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
1.1. Lift up the cover strip to the left and right -2- using a plastic spatula and pull it out of the hardtop body -1-. The roof strip clips are destroyed when they are removed.
2. Removing cover and bracket
2.1. Pull off cover -2A- and press out the bracet at the top and bottom using a plastic spatula.
Removing rear window
Refer to Removing and installing rear window (hardtop)
Turning hardtop
Place outer side of the hardtop on the assembly fixture.
3. Unclipping interior trim parts
3.1. Unclip interior trim parts -3- at the sides, front and rear from the hardtop body -1-.
4. Detaching seal at sides of roof frame
4.1. 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-.
4.2. Unscrew fastening screws -7- from the retaining rail -6-.
4.3. 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
5.1. Unscrew sheetmetal screws -9- from the retaining rail -10-.
5.2. Unscrew fastening screws -11- from the roof frame seal, detach the seal at the corners and remove it.
6. Pulling off rubber seal
6.1. Pull off the all-round rubber seal -12- at the rear.
7. Removing centring peg
7.1. Unscrew and remove fastening screws -13- from the centring peg -14-.
8. Removing locking lever
8.1. Unscrew and remove fastening screws -15- from the locking lever -16-.
9. Detaching roof liner at front
9.1. Lift the front retaining rail -17- of the roof liner -18- with a plastic spatula and pull it off.
10. Detaching roof liner at sides
10.1. Lift up the roof liner -18- on the left and right sides with a plastic spatula and disengage from the sheetmetal clips -19-.
11. Detaching roof liner at rear and transverse struts
11.1. Pull the plastic rail -20- on the roof liner -18- to the rear and detach it.
11.2. Remove the transverse struts -21- with the plastic sleeves -22- and remove the roof liner -18-.
12. Detaching insulation from the hardtop body
12.1. Undo the insulation -23- of the hardtop body -24- using a spatula.
13. Removing hardtop locking element
13.1. Unscrew and remove fastening screws -25- from the hardtop lock -26-.
14. Disconnecting wiring harness of the heated rear window
14.1. Drill out the 3.2 mm -27- tubular rivet. Disconnect electrical plug connection -28-, remove wiring harness with the hardtop locking element from the hardtop body.
15. Pressing expanding nuts out of the hardtop body
15.1. Press out expanding nuts -30- at the sides and front of the hardtop body -1-.
Assembling hardtop
INFORMATION: 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.
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
1.1. Press in expanding nuts -2- at the sides and front of the hardtop body -1- until they engage.
2. Fitting wiring harness of the rear window heater
2.1. Position wiring harness with the hardtop locking element, rivet the flat connector -3- onto the hardtop body -1- with a 3.2 mm tubular rivet and connect the plug connection -4-.
3. Sticking insulation on the hardtop body
3.1. Position the self-adhesive insulation -5- in the hardtop body -1- and press firmly into place.
4. Engaging roof liner at rear and transverse struts
4.1. Insert the transverse struts -6- with the plastic sleeves -7- into the hardtop body -1-.
4.2. Pull back the plastic rail -8- of the roof liner -9- and engage in the groove of the hardtop body -1-.
5. Engaging roof liner at sides
5.1. Engage roof liner -9- at the left and right sides in the sheetmetal clips -10-.
6. Fitting roof liner at front
6.1. Position the front retaining rail -11- of the roof liner -9- and clip it in.
7. Affixing Nitto tape to the hardtop body
7.1. Stick on a 2 cm wide strip of Nitto tape -12- at the front left and right of the hardtop body -1-.
8. Fitting roof frame seal and retaining rail
8.1. Engage roof frame seal in the hardtop body -1- at the corners and fasten with the fastening screw -13-.
8.2. Position the retaining rail -14- and tighten with the fastening screws -15-.
9. Fitting seal at sides of roof frame
9.1. The seal on the roof frame -16- at the sides consists of two parts. Position the lower seal with the retaining strip -17- on the roof frame -16- and fasten with the fastening screws -18-.
9.2. Press the upper seal -19- into the profile of the retaining rail -20-.
10. Fitting rubber seal
10.1. Position the self-adhesive rubber seal -21- at the rear and press firmly into place all around.
11. Fitting hardtop locking element
11.1. Screw in and tighten fastening screws -22- into the hardtop locking element -23-.
12. Fitting locking lever
12.1. Position the locking lever -24- on the hardtop body -1- and tighten with the fastening screws -25-.
13. Fitting centring pegs
13.1. Position the centring pegs -26- on the hardtop body -1- and tighten with the fastening screws -27-.
13.2. Turning hardtop
13.3. Place hardtop on the assembly fixture and lock with the latching levers at the rear and the locking lever at front.
13.4. Installing rear window
13.5. Refer to Removing and installing rear window (hardtop)
13.6. Turning hardtop
13.7. Place outer side of the hardtop on the assembly fixture.
INFORMATION: Once an interior trim part has been clipped in once, the old plastic clips are no longer usable and must always be replaced.
14. Fitting interior trim parts
14.1. Clip interior trim parts -28- at the sides, front and rear into the hardtop body -1-.
15. Fitting cover and bracket
15.1. A self-adhesive strip is affixed on the bracket. Remove the backing paper from the adhesive strip and position and clip in the bracket on the hardtop body.
15.2. Put the painted cover -29- on the bracket.
16. Applying putty on the roof ends
16.1. Apply putty on the roof ends at the front and rear.
17. Clipping in roof strip clips and cover strips
17.1. Fit the roof strip clip -30-.
17.2. Fit cover strip seal on the cover strip -31-.
17.3. Position cover strip on the hardtop body -1- and press into the roof strip clips.
Tightening torques
