Installation
INSTALLATIONHINT:
- When installing the soft top, put the switch into the manual mode.
- Use stainless steel staples with 1/2 and 3/8 in. size Use 1/2 in. size staples for the places where the tarpaulin overlaps.
1. INSTALL MOUNTING BRACKET TO TARPAULIN RAIL ASSEMBLY
a. Using a torx wrench, install the mounting bracket with the 2 screws.
Torque: 30 N.m (305 kgf.cm, 22 ft.lbf)
HINT: The screws should be located in the center of the oval hole.
b. Employ the same manner described above to the other side.
2. INSTALL CONVERTIBLE ROOF MOTOR ASSEMBLY
a. Install the convertible roof motor assembly and motor cover with the 4 bolts and washers.
Torque: 9.0 N.m (90 kgf.cm, 80 in.lbf)
b. Employ the same manner described above to the other side.
3. INSTALL RECLINING CONTROL LINK
a. Using a torx wrench, install the reclining control link with the screw.
Torque: 30 N.m (305 kgf.cm, 22 ft.lbf)
b. Employ the same manner described above to the other side.
4. INSTALL REAR TARPAULIN RAIL ASSEMBLY TO TARPAULIN RAIL PIVOT BRACKET
a. Using a torx wrench, install the rear tarpaulin rail assembly to the tarpaulin rail pivot bracket with the screw and nut.
Torque: 30 N.m (305 kgf.cm, 22 ft.lbf)
HINT: Before installing the screw, using a brass pin, adjust the location of the bush inside of the rear rail.
b. Using a torx wrench, install the 2 screws.
Torque: 30 N.m (305 kgf.cm, 22 ft.lbf)
c. Employ the same manner described above to the other side.
5. INSTALL TARPAULIN RAIL PIVOT BRACKET WITH REAR TARPAULIN RAIL ASSEMBLY AND CONVERTIBLE ROOF MOTOR ASSEMBLY
a. Install the tarpaulin rail pivot bracket with rear tarpaulin rail assembly and convertible roof motor assembly to the vehicle with the bolt and nut.
Torque: 58 N.m (590 kgf.cm, 43 ft.lbf)
b. Connect the connector.
c. Employ the same manner described above to the other side.
6. INSTALL TARPAULIN RAIL ASSEMBLY
a. Using a torx wrench, install the tarpaulin rail assembly with the 2 screws.
Torque: 30 N.m (305 kgf.cm, 22 ft.lbf)
b. Align the lock plate with the marked position.
c. Using a torx wrench, install the screw, nut and lock plate.
Torque: 30 N.m (305 kgf.cm, 22 ft.lbf)
d. Employ the same manner described above to the other side.
7. INSTALL NO.1 BOW LOCATING PIN, TARPAULIN LATCH AND NO.1 TARPAULIN BOW
a. Install the No.1 bow locating pin with the nut and washer.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
b. Using a torx wrench, install the tarpaulin latch with the 2 screws.
Torque: 25 N.m (255 kgf.cm, 18 ft.lbf)
c. Using a torx wrench, install the No.1 tarpaulin bow, 2 spacers and 4 bushings with the 2 screws.
Torque: 30 N.m 305 kgf.cm, 22 ft.lbf)
d. Employ the same manner described above to the other side.
8. INSTALL NO.3 TARPAULIN BOW
a. Using a torx wrench, install the No.3 tarpaulin bow with the 2 screws.
Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
b. Employ the same manner described above to the other side.
9. INSTALL REAR SIDE TOP TARPAULIN BOW PROTECTOR
a. Using a torx wrench, install the rear side top tarpaulin bow protector with the 2 screws.
b. Employ the same manner described above to the other side.
10. INSTALL RECLINING CONTROL PLATE WITH REAR SIDE TOP TARPAULIN BOW PROTECTOR AND SPACER
a. Using a torx wrench, install the reclining control plate with the rear side top tarpaulin bow protector and spacer with the 2 screws.
b. Employ the same manner described above to the other side.
11. INSTALL NO.4 TARPAULIN BOW AND BASE SETTING PLATE
a. Align the matchmark on the base setting plate with the No.4 tarpaulin bow as shown in the illustration.
b. Using a torx wrench, install the 2 screws.
