Replace the Top Cover
REPLACE THE TOP COVER1. Remove the headliner.
2. Remove the J hook, and open the top stack by folding the top stack backward from the top stack header area until it rests on the object placed on the tonneau panel.
3. Remove the screws mounting to the 1-bow.
4. Strip the top cover off the 1-bow.
CAUTION:
- Cover the cabin with a sheet to prevent drilling chips from entering the cabin.
- Because the 1-bow is made from aluminum, be careful not to drill a large hole.
5. Use a drill [dia 4.5 - 5.0 mm (dia 0.18 - 0.20 inch)] to break the rivet by drilling a hole, and remove the rivet from 1-bow. And then remove the side tension cable tab from 1-bow.
6. Rivet that remains in the rivet installation hole is kicked out by using knock pin punch of dia 3.0 mm (dia 0.12 inch) because of the other side of rivet.
7. Remove the band on the front side of the control link.
8. Strip the 2-bow listing strap of the top cover affixed to the 2-bow with double-sided tape.
9. Strip the 3-bow listing strap of the top cover affixed to the 3-bow with double-sided tape.
10. Strip the 4-bow listing strap of the top cover affixed to the 4-bow with double-sided tape.
11. Close the top stacks except for the 5-bow.
12. Remove the retainer and the weatherstrip from the 5-bow.
CAUTION:
- Cover the cabin with a sheet to prevent drilling chips from entering the cabin.
- Because the 5-bow is made from aluminum, be careful not to drill a large hole.
13. Use a drill [dia 4.5 - 5.0 mm (dia 0.18 - 0.20 inch)] to break the rivet by drilling a hole, and remove the rivet from 5-bow.
14. Rivet that remains in the rivet installation hole is kicked out by using knock pin punch of dia 3.0 mm (dia 0.12 inch) because of the other side of rivet.
15. Turn up the top cover from the 5-bow.
16. Remove the defogger connector from the rear window, and then remove the defogger harness from the top cover.
17. Turn up the top cover from the rear side rail.
18. Remove the side tension cable from the 4-bow link.
19. Remove the top cover.
20. Remove the doubled-sided tape from the 2-bow, 3-bow, and 4-bow, and then affix new doubled-sided tape in the same position.
21. Set the top cover to the top stack frame.
22. Install the side tension cable to the 4-bow link.
23. Install the top cover to the side rail rear.
24. Insert the defogger harness to the top cover and install the defogger connector to the rear window.
25. Place the mounting part of the top cover over the 5-bow.
26. Rivet the top cover on the 5-bow starting from the center of the 5-bow. This riveting work should be performed alternately on the right and left sides of the first riveting location as shown.
27. Install the weatherstrip and retainer to the 5-bow.
28. Remove the J hook, and open the top stack by folding the top stack backward from the top stack header area until it rests on the object place on the tonneau cover.
29. Wind the strap around the front side of the control link.
30. Rivet the side tension cable tab to the 1-bow according to the procedure below.
1. Insert the rivets into the 1-bow and side tension cable tab.
2. Insert "A" of the rivet into the rivet tool.
3. Pressing the flange surface of the rivet, move the handle of the rivet tool.
4. The thinnest point of "A" is cut and the rivet is held in the position.
31. Place the mounting part of the top cover over the 1-bow.
CAUTION: Because the 1-bow is made from aluminum, tightening the screw more then necessary results in damage to the screw hole. Be careful not to over tighten the screw.
32. Install the top cover to the 1-bow with screws.
33. Close the top stacks except for the 5-bow.
34. Affix the 2-bow listing strap of the top cover to the double-sided tape attached to the 2-bow.
35. Affix the 3-bow listing strap of the top cover to the double-sided tape attached to the 3-bow.
36. Affix the 4-bow listing strap of the top cover to the double-sided tape attached to the 4-bow.
37. Install the headliner.
38. Convertible top might not shut completely in the operation of convertible top switch when top cover is replaced. To make top cover become familiar with the vehicle after top cover is replaced, convertible top is closed according to the following procedure.
1. It puts it into the state to shut convertible top to the position of shown in the figure.
2. J hook is closed.
3. It puts it into the state to shut tonneau cover and the 5-bow completely pushing close switch of convertible top switch after ignition switch is turned on.