Service Procedure

NOTES:
Perform repairs in a clean work environment. Make sure your hands/gloves are clean.

Use fender covers when leaning over the sides of the vehicle. Use protective covering as needed if planning to be positioned inside the vehicle.

1. Remove the rear roof lower garnish with a suitable pry tool.





2. Cut two 10 mm x 100 mm pieces from the 1 mm sheet, and then install where shown in Figure 2.

3. Break off the locator pin with suitable pliers (see Figure 2)





4. Cut six 10 x 50 mm pieces from the 1 mm sheet, and apply to the clips as shown in Figure 3, and where circled in Figure 2.





5. Next, position the retractable hard top (or hard top) as shown in Figure 4.

CAUTION:
When left in a partially closed position, the hard top could slowly drop which could cause hard top damage.

6. Remove the rear roof upper garnish with a suitable plastic pry tool.








7. Break off flush both locator pins. See Figure 6, and arrows in Figure 5.

8. Remove any existing felt cloth from all clips.

9. Cut four 50 mm pieces from the tape roll, and then apply on the clips. See Figure 6, and circles in Figure 5.





10. Next, remove the front roof garnish with a suitable pry tool.

11. Apply felt cloth (from the tape roll) along the dotted line where shown in Figure 8.

^ Figure 9 shows side view (cutaway) of felt cloth position.





12. If felt cloth is already applied as shown in Figure 10, skip to Step 15.

^ If not, go to the next step.





13. Remove any felt cloth found at the sides of the clips (see Figure 12).

14. Cut seven 10 mm x 50 mm pieces from the 1 mm sheet, and apply to the clips as shown in Figure 10.





15. Apply felt cloth to both plates where shown in Figure 14.

^ Cut two 50 mm long pieces of felt cloth from the tape roll and wrap one at location #1 on each plate (see Figure 14).

^ Cut two 10 mm x 20 mm pieces from the 3 mm felt cloth sheet, and then apply one at location #2 on each plate (see Figure 14).





16. Next, drop down the headlining and lay out on the rear back seat to access the rear rib (see Figure 15).

^ Refer to the Electronic Service Manual (ESM) as needed.

^ Do not entirely remove the headlining. Leave the tether cords fastened.





17. Remove any existing pieces of felt cloth where outlined in blue in Figure 16.

18. Cut four 20 mm x 300 mm pieces (approximate in length) from the 2 mm sheet.

19. Apply the cut pieces across the length of the rear rib where outlined in blue in Figure 16.

^ Start and finish the application from edge to edge as shown in Figure 17.

20. Cut five 30 mm x 35 mm pieces from the 1 mm sheet.





21. Fold the longer length of each piece in half, and then cut a hole at the middle of the fold: 3 mm deep by 5 mm wide (see Figure 18).





22. Apply these pieces where shown in Figure 19 and 20.





23. Remove any existing pieces of clear tape from the edge of the rear rib (under blue outline). See Figure 21.

^ It is ok to leave the tapes adhesive on the rib.

24. Cut pieces from the tape roll, and then apply on the edge where outlined in blue and black (see Figure 21 and 22).

^ For easier application, cut the felt cloth in sections.

25. Remove any existing pieces of felt cloth from on and around the clips.








26. Cut four 10 mm x 50 mm pieces from the 1 mm sheet, and then apply one to each clip where shown in Figure 23 and 24.





27. Break off flush the locator pin, and then apply a piece of felt cloth tape where broken off (see Figure 25).

^ Felt cloth length (cut from the tape roll): 50 mm long

28. Inspect the center roof panel pins for felt cloth.

^ If felt cloth is found, skip to step 30.

^ If none, go to the next step.





29. Cut two 20 mm x 80 mm pieces from the 2 mm sheet, and then apply one on each center roof panel pin where shown in Figure 27.

NOTE:
The center roof panel pin in Figure 27 is shown as removed for easier viewing. Neither pin does not need to be removed to apply the felt cloth.





30. Cut two 20 mm x 20 mm pieces from the 2 mm sheet, and then apply one on each part on each side of the vehicle where shown in Figure 29.





31. Cut two 50 mm pieces from the tape role, and then wrap one on each rear window defogger connector (see Figure 30).





32. Apply "super glue" or equivalent adhesive to ALL tether cord clips where shown in Figure 31.

33. Reinstall the headlining.

^ Refer to the ESM as needed.

34. Next, fully close the hard top.





35. Proceed to open the hard top until the trunk lid is in the position shown in Figure 32.

36. If felt cloth is found under the flipper door where pointed in Figure 32, skip to Step 38.

^ If none found, go to the next step.





37. Cut six 20 mm x 30 mm pieces from the 3 mm sheet, and then apply under the flipper door as shown in Figure 33 and 34.





38. Next, adjust the side wedges on each side of the vehicles trunk as shown in Figure 36.

^ T40 Torx bolt torque: 23.5 - 27.5 Nm (2.4 - 2.8 kg-m, 17.3 - 20.3 ft lbs)

39. Next, fully close the hard top, and then open the trunk lid.

40. Adjust the trunk lid bumpers as follows:





a. Remove both bumpers, and then extend the rubbers all the way out (see Figure 37 and 38).

b. Turn the "flowers" until they bottom out under the rubbers (see Figure 39).

c. Reinstall both bumpers, and then carefully slowly close and latch the trunk lid.

d. Open the trunk lid, and then turn both "flowers" clockwise until they bottom out (see Figure 40).

^ Make this adjustment with the bumpers still installed.

^ Make sure the rubbers do not move during this step.





41. Next, close the trunk lid, open the hard top as shown in Figure 41, and then inspect for felt cloth.

^ If felt cloth is found, go to the next step.

^ If felt cloth is not found, cut two 15 mm x 15 mm pieces from the 3 mm sheet, and then apply on the parcel shelf finisher board where the adjusting bolts come in contact (one on each side). See Figure 41.

42. Locate the two adjusting bolts, and adjust the bolt heads to approximately 5.5 mm (0.20 inches). See Figure 41 and 42.

43. Close the hard top, and then open the trunk lid.





44. Measure the gap between the parcel shelf finisher board and rear roof lower garnishs sponge (it should be approximately 10 mm (0.40 inches)). See Figure 43, 44, and 45.

^ If ok, go to the next step.

^ If not, access the adjusting bolts and then readjust as needed.





45. Close the trunk lid, and then start opening the hard top until the trunk is opened as shown in Figure 32, and 46 above.

46. Inspect both driver and passenger side hinge dove tails (see Figure 46).

^ If either one is found worn, replace both.

> T20 Torx bolt torque: 3.5 - 4.5 Nm (0.36 - 0.46 kg-m, 31.0 - 39.8 in lbs)

47. Fully close the hard top, road test, verify repairs.