Torque: 25 N.m (255 kgf.cm, 18 ft.lbf)
c. Using a torx wrench, install the No.4 tarpaulin bow and base setting plate with the screw.
Torque: 30 N.m (305 kgf.cm, 22 ft.lbf)
d. Employ the same manner described above to the other side.
12. INSTALL TARPAULIN FRONT AND CENTER RAIL RETAINER
a. Using a torx wrench, install the tarpaulin center rail retainer by positioning and installing the 2 screws to the marked centerline on the tarpaulin rail assembly.
Torque: 17 N.m (175 kgf.cm, 13 ft.lbf)
NOTE: Install the shims with original thickness and original quantity in the original position.
b. Using a torx wrench, install the tarpaulin front rail retainer by positioning and installing the 3 screws to the marked centerline on the tarpaulin rail assembly.
Torque: 17 N.m (175 kgf.cm, 13 ft.lbf)
NOTE: Install the shims with original thickness and original quantity in the original position.
c. Check the gap between the tarpaulin front rear retainer and tarpaulin center rear retainer.
d. Employ the same manner described above to the other side.
13. IF NECESSARY, REPLACE SIDE STAY PAD
Mark new side stay pad in same position as removed side stay pad.
14. INSTALL SIDE STAY PAD
a. Install the side stay pad through the No.1 tarpaulin bow.
b. Align the marked lines of the No.1, No.2, No.3 and No.4 tarpaulin bow and side stay pad.
c. Using a staple gun, install the side stay pad to the No.4, No.3 and No.2 tarpaulin bows.
d. Employ the same manner described above to the other side.
NOTE: Keep the stay pad straight from No.1 bow to No.4 bow.
HINT:
- Measurement at vehicle center line.
- If there is excess stay pad material, trim at No.4 bow.
15. CHECK POSITION OF NO.1 BOW LOCATING PIN AND PIN HOLE
Check that when the bow control link is closed, the No.1 bow locating pin and pin hole are aligned.
16. ADJUST POSITION OF NO.1 BOW LOCATING PIN
Using a torx wrench, loosen the 4 screws of the mounting bracket to adjust the No.1 bow locating pin.
17. CHECK POSITION OF BOW CONTROL LINK UPSTOP
a. Unlatch the tarpaulin latch.
b. Measure the distance between the bottom surface of the No.1 bow and top surface of the header weatherseal as shown in the illustration.
A: 20 - 25 mm (0.79 - 0.98 in.)
18. ADJUST POSITION OF BOW CONTROL LINK UPSTOP
Loosen the nut and turn the upstop bolt.
19. CHECK POSITION OF BOW CONTROL LINK DOWN STOP
a. Fully open the convertible roof.
b. Place a straight edge across the top of the No.1 bow. Using a scale, measure the distance between the bottom of the straight edge and top of the quarter belt moulding as shown in the illustration.
A: 34.3 - 40.3 mm (1.350 - 1.587 in.)
20. ADJUST POSITION OF BOW CONTROL LINK DOWNSTOP
Loosen the nut and turn the downstop bolt.
21. ADJUST TARPAULIN LATCH SUB-ASSEMBLY
If there is a clearance or level difference between the windshield and the front edge of the tarpaulin cover when the tarpaulin cover is fully closed, turn the convertible roof hook to adjust it.
22. ADJUST GAP BETWEEN BOW CONTROL LINK AND GLASS
If a gap exists between the bow control link and front door glass, turn the adjusting screw to adjust it.
23. IF NECESSARY, REPLACE TARPAULIN BACK WINDOW
a. Cut away the lower flap of the removed tarpaulin back window along the marked line.
b. Position removed tarpaulin back window over a new one.
c. Mark the line on the new tarpaulin back window along the line cut in (a).
NOTE: Do not cut off excess material of new tarpaulin back window.
24. IF NECESSARY, REPLACE REAR TOP COVER TARPAULIN BOW
Using a drill, make a hole of Dia 4 mm (0.16 in.) on a new bow at the same position as the removed bow.
HINT: This guide hole is used to temporarily fix the rear top cover tarpaulin bow to the bow bracket so that proper screw position will be secured
25. INSTALL TARPAULIN BACK WINDOW
a. Install the tarpaulin back window to the No.4 tarpaulin bow by sliding it to the left.
