Document ID: 2878053
Removal Procedure
- Remove the folding top frame from the vehicle. Refer to Folding Top Frame Removal and Installation .
- Place the folding top frame and cover on a clean and dry surface with the top side (1) down and in the full open position.
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- Start the removal of the folding top cover at the number 1 bow. Do Not remove the number 1 bow or linkage from the frame. Remove the folding top cover number 1 bow garnish molding screws (1) and retainer (2),
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- Remove the rail guides, top handle pocket garnish and flipper doors. Refer to Folding Top Number 1 Bow Garnish Molding Replacement.
- Remove the screws (1) and the side tension cable (4) from the folding top cover on the left and right side completely. Refer to Folding Top Cover Side Tension Cable Replacement.
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- Remove the folding top side rear weatherstrip. Refer to Folding Top Side Rear Weatherstrip Replacement.
- Loosen the headliner to the number 2 bow and the rear window only. Refer to Folding Top Headlining Trim Panel Replacement
- Remove the folding top pivot bracket nuts located on each side of the rear window, under the folding top cover.
- Remove the folding top pivot brackets from the rear window.
- Disconnect the electrical connector from the rear window defogger.
- Remove the rear window defogger harness from the folding top cover, retain the harness to be reinstall in the new cover.
- Position the folding top (1) on the floor, sitting upright in the mid-open position with the 1 bow supported by a suitable support (2) as shown.
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- Support the front edge of the folding top using a appropriate stand of about 30 inches or higher off the floor this will allow access to drilling out the rivets for the side straps and elastic strips.
- Remove the folding top cover from the number 5 bow. Refer to Folding Top Number 5 Bow Replacement.
- Remove the number 5 bow weatherstrip from the number 5 bow, mark the left and right side and center of the weatherstrip to the bow, for reinstalling.
- Drill out the side straps rivets from the folding top cover on the left and right side.
- Drill out the rivets from the side control cords on the left and right side.
- When removing the folding top cover, take note on the placement of each top cover bead and the direction to each of the bows 2, 3 upper 3.5 lower and the 4 bow.
- Mark the starting and stopping point of the folding top cover bead with the opening in the bow track for reinstalling.
- Do this from the right side (Passenger Side), remove the old folding top cover and beads (1) from the tracks (2).
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- Remove the folding top from the vehicle.
- Remove the number 2 bow from the folding top frame assembly as follows: Refer to Folding Top Number 2 Bow Replacement.
- Drill out the four rivets that attach the number 2 bow brackets to the number 2 bow, two at each end.
- With an assistant, technicians should stand on each side of the car, simultaneously holding the number 2 bow with one hand and pulling outward the number 2 bow brackets with the other hand.
- Gradually increase the pull force until the number 2 bow bracket is disengaged from the number 2 bow.
- Remove the number 2 bow from the vehicle.
Note: The folding top Must be removed from the vehicle to perform this procedure.
Note: Leave the headliner installed from the number 3 bow rearward.
Warning: Use the proper eye protection when drilling to prevent metal chips from causing physical injury.
Note: Move the folding top cover out of the way to mark the locations of the side straps. Always check the drill scale, to size the drill. Do Not over size the hole.
The drill bit size is critical for proper retention of the rivets, 1/8” bit should be used for the 3.2 mm (0125 in) holes.
The drill bit size is critical for proper retention of the rivets, 1/8” bit should be used for the 3.2 mm (0125 in) holes.
Note: Use the appropriate tool, cut the material loose from the bead that retains the folding top cover to the bows only if Not reusing the folding top cover. Do not cut the headliner material or bead.
Note: Make sure to retain the thrust washers and bushings from disassembly of the number 2 bow brackets and balance links. However, if parts are lost, extras are included in the folding top cover replacement kit.
Note: The number 2 bow end brackets are made of plastic and will likely break/snap during removal.
Note: Always check the drill scale, to size the drill. Do Not over size the hole. The drill bit size is critical for proper retention of the rivets, 13/64” bit should be used for the 5 mm (0.197 in) holes.
Installation Procedure
- Lay out the new corded folding top cover (1) on a clean, protected surface.
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- Trial fit the folding top cover retaining beads (1) into their corresponding bows. If installation is extremely difficult, it may be necessary to remove some material from all of the beads, prior to their full installation. Use sand paper to remove material from the folding tops cover beads to reduce/eliminate interference.
