Removal and Replacement
Replacing the roll-over bar cassette
Disassembly
Preparations
Fold the soft top up as illustrated.
make a note of the anti-theft radio code.
ignition off.
disconnect the battery negative lead.
Removing the roll-over bar cassette
Preparations
Remove:
- the rear seat. Rear seats Rear Seats.
- parcel shelf. Parcel shelf Service and Repair.
- 4 screws for the loudspeaker.
Removing the roll-over bar cassette
Warning! The roll-over bar is raised by a spring. The force is sufficient to cause an injury. It is important that no one is standing above the roll-over bar when it is deployed. The roll-over bar operating range is approximately 50 cm which is also the safety distance from the bar.
Caution! In the event of a fault in the roll-over bar the whole cassette should be replaced. No repairs on the cassette are permitted.
Raising the roll-over bar
Insert a narrow screwdriver to the locking catch and press on the upper side of the catch as illustrated. The roll-over bar will then slide up.
Removing the loudspeaker splitting filter
Remove the clip from the connector.
Remove 3 screws from the splitting filter. Remove wiring and splitting filter through the loudspeaker hole.
Remove:
- 4 rubber plugs in the front edge of the soft top storage space.
- 4 screws for the roll-over bar cassette.
connect the terminal to the battery negative lead.
ignition on.
Fold the soft top back as illustrated.
Removing the roll-over bar cassette
Remove the clip from the connector.
Pull the wiring out through the loudspeaker hole.
Carefully press the catch and separate the connector.
Slacken off the two lower screws for the roll-over bar cassette.
Note! The 2 lower screws for the cassette should only be slackened off.
Lift out the roll-over bar cassette.
Caution! If the clips break they must be replaced.
Reassembly
Assemble in reverse order
Note! The roll-over bar cover need not be replaced yet because a function test will be carried out.
Pushing down the roll-over bar
Press the catches to one side and hold them in that position. Then press the roll-over bar down by hand until it reaches the bottom position and then release the catches.
Caution! Ensure that the roll-over bar is secured by the catch in the lower position.
Conclusion
Checking roll-over bar
Warning! The roll-over bar is raised by a spring. The force is sufficient to cause an injury. It is important that no one is standing above the roll-over bar when it is deployed. The roll-over bar operating range is approximately 50 cm which is also the safety distance from the bar.
Caution! In the event of a fault in the roll-over bar the whole cassette should be replaced. No repairs on the cassette are permitted.
Raising the roll-over bar
Insert a narrow screwdriver to the locking catch and press on the upper side of the catch as illustrated. The roll-over bar will then slide up.
When checking
At least 3 rotations of the toothed shaft (1) should be visible above the edge of the cassette.
Press the locking catches to one side.
Release the catches.
Note! The roll-over bar must not move upwards any further when the catches are released.
Checking roll-over bar limit position
Press the catches to one side once again and hold them in that position.
Pull the roll-over bar upwards by hand until it reaches its limit position (which it may have done already).
When pulled up by hand it should not move any further. If it does not move noticeably it has reached the limit position.
Note! The roll-over bar must reach its limit position.
If the roll-over bar does not reach its limit position, try again. Press the roll-over bar down according to Pushing down the roll-over bar and slide the bar up according to Sliding up the roll-over bar .
If the second attempt fails, replace the roll-over bar cassette.
Final check
Press the catches to one side and hold them in that position. Then press the roll-over bar down by hand until it reaches the bottom position and then release the catches.
Caution! Ensure that the roll-over bar is secured by the catch in the lower position.
Ignition in position II. Reconnect battery negative lead
Check
Note! Check that the Roll-over Protection System warning lamp has not failed by switching on the ignition. The Roll-over Protection System warning lamp should light and go out after approximately 5 seconds.
Check that the Roll-over Protection System warning lamp in the combined instrument panel is not constantly lit.