NOTE:
- When sliding the tarpaulin back window, be careful not to forcibly pull it. Otherwise the tarpaulin back window will be torn off.
- If it requires excessive sliding force, check the width of the groove on the bow.
HINT: Align the center line of the back window with the center line on the No.4 bow.
b. Using a torx wrench, install the side rail extension with the screw.
Torque: 12 N.m (125 kgf.cm, 9 ft.lbf)
c. Align the notch on the tarpaulin back window with the center line on the rear top cover tarpaulin bow.
d. Align the tarpaulin back window front side with the marked line on the rear top cover tarpaulin bow.
e. Align the rear top cover tarpaulin bow upper edge with the marked line on the tarpaulin back window.
f. Employ the same manner described above to the other side.
g. Using a staple gun, install the tarpaulin back window to the rear top cover tarpaulin bow.
h. Align the stay pad of the tarpaulin back window with the marked line on the rear top cover tarpaulin bow.
i. Using a staple gun, install the stay pad of the tarpaulin back window to the rear top cover tarpaulin bow.
j. Employ the same manner described above to the other side.
26. CLOSE CONVERTIBLE ROOF
Close the convertible roof but do not latch it.
27. IF NECESSARY, REPLACE TARPAULIN COVER
a. Cut away the quarter flap of the removed tarpaulin cover along the marked lines.
b. Position removed tarpaulin cover over a new one.
c. Mark the line on the new tarpaulin cover along the line cut in (a).
NOTE: Do not cut off excess material of new tarpaulin cover.
28. INSTALL TARPAULIN COVER TO NO.1 TARPAULIN BOW
a. Put the tarpaulin cover over the vehicle.
b. Using a heat light, heat the adhesive tape, and remove it.
NOTE: Do not heat the adhesive tape excessively.
c. Wipe off stains with cleaner.
d. Stick a new adhesive tape to the No.1 tarpaulin bow.
e. Align the front end of tarpaulin cover to the No.1 tarpaulin bow.
f. Stick the tarpaulin cover to the adhesive tape on the No.1 tarpaulin bow.
HINT:
- Align the slit of the tarpaulin cover with the center of the No.1 bow.
- Position the top cover binding along the depression cast into the No.1 bow.
29. OPEN CONVERTIBLE ROOF HALFWAY
30. INSTALL TARPAULIN COVER TO NO.4 TARPAULIN BOW
a. Mark the position of the both ends of the adhesive tape on the No.4 tarpaulin bow.
b. Using a heat light, heat the adhesive tape, and remove it.
NOTE: Do not heat the adhesive tape excessively.
c. Wipe off stains with cleaner.
d. Align a new adhesive tape with the marked lines, and stick it to the No.4 tarpaulin bow.
e. Stick the tarpaulin cover to the adhesive tape on the No.4 tarpaulin bow.
HINT: Align the slit of the tarpaulin cover with the center of the No.4 bow.
f. Using a staple gun, install the tarpaulin cover to the No.4 tarpaulin bow.
HINT: Staple the tarpaulin cover and No.4 tarpaulin bow at intervals of 10 mm (0.39 in.).
31. INSTALL TARPAULIN COVER TO REAR TARPAULIN RAIL ASSEMBLY
a. Connect the cable with the screw.
b. Using a heat light, heat the adhesive tape, and remove it.
NOTE: Do not heat the adhesive tape excessively.
c. Wipe off stains with cleaner.
d. Stick a new adhesive tape to the rear tarpaulin rail.
e. Stick the tarpaulin cover to the adhesive tape of the rear tarpaulin rail assembly.
f. Employ the same manner described above to the other side.
32. INSTALL REAR TARPAULIN RAIL RETAINER
a. Install the rear tarpaulin rail retainer with the 6 screws.
b. Employ the same manner described above to the other side.
33. CLOSE CONVERTIBLE ROOF
Close the convertible roof but do not latch it.