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- Starting from the right side (Passenger Side), position the folding top cover bead (1) to the beveled edge at the end of each bow.
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- With an assistant, alternately feed the beads into the channels of the bows number 3, number 3.5 and number 4. Continue to work the beads across to the opposite side until the all the folding top cover beads are centered to the marks taken in steps 17 and 18 of this procedure.
- The headliner bead goes in the rear number 2 bow slot (1) and the top cover bead goes in the front number 2 bow slot (2). The number 2 bow is shown upside down in the graphic above for illustration purposes only.
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- Slide the number 2 bow (1) over the folding top cover bead and the headliner bead at the same time as shown above.
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- Reassemble the number 2 bow bracket bushings (1).
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- With an assistant, partially install the thrust washers and number 2 bow brackets to the number 2 bow, while simultaneously angling the brackets into position on the linkage on each side.
- Reinstall only the outboard rivets (1) on each side of the number 2 bow (2) to secure the number 2 bow brackets at this time.
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- Rivet the new folding top cover number 5 bow bracket cord (1) to the new holes on the left and right number 5 bow brackets along with the water bag cord and the headliner control strap (2) as shown.
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- Reinstall the balance link pins (1) and retaining clips (2) on each side.
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- Install the rear window defogger harness to the folding top cover.
- Connect the electrical connector to the rear window defogger.
- Install the folding top pivot brackets to the rear window.
- Install the folding top pivot bracket nuts located on each side of the rear window.
- Install the headliner to the number 5 bow and the rear window. Refer to Folding Top Headlining Trim Panel Replacement
- Attach approximately 3 feet of 16-gauge wire to the top of the side tension cable spring, feed the wire through the bottom of the folding top cover pocket opening until it reaches the top opening.
- Connect the wire to the side tension cable (4) at the bottom and pull it up through the folding top cover pocket. Refer to Folding Top Cover Side Tension Cable Replacement.
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- Remove the wire from the side tension cable end.
- Install the folding top cover edge binding retainer into the rear weatherstrip retaining channel on the left and right sides of the top.
- Reinstall the folding top frame assembly to the vehicle. Refer to Folding Top Frame Removal and Installation.
- Install the side tension cable spring end screw (1) to the number 1 bow on the left and right side, tighten to 9 Nm (80 lb in)
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- Position the folding top (1) in the mid-open position. Clear any contents out of the rear seat and move the front seats forward. The technician will need to stand in the back seat to route and rivet the control cords and straps to the folding top frame.
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- When installing the inboard/left side cord, use routing and P-clip eyelet and straps orientation:
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- Number 2 Bow (1)
- Control Link (2)
- Rear Number 1 Bow Link (3)
- Headliner Strap (4)
- When installing the outboard/left side cord, use routing and P-clip eyelet and straps orientation:
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- Number 2 Bow (1)
- Control Link (2)
- Rear Number 1 Bow Link (3)
- Balance Link (4)
- Headliner Strap (5)
- Rear Top Cover Strap (6)
- Rivet a new P-clip to the inboard hole of the number 2 bow bracket on the left and right sides following the steps:
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- Route the existing cord (1) (no color dot) off the headliner tab upward through the bottom of the P-clip (2).
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- Position the clip to the number 2 bow so that the P-clip (1) is facing outboard as shown.
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- Install the rivet
- Rivet a new eye loop to the remaining inboard-most hole on the left and right sides of the number 2 bow following the steps:
- Grab the 735 mm (29 in) yellow control cord, which is attached to a tab off the binding of the top cover.
- Route the cord downward through the large eye loop (1) with the eye loop angled downward as shown.
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- Install the rivet on the number 2 bow through the small eye loop hole with the large eye loop hole (1) aimed outboard as shown.
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- Rivet a new 75 degree bend eye loop to the hole previously drilled in the left and right rear number 1 bow link following the steps:
- Holding the (1) eye loop with the 75 degree bend, route the yellow (2) and orange (3) top cover control cords down through the large eye loop opening.
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- Grab the eyelet on the end of the blue and white top cover control cord. Put the eyelet (1) on the new rivet, then add the eye loop (2) through the small hole.
