Convertible Top Material

Convertible Top Material (76.86.12)

Removal

1. Remove carpet from top stowage compartment.
2. Disconnect backlight heater harness multiplugs.







3. Ensuring that backlight heater harness is clear, power top to fully lowered position.
4. Remove rear seat cushion.
5. Remove rear seat squab.
6. Remove LH and RH rear quarter trim cappings.
7. Remove LH and RH rear quarter trim panels.
8. Remove rear speaker assemblies.
9. Slacken and remove nuts securing squab panel stiffener bracket to BIW and remove bracket from vehicle.







10. Remove heated backlight from roof.
11. Noting their positions, remove staples securing cover to backlight frame and release cover from frame.







12. NOTE: Do not allow top to latch.

Power top to 3/4 closed position.

13. Remove battery cover and disconnect ground cable from battery terminal.
14. Position trunk RH liner for access and turn hydraulic pump valve fully counter-clockwise to manual operation position.







15. Remove LH cantrail seal and carrier.
- Slacken and remove screws securing LH cantrail seal to frame and withdraw seal.
- Slacken and remove screws securing LH cantrail seal carrier and remove seal carrier from vehicle.







16. Slacken and remove screws securing RH cantrail seal to frame and remove seal.
17. Slacken and remove screws securing RH cantrail seal carrier and remove seal carrier.
18. Remove LH main column seal and carrier.
- Withdraw LH main column seal from carrier.
- Slacken and remove screws securing seal carrier and remove carrier from vehicle.







19. Release and remove RH main column seal from carrier.
20. Slacken and remove screws securing RH main column seal carrier and remove carrier.
21. Remove latch striker and guide pins.
- Slacken and remove latch striker securing screws and remove striker from header plate.
- Slacken and remove screws securing latch plate guide pins to frame and remove guide pins.







22. Slacken and remove screws securing latch plate to frame and remove latch plate.







23. Noting positions for installation, release bonded sections of cover from frame.
24. Disconnect convertible top side tension cables from frame.







25. Release cover front retaining rod from retaining clips in frame and remove rod from cover.







26. Manually close but do not latch top.
27. Slacken and remove screws securing headlining rear quarters to main column bracket cover plates.







28. Release and remove headlining rear securing rods.







29. Slacken and remove bolts securing rear tack strip to BIW.







30. Withdraw tack strip from vehicle and remove end covers from tack strip.







31. Apply protective tape to adjacent painted areas of BIW.
32. Position tack strip clear of BIW and drill out pop rivets securing tack strip to cover.







33. Release cover from tack strip and withdraw side tension cables through cover piping.







34. Remove cover from vehicle.
35. Remove sealing strip from backlight frame and clean off any residual sealant.
36. Noting positions for installation, clean residual adhesive from frame.
37. Using white spirit, ensure that frame is grease free and dry.

Installation

1. Apply new sealant strip to backlight frame.







2. Place cover on clean work surface, fold in half to determine centre and mark centreline with tape at rear edge.
3. Measure and mark centreline of tack strip.
4. Position cover on frame, aligning tape with tack strip centreline.







5. NOTE: It may be necessary to use a suitably soft drift and mallet to fully seat cover in tack strip.

Fit and fully seat rear edge of cover in tack strip retaining flange.







6. Using a suitable pointed tool pierce cover through existing holes in tack strip, drill through penetrations and pop rivet cover to tack strip.
7. Fit end covers to tack strip.
8. Position tack strip on BIW and commencing in centre fit and tighten securing bolts.







9. Using a piece of welding rod or similar material, draw side tension cables through cover piping.







10. Ensure that cover is correctly positioned on frame.
11. Manually lower top to halfway position.
12. Connect side tension cables to frame.







13. Apply adhesive to adjacent front positions of cover and frame and fully seat cover on frame.







14. Fit front retaining rod to cover and seat rod in retaining clips.







15. Position latch plate and fit and tighten securing screws.







16. Fit guide pins and latch striker.
- Position guide pins and fit and tighten securing screws.
- Position latch striker and fit and tighten securing screws.







17. Fit cantrail seal carriers.
- Position cantrail seal carriers and fit but do not securing screws.
- Ensuring that seal carriers are positioned towards outboard end of elongated holes, tighten securing screws.







18. Fit and fully seat cantrail seals in carriers and fit and tighten securing screws..
19. Connect ground cable to battery terminal.
20. Turn hydraulic pump valve fully clockwise to power operation position.







21. Ensuring that rear quarter lights are fully lowered, power top to fully up and latched position.
22. Apply adhesive to adjacent areas of cover and frame at main column and fully seat cover on frame.







23. Power top to half down position.
24. Fit main column seal carriers.
- Position main column seal carriers and fit but do not tighten securing screws.
- Ensuring that carriers are positioned towards outboard end of elongated holes, tighten securing screws.







25. Fit and fully seat main column seals in carriers.
26. Power top to fully up and latched position.
27. Staple cover to backlight frame.
- Commencing at bottom centre and working to position half-way up one side, staple cover to backlight frame. If necessary, slit cover within backlight frame to relieve tension.
- Repeat stapling operation along opposite side.







28. Commencing at top centre, staple cover along top and down sides to meet previous stapling, if necessary, gradually slitting cover within frame to relieve tension in fabric. At each corner, add a further outer row of staples for reinforcement.







29. Trim off excess fabric to facilitate backlight fitment.







30. Position headlining and fit and fully seat rear securing rods.







31. Position headlining over cover plates and fit and tighten securing screws.







32. Remove protective tape from BIW.
33. Power top from fully down to fully up positions, checking for satisfactory operation and ensuring that cover is correctly tensioned and free from rippling.
34. Position squab panel stiffener bracket and fit and tighten securing nuts.







35. Fit heated backlight.
36. Fit carpet to convertible top stowage compartment.
37. Fit rear speaker assemblies.
38. Fit rear quarter trim panels.
39. Fit rear quarter panel cappings.
40. Fit rear seat squab.
41. Fit rear seat cushion.
42. Connect backlight heater harness multiplugs.
43. Fit battery cover.