34. INSTALL TARPAULIN COVER TO REAR TOP COVER TARPAULIN BOW
a. Align the rear top cover tarpaulin bow front side with the marked line on the tarpaulin cover.
b. Align the rear top cover tarpaulin bow upper edge with the marked line on the tarpaulin cover.
c. Using a staple gun, install the tarpaulin cover to the rear top cover tarpaulin bow.
d. Employ the same manner described above to the other side.
e. Put the rear top cover tarpaulin bow with tarpaulin cover and back window into the vehicle.
NOTE: Do not apply excessive force to the tarpaulin bow.
35. INSTALL SPLASH SHIELD
36. INSTALL TARPAULIN COVER TO NO.2 AND NO.3 TARPAULIN BOW
a. Using a heat light, heat the adhesive tape, and remove it.
NOTE: Do not heat the adhesive tape excessively.
b. Wipe off stains with cleaner.
c. Stick a new adhesive tape to the No.2 and No.3 tarpaulin bows.
d. Stick the tarpaulin cover to the adhesive tape on the No.2 and No.3 tarpaulin bows.
37. CONNECT REAR TOP COVER TARPAULIN BOW
a. Using a guide pin tool, correctly set the rear top cover tarpaulin bow to the bow bracket.
b. Using a torx wrench, connect the rear top cover tarpaulin bow with the 2 screws.
Torque: 25 N.m (255 kgf.cm, 18 ft.lbf)
c. Employ the same manner described above to the other side.
38. INSTALL TARPAULIN COVER TO NO.1 TARPAULIN BOW
a. Pass the cable through the tarpaulin cover to the rear tarpaulin rail assembly.
b. Connect the cable to the rear tarpaulin rail assembly with the screw.
c. Install the screw.
d. Employ the same manner described above to the other side.
39. INSTALL TARPAULIN HEADLINING
a. Install the tarpaulin headlining to the No.4 tarpaulin bow by sliding the tarpaulin headlining.
NOTE: When sliding the headlining, be careful not to forcibly pull it. Otherwise the headlining will be torn off.
b. Install the front end of tarpaulin headlining with the 10 screws.
c. Install roof header garnish assembly with the 12 screws.
d. Push the tarpaulin headlining into the No.2 and No.3 tarpaulin bow.
40. INSTALL TABS OF TARPAULIN HEADLINING
a. Install the 2 screws.
b. Employ the same manner described above to the other side.
41. INSTALL TARPAULIN REAR RAIL RETAINER
a. Using a heat light, heat the adhesive tape, and remove it.
NOTE: Do not heat the adhesive tape excessively.
b. Wipe off stains with cleaner.
c. Stick a new adhesive tape to the rear tarpaulin rail.
d. Stick the tarpaulin headlining to the adhesive tape of the rear tarpaulin rail assembly.
e. Install the tarpaulin rear rail retainer by positioning and installing the 4 screws to the marked screw head markings on the tarpaulin rear rail retainer.
NOTE: Install the shims with original thickness and original quantity in the original position.
f. Check the gap between the tarpaulin center rail retainer and tarpaulin rear rail retainer.
g. Check the gap between the tarpaulin front rail retainer and tarpaulin center rail retainer.
h. Employ the same manner described above to the other side.
42. INSTALL NO.2 ROOF SIDE RAIL GARNISHES
a. Install the No.2 roof side rail garnish with the 3 screws.
b. Install the tarpaulin center rail weatherstrip.
c. Employ the same manner described above to the other side.
43. INSTALL TARPAULIN REAR RAIL WEATHERSTRIPS
44. INSTALL FRONT ROOF SIDE RAIL GARNISH
a. Install the 4 screws.
b. Connect the garnish and tarpaulin headlining with the clip.
c. Employ the same manner described above to the other side.
45. INSTALL TARPAULIN FRONT RAIL WEATHERSTRIPS
a. Install the tarpaulin front rail weatherstrip.
b. Using a torx wrench, install the retainer with the 2 screws.
c. Employ the same manner described above to the other side.
46. INSTALL QUARTER TRIM AND BACK BELT MOULDING
47. INSTALL FRONT DOOR SCUFF PLATES
48. INSTALL REAR SEAT CUSHION AND SEATBACK ASSEMBLY
49. INSTALL TARPAULIN STORAGE COVER
a. Install the tarpaulin storage cover to the splash shield
b. Install the clips.
c. Connect the back window wire harness.
d. Connect the quarter window shield with the 3 screws and clip.