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- Install the rivet to the rear number 1 bow link with the orientation of the 75 degree bend of the large eye loop angled inboard as shown in the insert above and the loop (1) and the cord eyelet (2) as shown.
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- Rivet the end eyelets of the headliner cord (no color dot), along with a new P-clip, to the forward hole previously drilled in the left and right control links following the steps:
- Grab a new P-clip (1) and route the yellow and orange control cords through the P-clip as shown.
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- Insert a new rivet in the headliner eyelet, then through the P-clip (with the yellow and orange cords already running through it) and position them to the forward hole previously drilled in the control links.
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- Install the rivet to the control link with the orientation of the cord eyelet (1) and the P-clip (2) as shown.
- Rivet a new eyelet, along with the rear strap that is attached to the top cover binding, to the rearward hole previously drilled in the left and right control links following the steps:
- Route the yellow and orange control cords down through the large hole in a new eye loop (1) with the eye loop angled upward as shown.
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- Grab the rear top cover strap (1) strap as shown above.
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- Insert a new rivet through the small eye loop (1), then through the strap (2) as shown.
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- Ensure that the rear strap (1) of the folding top cover is not hung up behind the wishbone, But is clear of the wishbone link (2) as shown.
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- Install the rivet to the control link with the orientation of the rear top cover strap (1) and the eyelet (2) as shown.
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- Rivet both end eyelets of the yellow and orange control cords to the hole previously drilled in the left and right balance links following the steps:
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- Insert a new 3.2 mm (0.125 in) rivet through the end eyelets on first the yellow (1), and then the orange (2), control cords.
- Attach the rivet to the hole in the balance link as shown.
- Balance the new cross-car control cord in the folding top cover’s second pocket by completing the following steps:
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- Cycle the folding top to the half open position.
- Locate the second pocket control cord with the orange paint dot on the eyelet (1), which is the longer of the two cords riveted to the balance link.
- With your index finger, pull the cord forward, taking out the slack.
- When the cords (1) are even from side to side, there will be a gap of about 25 mm (1.0 in) (A) between your finger and the balance link as shown. If the gap is less than an inch, reach into the folding top cover and gently pull the cord towards you, then recheck the gap. Noting the gap on one side, go to the other side of the folding top and repeat the process. Repeat this process from side to side until the gaps are equal.
- Install the folding top cover over the number 1 bow. Refer to Folding Top Cover Replacement.
- Install the rail guides, top handle pocket garnish and flipper doors. Refer to Folding Top Number 1 Bow Garnish Molding Replacement.
- Install the number 1 bow garnish molding screws (1) to the retainer (2) and tighten to 7 Nm (62 lb in).
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- After balancing the cross car cord and completing the folding top cover installation, cycle the folding top to the fully stowed position before cycling the folding top closed.
- Verify proper operation of the folding top.
- Place the folding top in the lock position, check for appearance and fit.
- Inspect the front edge of the folding top to windshield frame for a good seal.
- Water test the vehicle to ensure a proper water tight seal.
Note: Ensure the folding top cover and headliner beads are installed in the right direction for the following bows, 2 3 upper 3.5 lower and the 4.
Caution: Refer to Fastener Caution.
Note: The graphic view is with the top in mid-open position and the right side view would mirror the left. The top frame links and strap referenced later in the instructions are noted in the callouts.
Note: The graphic view is with the top in mid-open position and the right side view would mirror the left. The top frame links and strap referenced later in the instructions are noted in the callouts.
Note: The three cords added to each side of the top cover are color-keyed with paint dots on the cord eyelets. The orientation of the three colors blue and white (1), yellow (2), and orange (3) is shown above. The following steps will reference them as the blue and white, yellow, or orange control cords.
Note: The headliner cord end eyelets will be riveted at a later step. They can hang off the top side of the P-clip for now.
Note: The headliner control cord must be routed through the P-clip before installing the rivet.
Note: The steps in the next several sections will normally need to be performed with the an assistant.
Note: The eye loops that attach to the left and right sides of the number 1 bow link have a 75 degree bend. These two eye loops are to be used only for that location.
Note: The large eye loop should already have the yellow and orange control cords routed through it, prior to attaching the rivet.
Note: The large eye loop should already have the yellow and orange control cords routed through it prior to attaching the rivet. Also ensure that the cover strap is oriented straight down and under the link and not angled forward or rearward.