Convertible Top Frame: Service and Repair

Replacing Convertible-top Frame

Tools







Illustrated on the 911 Carrera Cabriolet (996)







Assembling convertible-top frame

Removal tool for removing retaining clips -7-.

INFORMATION: Ensure that the assembly aids are seated firmly. The assembly aids must be recalibrated after removal. Refer to Adjusting Cabriolet convertible top.

1. Installing convertible-top support.







1.1. Position convertible-top support -1- on the assembly aids and screw on with the fastening screws -3- or fastening nut -2-.
1.2. Tightening torque: 23 Nm (17 ftlb.)

INFORMATION: Use assembly grease when fitting the pins.

2. Installing roof frame 2.







2.1. Insert bushing -4- 10x12x15 into the bore on the outer side of roof frame 2 -5-.
2.2. Position roof frame 2 -5- on the convertible-top support -1- and connect with pin -6- . Secure the pin -6- with the retaining clip -7- SLB 10.

INFORMATION: Use assembly grease when fitting the pins.

3. Installing roof frame 3.







3.1. Insert bushing -4- 10x12x15 into the bore on the inner side of roof frame 3 -8-.
3.2. Position roof frame 3 -8- on the convertible-top support -1- and connect with pin -9- . Secure the pin -7- SLB 10 with the retaining clip -9-.

INFORMATION: Use assembly grease when fitting the pins.

4. Installing roof frame 1.







4.1. Insert bushing -10- 8x10x5.5 into the bore on the outer and inner side of roof frame 2 -5- and roof frame 3 -8-.
4.2. Position roof frame 2 -5- and roof frame 3 -8- on roof frame 1 -11- and connect with the pin -12- and -13-. Secure the pin -7- SLB 10 with the retaining clip -12, 13-.

5. Installing main bow.







5.1. Position main bow -14- on convertible-top support -1-.
5.2. Position square hole washer -15- and washer -16- on the main bow. Secure the main bow -1- with the fastening screw -17- . Coat the fastening screw -17- with Loctite 270 and screw in.
5.3. Tightening torque: 9 Nm (7.0 ftlb.)

6. Installing corner bow.







6.1. Insert bushing -4- 10x12x15 into the bore of the corner bow -18-.
6.2. Insert corner bow -18- on the convertible-top support -1- and insert the anti-spread lock -19- . Secure the anti-spread lock with the retaining pin.

7. Installing tension bow.







7.1. Insert bushing -20- into the bore of the main bow -14-.
7.2. Position tension bow -21- on the main bow and press in the anti-spread lock -19-. Secure the anti-spread lock with the retaining pin.

8. Installing the tension cable.







8.1. Insert tension cable -22- into the ball head -23- of the tension bow -21-.

9. Installing centring pegs.







9.1. Position centring pegs -24- on the roof frame 1 -11- on the left and right and tighten with the fastening screws -25-.
9.2. Tightening torque: 7 Nm (5 ftlb.)
9.3. Affix cover cap -26- onto the centring pegs with Loctite 270.

10. Installing wedge.







10.1. Position wedge -27- on the main bow -14- and tighten with the fastening screws -28-.
10.2. Tightening torque: 2.8 Nm (2.0 ftlb.)

11. Installing drive lever.







11.1. Position drive lever -29- on the main bow -14- and secure the drive lever -29- with retaining clip -7- SLB 10.

Installing electrical wiring harness

12. Installing wiring harness on roof frame 1 and 3.







12.1. Clip the fastened clips on the convertible-top wiring harness -30- into the holes provided on roof frame 1 -11- (clipped in 3 positions).
12.2. Clip the fastened clips on the wiring harness -30- into the holes provided on roof frame 3 -8- (clipped in 2 positions).
12.3. Dimension -inset X- up to model year 2001. Position angle on roof frame 3 and screw in with the fastening screws -33- . Fit rubber sleeve -31a- and plastic cover -31b- on the bracket -31-.
12.4. Tightening torque: 2.8 Nm
12.5. Dimension -inset Y- as of model year 2002. Position plastic bracket -32- on roof frame 3 and screw in with the fastening screws -33-.
12.6. Tightening torque: 2.8 Nm

13. Installing wiring harness on convertible-top support







13.1. Clip wiring harness -30- into the holes provided on the convertible-top support -1-.

14. Installing wiring harness on convertible-top support







14.1. Clip wiring harness -30- into the holes provided on the convertible-top support -1-.

15. Installing potentiometer.







15.1. Insert potentiometer fork into the pins of the hydraulic housing.
15.2. Position potentiometer -34- on the convertible-top support -1- and tighten with the fastening screws -35-.
15.3. Tightening torque: 2.8 Nm (2.0 ftlb.)
15.4. Insert the wiring harness -30- into the fastening clips -36- on the convertible-top support -1-.

