Action

1. Open the tonneau cover.

2. Open the access flaps half way using ISAT.

3. Remove the plastic cover from the bottom of the tonneau cover.

4. Remove both actuating rods.

5. Press the down button on ISAT so the motor goes to the "flaps closed" position. Disconnect SAT and turn off the ignition.

6. Disconnect the electrical connector for the fifth bow latch motor.

Unscrew the four 6mm screws.

Remove the fifth bow latch motor.

7. Placing the fifth bow latch motor on a bench, remove the five T30 torx screws that secure the plastic plate to the motor assembly.

8. Remove the motor and the two existing racks.

9. Coat the new racks with a thin coating of wheel bearing grease.





10. Install the upper rack, P/N 48 52 711 (triangular end) in the upper position. See Figure 1.

Install the lower rack, P/N 48 52 729 (L-shaped end) on the bottom. See Figure 1 on.

11. Push the upper rack all the way to the left and the lower rack all the way to the right until the end stops come up against the plastic housing. See Figure 1.

12. Insert the motor from behind. Apply Loctite 242 (blue) to the screws and retighten them.

Tightening torque: 88.8in.lbs. (10Nm).

13. Apply a small amount of wheel bearing grease to the racks in the pinion gear through the access hole in the cover.

14. Reinstall the complete motor assembly in the car, being sure to connect the two safety cables to the upper screws. Reconnect the electrical connectors.

Be sure that the latches themselves are free moving and lubricated. We have seen instances where the split in the roll pin for the access flap drive was in the wrong position and caused friction against the lever arm. These roll pins can be hard to rotate but plastic nut 40 87 128 can be pressed on to the pin.

15. Measure both actuating rods. Overall length from the center of the holes in the clevis to the center of the rod at the other end should be 285 mm. Adjust accordingly. See figure 2.

16. Reinstall both rods.

17. Using the Convertible top switch, check the operation of the top.

18. Reinstall the plastic cover on the tonneau cover.

19. Check and adjust the top programming, if necessary, paying particular attention to the values for the fifth bow and tonneau cover. If the actual values are too close to, or equal to the programmed values, the top function could be interrupted especially under strong sun load. Follow the guidelines below for programming:

a. Connect ISAT. Contact TSAS and be sure the 5th bow latches are "open".

b. Read the "Programmed Value." Example: 46

c. Drive the 5th bow with ISAT until it compresses the seal against the tonneau cover. Hold for at least 5 seconds. Read the "Actual Value". Example: 44

d. Raise the "Programmed Value" by 2-4 units. Example: 48. The actual amount can differ from car to car but the goal is to soften the pressure of the 5th bow motors against the tonneau cover and allow 5th bow latches to draw the cover down. If you add too much, the latches may not line up with the strikers. The goal is to reduce the clamping force of the latches and should reduce the tendency to jam. If the programmed value is too close to the actual value, it can cause the ECM not to allow the top to move.

e. Operate the top through the full range. With the 5th bow lower limit properly programmed, the top should operate as follows:

1. Closing the top: The 5th bow should touch the tonneau with the seal slightly compressed and when the latches engage, they should not draw the 5th bow down tightly against the tonneau.

2. Opening the top: When the top switch is pressed, the latches should release and about 1 second afterward the 5th bow should start to lift.