SOFT TOP

Removal and Installation of Roof Actuator

REMOVAL

1. Remove soft top assembly. Refer to RF-87, "Removal and Installation of Soft Top Assembly".
2. Remove nuts and then remove roof actuator (RH/LH).

   NOTE: If removal is difficult, rotate motor axis to remove them.

   [Diagram: Roof actuator assembly attached to soft top frame with nuts.]

3. Disconnect soft top actuator harness connector.

INSTALLATION

Install in the reverse order of removal.

Removal and Installation of 5th Bow Drive Unit

REMOVAL

1. Uninstall soft top assembly from the vehicle.
2. Remove roof actuator (RH/LH) from the soft top.

   NOTE: If removal is difficult, rotate motor axis to remove them.

   [Diagram: Roof actuator assembly attached to soft top frame with nuts.]

3. Disconnect 5th bow operating rod (RH/LH) at the frame side by pulling out the holder.

   NOTE: This step will make the 5th bow up and down motion easier.

   [Diagram: 5th bow operating rod connected to frame via holder; shows removal action.]

4. Make sure that the limit switch contact around the rotation axis of the 5th bow on the left side of soft top is protected with tape.
5. Open the soft top manually, and put a stand under the 1st bow. Then fix the soft top not to move during this procedure.

   NOTE: Put a waste cloth between the front lock and the stand not to make any scratches to the soft top.

6. Remove the C link and 5th bow weatherstrip.
7. Remove the soft top cover retainer (5th bow retainer) from 5th bow by taking out screws.

   [Diagram: Soft top cover retainer attached to 5th bow with screws.]

8. Drilling rivets attaching the soft top cover to 5th bow, then pull up the soft top cover bottom edge.

   NOTE: Use 4 mm (0.16 in) diameter drill bit to remove the rivet head. When drilling rivets, be careful not to damage the soft top cover.

9. Drilling rivets with retainers attaching with tags from the soft top cover, 5th bow finisher and the 5th bow.

   NOTE: Use 4 mm (0.16 in) diameter drill bit to remove the rivet head. The soft top cover is separated from 5th bow.

   [Diagram: Soft top cover, 5th bow finisher, and 5th bow connected by retainers and rivets.]

10. Drilling rivets under retainers by using 4 mm (0.16 in) diameter drill bit.

    [Diagram: Rivets securing retainer to 5th bow, showing drilling action.]

11. Remove pads from 5th bow finisher.

    [Diagram: Pads attached to the 5th bow finisher.]

12. Roll the soft top cover bottom edge up, and disconnect defogger harness connector from the rear window glass.

    [Diagram: Defogger harness connector disconnected from rear window glass.]

13. Pull out glass stays from sleeves on each side of the rear window glass.

    [Diagram: Glass stays being pulled from sleeves on rear window glass.]

14. Remove 5th bow side finisher (RH/LH) by removing screws.

    [Diagram: 5th bow side finisher removed using screws.]

15. Remove 5th bow finisher by pulling the finisher up.

    [Diagram: 5th bow finisher being pulled upwards, possibly indicating clips.]

16. Remove glass stays from 5th bow by removing screws from the bottom of the 5th bow.

    NOTE:

    • When removing glass stays, support 5th bow to avoid a bend of glass stay. This bend may happen by the weight of the 5th bow and the tensile force of the tether from the soft top cover.
    • Be careful not to damage the 5th bow nor to be hurt by the falling 5th bow, because the 5th bow is heavy and moves freely after removing glass stays.

    [Diagram: Glass stays removed from 5th bow using screws; shows protection tape.]

17. Disconnect 5th bow drive unit harness connector.

    [Diagram: 5th bow drive unit harness connector disconnected via screw.]

18. Remove 5th bow drive unit and rails together from 5th bow by removing screws.

    NOTE:

    • After removing drive unit and rails, not to pull rails. Otherwise, the wire in the rail may be damaged.
    • The screws are not reusable.

    [Diagram: 5th bow drive unit and rails attached to 5th bow with screws; shows screw locations.]

INSTALLATION

Preparation Work

1. Blow remains of rivet toward both ends of 5th bow with compressed air if they are entering into 5th bow.

   [Diagram: Air gun used to blow rivet remains from 5th bow.]

2. Remove the remains drawn to both ends by the air blow from the gap.

   [Diagram: 5th bow showing "remains take out hole" for debris removal.]

3. For fixing harness to 5th bow and Soft top frame, see next figure.

   [Diagram: Views A-D showing harness clamps securing wiring to 5th bow and soft top frame.]

   [Diagram: Overall routing of harness along 5th bow secured with unwoven cloth tape; arrows indicate attachment points.]

Harness Routing and Securing

[Diagram: Detailed routing of "No. 5bow motor harness" secured with tape, clips, and bands.]

[Diagram: Detailed routing of "No. 5bow motor harness" secured with tape, clips, and bands.]

[Diagram: Routing of "No. 5bow motor harness" along soft top frame, secured with tape and clips.]

1. Replace rivet retainer on back of 5th bow finisher with a new one.
2. Secure 5th bow finisher with rivet, and then apply nonwoven fabric.
3. Install 5th bow finisher and 5th bow finisher (RH/LH).
4. Apply pad on 5th bow finisher.

   NOTE: Apply pad to the original position.

   [Diagram: Retainer, pad, and finisher placement on 5th bow.]

Installation

Install in the reverse order of removal.