Disassembling and Assembling Hardtop
Disassembling And Assembling Hardtop
Disassembling Hardtop
Preparation
Place hardtop on the assembly fixture and lock with the latching levers and the locking lever at front.
1. Detaching cover strips and roof strip clips
1. Lift up the cover strip to the left and right -1- using a plastic spatula and pull it off. The roof strip clips are destroyed when they are removed.
Removing rear window
Turning hardtop
Place outer side of the hardtop on the assembly fixture.
2. Removing centering peg
- Unscrew the fastening screws -26- from the centering peg -27A and 27- and remove them.
3. Unclipping interior trim parts
- Unclip interior trim parts -2- at the side, front and rear from the hardtop body -3-.
4. Detaching seal at sides of roof frame
1. The seal on the roof frame -4- at the sides consists of two parts. Pull the upper seal -5- out of the profile of the retaining rail -6-.
2. Unscrew fastening screws -7- from the retaining rail -6-.
3. Remove the seal below it together with the retaining rail -8- from the roof frame -4-.
5. Undoing and detaching the retaining rail and roof frame seal
1. Unscrew sheetmetal screws -9- from the retaining rail -10-.
2. Unscrew pan-head screw -11- from the roof frame seal, detach the seal at the corners and remove it.
6. Pulling off rubber seal
- Pull off the surrounding rubber seal -12- to the rear and pull it out at the ends from the roof frame seal -13-.
7. Detaching roof liner at front
1. Lift the front retaining rail -14- of the roof liner -15- with a plastic spatula and pull it off.
8. Detaching roof liner at sides
- Lift up the roof liner -15- on the left and right sides with a plastic spatula and disengage from the sheetmetal clips -16-.
9. Detaching roof liner at rear and transverse struts
1. Pull the plastic rail -17- on the roof liner -15- to the rear and detach it.
2. Remove the transverse struts -18- with the plastic sleeves -19- and remove the roof liner -15-.
10. Detaching insulation from the hardtop body
- Undo the insulation -20- of the hardtop body -21- using a spatula.
11. Removing foam strips
- Carefully pull off the foam strips -22- on the B-pillar -A-, rear roof -B- and on the front centering peg -C- or foam pad -23- to the left and right.
12. Removing locking lever
- Unscrew and remove fastening screws -24- from the locking lever -25-.
13. Removing hardtop locking element
- Unscrew and remove fastening screws -28- from the hardtop lock -29-.
14. Disconnecting wiring harness of the heated rear window
- Drill out the dia 3.2 mm -30- tubular rivet. Disconnect electrical plug connection -31-, remove wiring harness with the hardtop locking element -29- from the hardtop body -1-.
15. Pressing expanding nuts out of the hardtop body
- Press out expanding nuts -32- at the sides and front of the hardtop body -33-.
Assembling Hardtop
Positioning the hardtop
Set the hardtop down on the assembly fixture on the outer side of the roof.
1. Pressing expanding nuts into the hardtop body
NOTE:
- Please observe the coloured installation position of the expanding nuts.
- 1A = yellow
- 1B = white
- 1C = green
- 2A = red
- 2B = white
1. Beginning in a leftward direction of travel
- One red -2A- expanding nut
- Three yellow -1A- expanding nuts
- One green -1C- expanding nut
- One white -1B- expanding nut
- Press three green -1C- expanding nuts into the hardtop body.
1. Beginning in a rightward direction of travel
- One white -2B- expanding nut
- Three yellow -1A- expanding nuts
- One green -1C- expanding nut
- One white -1B- expanding nut
- Press three green -1C- expanding nuts into the hardtop body.
1. Press the expanding nuts at the front -1B- into the hardtop body in the direction of travel.
2. Fitting wiring harness of the rear window heater
- Position wiring harness with the hardtop locking element, rivet the flat connector -3- onto the hardtop body with a dia 3.2 mm tubular rivet -1- and connect the flat connector to the cable lug -4-.
3. Fitting hardtop locking element
1. Screw in and tighten fastening screws -5- into the hardtop lock element -6-.
4. Sticking felt strips on inside of window aperture
- Stick a felt strip -7- approx. 2 cm wide along the window aperture on the rivet joints of the hardtop body -1-.
5. Sticking insulation on the hardtop body
- Position the self-adhesive insulation -8- in the hardtop body -1- and press firmly into place.
6. Fitting locking lever
1. Position the locking lever -11- on the hardtop body -1- and tighten with the fastening screws -12-.
7. Sticking in foam strips and foam pads
1. Position the foam strips -13- on the B-pillar -A-, rear roof -B- and on the front centering peg -C- or foam pad -14- to the left and right and press in firmly.
8. Engaging roof liner at rear and transverse struts
1. Insert the transverse struts -15- with the plastic sleeves -16- into the hardtop body -1-.
2. Pull back the plastic rail -17- of the roof liner -18- and engage in the groove of the hardtop body -1-.
9. Engaging roof liner at sides
1. Engage roof liner -18- at the left and right sides in the sheetmetal clips -19-.
NOTE: If the hardtop body is new, the sheetmetal clips on the left and right must be bent over to the outside using a plastic hammer.
10. Fitting roof liner at front
1. Position the front retaining rail -20- of the roof liner -18- and clip it in.
11. Fitting rubber seal
1. Insert self-adhesive rubber seal -22- at the ends of the roof frame seal -21-.
2. Remove backing of the rubber seal and press firmly into place at the rear on all sides.
12. Affixing Nito tape to the hardtop body
1. Stick on a 2 cm wide strip of Nito tape -23- at the front left and right of the hardtop body -1-.
13. Fitting roof frame seal and retaining rail
1. Engage roof frame seal in the hardtop body -1- at the corners and fasten with the fastening screw -24-.
2. Position retaining rail -25- and screw down using the sheetmetal screws -26-.
14. Fitting seal at sides of roof frame
1. The seal on the roof frame -27- at the sides consists of two parts. Position the lower seal with the retaining strip -28- on the roof frame -27- and fasten with the fastening screws -29-.
2. Press the upper seal -30- into the profile of the retaining rail -31-.
15. Fitting interior trim parts
NOTE: Once an interior trim part has been clipped in once, the old plastic clips are no longer usable and must always be replaced.
1. Clip interior trim parts -32- at the side, front and rear into the hardtop body -1-.
16. Fitting centering pegs
1. Position the centering peg -9- on the hardtop body -1- and tighten with the fastening screws -10-.
17. Clipping in roof strip clips and cover strips
1. Fit the roof strip clip -34-.
2. Fit cover strip seal on the cover strip -33-.
3. Position cover strip on the hardtop body -1- and press into the roof strip clips.
Tightening Torques
