Soft Top Cover, Headlining and Rear Window

Soft top cover, headlining and rear window

Removing







1 Operate the soft top to half open position and position the soft top support special tool (16) 82 93 144 so that the soft top does not fall when the hydraulic pressure is released.
2 Remove the front seals and their retainers.
3 Remove the retainer strip in the first bow front edge (9 screws).
4 Lift up the upholstery by the handle with a small screwdriver and remove the handle by pulling the pins out of the groove.
5 Remove the covers that are fastened to the front rail with two plastic clips. Hold the soft top support so that it does not release when the covers are folded out.







6 Remove the headlining from the first bow. The headlining is attached to the front rail with a screw on each side and is also hooked on at the front edge and has elastic bands at the sides.
7 Fold up the soft top outer cover from the first bow.
8 Drill out the pop rivets for the side cables, three on each side. Clean the holes from burrs.
9 Remove the soft top support and balance the soft top.
10 Remove the screws in the second bow and remove the plastic retainer.
11 Remove the plastic retainer for the third bow.







12 Drill out the rivets that secure the elastic bands.
13 Remove the screws that secure the headlining to the rear rail.
14 Remove the seal for the rear rail.
15 Remove the cable from the rear rail.
16 Remove the soft top outer cover from the third bow.
17 Raise (close) the soft top mechanism. Pull out the cables if the soft top fabric is to be replaced.







18 Raise the fifth bow and remove the elastic bands around the lock lugs on the fifth bow.
19 Remove the three screws that secure the headlining to the fifth bow.
20 Unplug the connectors for rear window electric heating and remove the window guide by the window.
21 Mark the fifth bow middle position on the seal. Remove the seal from the fifth bow and remove the screw securing the fifth bow seal.

Important
Pull away the seal carefully so that it is not damaged.

22 Drill out the pop rivets (4 pcs) in the corner of the fifth bow and clean the holes from drill burrs. Remove the soft top fabric from the fifth bow.
23 Remove the rear window mounting from the lock lugs and lift away the soft top outer cover and the headlining along with the rear window.

Dismantling soft top cover, headlining and rear window







1 Position the soft top fabric with the rear window on a work bench.
2 Manufacture a tool as shown in the illustration.
3 Lift up the clip with the tool and position a knife underneath.
4 Pull out the clip using the tool and follow up with the knife so that the windscreen frame is not damaged.
5 Continue in the same manner with the rest of the clips around the rear window until the window is removed.
6 Lift away the rear window and, if needed, replace the soft top outer cover, headlining or rear window.

Assembling soft top cover, headlining and rear window

NOTE: Replace or touch up the paint the windscreen frame if it is damaged.






1 Position the rear window in the soft top cover frame. Fit the loose frame and fit the headlining against the rear window seal.
2 Secure the frame, headlining and top cover at the middle markings.






3 Fit a clip on each side of the markings. Use special tool pliers (16) 30 12 598 to open the clips. Then fit the clip on the frame.

WARNING: Use safety glasses since the clips can release from the pliers.

4 Fold back the headlining and fixate it against the marking at the front edge Fit a clip on each side of the marking.
5 Then fit clips in the same manner on the sides of the frame.
6 Fit the remaining clips around the windscreen frame.

Fitting

When replacing the soft top outer cover the cables must be transferred to the new roof.






1 Fit the roof in position on the soft top mechanism.
2 Hang the rear window in the fifth bow.
3 Centre the rear window marking against the fifth bow centre marking.
4 Sit on the member for the backrest and relieve the rear window with your knees. Centre the top fabric and fold it around the fifth bow and into the groove.
5 Start in the middle and fit the fifth bow seal. Use the centre marking made when removing. Continue to the corners and fit the four pop rivets. Fit the rest of the seal.
6 Tighten down the seal.
7 Fit the elastic band and window guides. Plug in the connectors for electric rear window heating.
8 Fit and tighten the three screws for the headlining in the fifth bow.
9 Refit the elastic band around the fifth bow lock lugs.






Adjust the window guides so that the measurement on the rod between the ball mounting end points is 102 mm.






10 Lower the fifth bow.
11 Fit the cable without fastening it to the rear rail.
12 Pop rivet the cable to the first bow.
13 Raise the soft top to half open position and balance it.
14 Stretch the top cover fabric and fold it over the first bow.
15 Raise (close) the soft top and lock it to the windscreen frame.






16 Use a spring-scale and adjust the cable to 6 kg, then tighten the cable mounting.
17 Fit new double-backed tape on the third bow. Stretch the top cover fabric towards the third bow and fold the fabric edge around the bow. Fit the plastic retainer for the headlining in the third bow. Make sure that the headlining and top cover midlines are directly lined up.
18 Fit new double-backed tape on the second bow. Stretch the top cover fabric towards the second bow and fold the fabric edge around the bow. Fit the plastic retainer for the headlining in the second bow. Make sure that the headlining and top cover midlines are directly lined up. Press on the plastic clip.






19 Screw down the seal for the rear rail.
20 Fasten the headlining in the rear rail.
21 Pop rivet the elastic bands to the middle rail.






22 Fit the headlining elastic bands in the first bow.
23 Fasten the headlining to the first bow.






24 Remove the special tool (16) 82 93 144 and fit the plastic cover on the first bow.
25 Fit the special tool (16) 82 93 144 and fit the handle, also refit the upholstery by the handle.
26 Refit the retainer strip on the first bow.

Important
Take care so that the magnets for the lock are not damaged.

27 Fit the front seal retainers.
28 Lubricate the seals with soapy water. Position the outer edge in the groove and press in the seal. Start from the back and work towards the front. Fit the front screw.
29 Connect the diagnostics tool and erase any diagnostic trouble code.
30 Check so that there is no water leakage by spraying water from above at an angle.
Never use high-pressure jets.