Top Cover, Headliner and Side Stay Pad Removal and Installation

REPLACE THE TOP COVER AND HEADLINER

REPLACE THE HEADLINER

1. Fully open the door window glass and the quarter window glass.

2. Remove the weatherstrip with which the topstack door window glass or the quarter window glass interferes.









3. Remove the speaker subwoofer trim of the rear seat back and take out the dedicated tool for the topstack.
4. Remove the woofer and close the valve of the pump motor assembly.





5. Remove the topstack cover clip and turn up the topstack cover so that the topstack linkage can be seen.









6. Insert the dedicated tool into the hexagon hole and turn the tool downward to release the lock of the 5-bow.





7. Raise the 5-bow and keep it open.
8. On the tonneau panel, set a strong object (such as a strong cardboard box) that can support the topstack.
9. Remove the J hook, and open the topstack by folding the topstack backward from the topstack header area until it rests on the object placed on the tonneau panel.
10. Remove the guide pins from the both ends of the 1-bow.
NOTE:
Insert a tool through the clearance between the headliner and the top cover to lock the mounting nut of the guide pin, and then remove the guide pin.

11. Remove the 1-bow trim.
12. Remove 8 screws mounting the headliner to the 1-bow and 2 screws mounting the side rail.
13. Remove the headliner holder from the 2-bow.
14. Remove the headliner holder from the 3-bow.
15. Remove the headliner holder from the 4-bow.
16. Close the topstacks except for the 5-bow.
17. Remove the hook at the end of the rubber band from the link.
18. Remove the clip on the 5-bow.
19. Strip and remove the headliner from the top cover glass periphery.
20. Remove the J hook, and open the topstack by folding the topstack backward from the topstack header area until it rests on the object placed on the tonneau panel.
21. Install the headliner to the 1-bow and the side rail.
22. Fit the 2-bow to the headliner holder.
23. Fit the 3-bow to the headliner holder.
24. Fit the 4-bow to the headliner holder.
25. Install the guide pins from the both ends of the 1-bow.
NOTE:
Insert a tool through the clearance between the headliner and the top cover to lock the mounting nut of the guide pin, and then install the guide pin.

26. Install the 1-bow trim.
27. Close the topstacks except for the 5-bow.
28. Affix the fastener tape of the headliner around the top cover glass.
29. Attach the clip of the headliner to the 5-bow.
30. Place the hook attached on the rubber band end of the headliner on the link.

REPLACE THE TOP COVER

1. Remove the headliner (Refer to ).

2. Remove the J hook, and open the topstack by folding the topstack backward from the topstack 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.





5.
CAUTION:
Cover the cabin with a sheet to prevent drilling chips from entering the cabin.

CAUTION:
Because the 1-bow is made from aluminum, be careful not to drill a large hole.

Use a drill [4.5 - 5.0 mm (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 topstacks except for the 5-bow.
12. Remove the retainer and the weatherstrip from the 5-bow.





13.
CAUTION:
Cover the cabin with a sheet to prevent drilling chips from entering the cabin.

CAUTION:
Because the 5-bow is made from aluminum, be careful not to drill a large hole.

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 topstack 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 topstack by folding the topstack backward from the topstack 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.
32.
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.

Install the top cover to the 1-bow with screws.
33. Close the topstacks 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.(Refer to ).





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.

REPLACE THE SIDE STAY PADS

Replace the side stay pads as described below. The procedure is the same for both sides.

1. Remove the headliner (Refer to ).

2. Remove the top cover (Refer to ).

3. Close the topstacks except for the 5-bow.





4.
CAUTION:
Cover the cabin with a sheet to prevent drilling chips from entering the cabin.

CAUTION:
Because the 5-bow is made from aluminum, be careful not to drill a large hole.

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. And then remove the side stay pad from the 5-bow.
5. 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.





6.
CAUTION:
Cover the cabin with a sheet to prevent drilling chips from entering the cabin.

CAUTION:
Because the 4-bow is made from aluminum, be careful not to drill a large hole.

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 4-bow. And then remove the side stay pad from the 4-bow.
7. 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.





8.
CAUTION:
Cover the cabin with a sheet to prevent drilling chips from entering the cabin.

CAUTION:
Because the 3-bow is made from aluminum, be careful not to drill a large hole.

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 3-bow. And then remove the side stay pad from the 3-bow.
9. 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.





10.
CAUTION:
Cover the cabin with a sheet to prevent drilling chips from entering the cabin.

CAUTION:
Because the 2-bow is made from aluminum, be careful not to drill a large hole.

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 2-bow. And then remove the side stay pad from the 2-bow.
11. 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.





12. Remove the side stay pad from the 1-bow.
13. Remove the double-sided tape from the 1-bow, and affix new double-sided tape in the same position.
14. Set the side stay pad hook to the 1-bow.





15. Follow the procedure below to install the side stay pads with rivets to the 2-bow, 3-bow, 4-bow, and 5-bow in that order.
(1) Insert the rivets into the side stay pad and bow.
(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.
16. Install the top cover (Refer to ).
17. Install the headliner (Refer to ).