position plastic textile strap (19) below hydraulic lines and between soft top bow (34).

34

Remove rear window

 Installation: Glue soft top canvas (4) to rear window frame (25) with seal at upper transitions to achieve better seal.

AR67.20-P-5145QA

 Assembly wedge

*110589035900

Sealing

*BR00.45-Z-1050-01A

Adhesive fabric tape

*BR00.45-Z-1062-02A

35

Knock off rivet (21) on left

 Remove rivet residues.

Hand riveter

Rivet

*BR00.45-Z-1006-13A

36

Loosen elastic band (22), fabric tape (23) and synthetic fabric tape (53) from attachment point.

 Installation: Before installing elastic band (22) check manufacture date of soft top canvas (4). See: 

Check manufacture date of soft top canvas

AR77.31-P-1001-02QA

 Attach elastic band (22) to attachment point according to manufacture date of soft top canvas (4). See: 

Manufacture date for soft top canvas as of 22.02.07

AR77.31-P-1001-03QA

Manufacture date for soft top canvas up to 22.02.07

AR77.31-P-1001-03QB

37

Loosen lug (58) form rear window frame (25)

38

Drill out rivet (52)

 Remove rivet residues.

Hand riveter

Rivet

*BR00.45-Z-1018-13A

39

Separate plastic clip (27) on sliding rail (30) on left

 Installation: Check mounting clip, replace if necessary.

40

Remove elastic band (28) with elastic band (29) on left

41

Lift soft top canvas (4) on left side

42

Knock off rivet (41) on sliding rail (30) on left

 Remove remains of rivets.

Hand riveter

Rivet

*BR00.45-Z-1006-13A

43

Knock off rivet (51)

 Remove remains of rivets.

Hand riveter

Rivet

*BR00.45-Z-1006-13A

44

Remove water bag (50)

45

Pull upper lug (54) out of rear window frame (25).

46

Pull lower lug (55) out of rear window frame (25).

47

Knock off rivet (26)

 Remove rivet residues.

Hand riveter

Rivet

*BR00.45-Z-1007-13A

48

Remove water bag (50) and pull out soft top bow (34).

49

Knock off rivet (24) on soft top canvas (4) on left

 Remove rivet residues.

Hand riveter

Rivet

*BR00.45-Z-1006-13A

50

Loosen soft top canvas (4) with water bag (50) from rear window frame (25) on left.

 Carefully loosen glued soft top canvas (4) with water bag (50) from rear window frame (25) to prevent tearing.

51

Loosen fabric adhesive tape (48) from soft top frame (40) and remove.

 Installation: Mask rivet (36) with fabric adhesive tape (48) to prevent chafing on soft top canvas (4).

Adhesive fabric tape

*BR00.45-Z-1062-02A

52

Knock off rivet (36) on spring (37) with tension cable (38) to soft top canvas (40) on left

 Installation: Rivet spring (37) with tension cable (38) to soft top frame (40) with rivet (36) on left.

Hand riveter

Adhesive fabric tape

*BR00.45-Z-1062-02A

Rivet

*BR00.45-Z-1006-13A

53

Unclip retaining bracket (39) with tension cable (38) from soft top bow (34) on left

 Installation: Insert retaining block (39) with tension cable (38) into soft top bow (34) on left and break in.

54

Remove retaining bracket (39) from tension cable (38).

55

Pull out tension cable (38) through water bag (50)

56

Remove bolt (31) from soft top bow (34).

57

Detach elastic band (32) with guide (33)

58

Guide elastic band (32) with guide (33) through soft top bow (34)

59

Pull plastic insert (57) out of water bag (50).

 Installation: Check plastic insert (57) for damage and replace if necessary.

60

Detach upholstery mat (56) from soft top frame (40) and soft top bow (34).

 Installation: Align upholstery mat (56) with aid of holes (arrows) along edges of soft top frame (40) and soft top bow (34).

61

Remove soft top canvas (4)

 Installation: Move fabric tapes (42) for soft top canvas (4) through plastic rail (44) and fasten with clips (43).

62

Remove glue residues in cross-hatched areas.

 Installation: Mask cross-hatched areas with double-sided adhesive tape.

Adhesive fabric tape

*BR00.45-Z-1062-02A

63

Remove sealing profile from rear window frame (25)

 Installation: Mask edges of rear window frame (25) on left side with sealing profile.

Sealing profile

*BR00.45-Z-1086-01A

64

Mark rivet hole

 Mark rivet hole on older vehicles, if a soft top canvas (4) with newer production status is installed.

 Drill rivet holes approx. 7 mm away from the edge of the largest hole, directly in front of the inclined side.

65

Drill rivet hole into soft top bow (34).

 Rivet hole must be drilled on older vehicles only if a soft top canvas (4) with newer production status is installed.

66

Fit water pocket (50) to soft top canvas (4)

Up to VIN 053405, with soft top canvas, color: black, blue, gray

AR77.31-P-1001-01QA

67

Install in the reverse order

68

Perform function test

69

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

70

Clean inside of vehicle

Wet/dry vacuum cleaner
gotis://P_00.12_06.0

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-1007-01A

Bolt, retaining rail to soft top bow

Nm

5

Number

Designation

Order number

BR00.45-Z-1050-01A

Top rear folding roof sealing

A 170 795 11 98

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-1062-02A

Adhesive fabric tape

A 007 989 28 85

BR00.45-Z-1006-13A

Blind rivet, mount, tension 3.2X9,5 K9,5

A 004 990 35 97

BR00.45-Z-1007-13A

Rivet

A 004 990 36 97

BR00.45-Z-1017-13A

Cap

A 208 776 00 64

BR00.45-Z-1018-13A

Rivet, mount, clip 3.2X9,5

A 004 990 34 97