16. Connect electrical plug connection.







16.1. Connect electrical plug connection -37-.

Additional assembly instructions for installing electrical wiring harness as of model year 2002 (convertible top with glass window)

17. Installing wiring harness of rear window heating.







17.1. Lay wiring harness as shown in the illustration.
17.2. Fit the tie-wrap -38-.
17.3. Position the fastening clips -40- and tighten with the fastening screws -39-.

Replacing potentiometer

1. Cut off faulty potentiometer behind the wiring of the spare potentiometer using a pair of side cutters.

- Join wires using crimp connector and crimping tool.
- Cut off lines to different lengths (due to the shrink connection).
- Slide shrink-fit hose over the leads.
- Strip 10 mm of insulation off the wires.
- Connect wires with crimp connectors (do not confuse colours of the individual wires).
- Shrink shrink-fit hoses with a hot-air gun. It is essential that all wires are watertight.
- Wrap commercially available PVC tape all around the area of the connection points.

Installing potentiometer.

Installing tension strap

INFORMATION: Additional assembly instructions for installing tension strap as of model year 2002 (convertible top with glass window)

18. Installing tension strap on roof frame 1.







18.1. Position tension strap -41- on roof frame 1 -11- and screw in with the fastening screws -42-.
18.2. Tightening torque: 5 Nm (3.5 ftlb.).

20. Installing tension strap on the main bow.







20.1. Position tension strap -41- on main bow -14- on the holes provided, rivet on the tension strap -41- with the pop rivets -43- (parts scope component of convertible-top covering).

21. Installing tension strap on the corner bow.







21.1. Position tension strap -41- on corner bow -18- on the holes provided, rivet on the tension strap -41- with the pop rivets -43- (parts scope component of convertible-top covering)

22. Installing tension strap on the tension bow.







22.1. Position tension strap -41- on tension bow -21- on the holes provided, rivet on the tension strap -41- with the pop rivets -43- (parts scope component of convertible-top covering)

23. Installing plastic panel.







23.1. Insert fastening clip -44a- onto the tab of the plastic panel -44- from behind and turn 90 degrees clockwise.
23.2. Position plastic panel -44- on roof frame 1 -11- and screw in with the fastening screws -45-.
23.3. Tightening torque: 5 Nm (3.5 ftlb.).

Additional assembly instructions for installing tension strap as of model year 2002 (convertible top with glass window)

INFORMATION: Position the bracing strap -41a- as illustrated.

23. Installing tension strap and bracing strap on the tension bow.







23.1. Position tension strap -41- and bracing strap -41a- on the holes provided on the tension bow -21- , rivet on the tension strap -41- with the pop rivets -43- (parts scope component of convertible-top covering)

Installing styling frame

24. Installing styling frame on roof frame 3.







24.1. Screw on draught deflector -46- on the front face of the styling frame -48- with the fastening screw -47-.
24.2. Tightening torque: 1.7 Nm (1.0 ftlb.)
24.3. Position styling frame on roof frame 3 -8- and tighten with fastening screws -49-.
24.4. Tightening torque: 1.7 Nm (1.0 ftlb.)

26. Installing styling frame on roof frame 2.







26.1. Screw on fabric guide plate -50- and styling frame -51- with the Torx screws T 15 -52- and the washers -52a-.
26.2. Tightening torque: 1.7 Nm (1.0 ftlb.)
26.3. Position styling frame -51- on roof frame 2 -5- . Adjust gap dimension -A = 3.1 + 0.5- between styling frames 2 and styling frame 3 -48-. Screw on fastening screws -53- and the washers -53a-.
26.4. Tightening torque: 9 Nm (7.0 ftlb.)

Installing seals on the styling frame

26. Installing seal on styling frame (roof frame 3).







26.1. Position aluminium profile -54- on the styling frame -48- and screw on with the fastening screws -55-.
26.2. Insert the seal -56- into the aluminium profile -54-.
26.3. Tightening torque: 1.7 Nm (1.0 ftlb.)

28. Installing seal on styling frame (roof frame 2).







28.1. Position aluminium profile -57- on the styling frame -51- and screw on with the fastening screws -58-.
28.2. Insert the seal -59- into the aluminium profile -57-.
28.3. Tightening torque: 1.7 Nm (1.0 ftlb.)

Materials and tools







Tightening torques







Test and adjustment values