Headliner Tensioning System, Removing and Installing

Headliner tensioning System, Removing And Installing --> 11.03

Vehicles 12.03 -->

NOTE:
- Open or close (half way open position is suitable) convertible top as needed to ease working (repair work, servicing) on headliner tensioning system.
- Before opening and closing convertible top, make sure there is enough room above.
- Each side of vehicle has a headliner tensioning system, consisting of a guide, guide rail headliner (with tied cables, cable shoes, cable track guide with cable shoes and deflectors) and a reinforcement plate.
- The following description is for right-hand side of convertible top cover.

Removing







- Remove three pop rivets - 1 - and release headliner guide rail - 3 - from frame - 2 - and from guide headliner - 4 -.

NOTE: If guide rail is scratched or damaged or plastic shavings are present, replace guide rail.







- Remove two pop rivets - 1 - from frame and loosen cable shoes.

NOTE:
- Observe installation position of cable shoes.
- If necessary, use drift to remove pop rivet.







- To remove guide rail headliner - 1 - from reinforcement plate - 2 -, unclip securing clips - 3 - of reinforcement plate using screwdriver. To do this, start this work step from bottom - arrow -.







- Untie both cables - 1 - from guide rail headliner and pull out of deflector (center), out of deflector eyelet (bottom) and out of deflector (top) - arrows - (upper deflector is not shown in illustration).

NOTE:
- When using new guide rail headliner, cut cables to ease work step.
- Observe installation position of cables on guide rail headliner in deflectors and deflector eyelet (bottom).







- Push securing clips - 1 - inward toward headliner.
- Remove roof edge trim.







- Remove securing bolt at roof edge and pull out tension strap with reinforcement plate in - direction of arrow -.

Installing
- Tie an approx. 92 cm (3 feet) long cable to tension strap cable shoe.







- Insert reinforcement plate with tension strap into headliner - arrow -.

NOTE:
- Use strong flexible cable (long enough to insert into headliner) in form of "Y" at end to ease insertion of reinforcement plate.
- Observe original installation position of reinforcement plate.







- Press securing clips - 1 - of reinforcement plate out of headliner.

NOTE: Remove new deflectors and deflector eyelet from cables when using new guide rail headliner. Only use new deflectors and new deflector eyelet when deflectors and deflector eyelet are damaged.







- Guide lower cable - 1 - through deflector (center) - 2 - and then through deflector eyelet - 3 -.







- Guide upper cable through upper deflector - arrow -.







- Guide both cables through holes in guide rail headliner and tie knots - 1 - at original position.

NOTE:
- Cables must be tied at rear side of guide rail headliner.
- Tie knot as close as possible to cable end.







- Secure guide rail headliner - 1 - to reinforcement plate - 2 -. To do so, carefully press securing clips - 3 - together using pliers. Observe correct seating of securing clips to holes of guide rail headliner.

NOTE: Make sure cables are not jammed between guide rail headliner and reinforcement plate.







- Slide guide - 1 - into guide rail headliner - 2 -.

NOTE:
- Upper cable - 3 - must be routed behind guide.
- Lower cable - 4 - must be routed in front of guide.







- Insert guide - 1 - into frame - 2 - and secure two lower points - 3 - using pop rivets.







- Bring upper cable - 2 - behind cross rail - 1 - and over extended frame - 3 -.

NOTE: Guide cable through highest and rearmost point.







- Guide upper cable - 1 - with sliding cable shoe - 2 - to inclined frame - 3 -.
- Rivet sliding cable eyelet - 2 - (flat side of eyelet to frame) to vertical frame - 4 - and upper point of guide - 5 - in an angle of approx. 45° with horizontal line of vehicle.
- Secure upper eyelet - 1 - to inclined frame - 3 - (flat side of eyelet to frame) with upper hole and with angle of approx. 45° with horizontal line of vehicle - arrow -.

CAUTION:
- Cable may be damaged when riveted into lower bore.
- Place flat side of both cable eyelets onto frame, otherwise there is risk of malfunction.







- Secure lower eyelet - 1 - to frame.







- Pull cable secured to eyelet out until eyelet is reached - arrow -.
- Install strap eyelet.
- Untie cable from eyelet.
- Open and, if necessary, close convertible top cover to check correct operation of convertible top cover.
- Install roof edge trim after finishing repair work on headliner tensioning system.