Remove/Install Soft Top - AR77.30-P-1002LWR
Model 205.4
Model 238.4
Shown on left side of vehicle
Shown on left side of vehicle
Shown on left side of vehicle
Shown on left side of vehicle
| Risk of injury when performing check and repair work in area of roll bar | Keep body parts out of the area where the roll bars extend. Do not use the cover in the area of the roll bar as a storage place for objects. |
AS91.00-Z-0003-01LCA | |
| Risk of injury during testing and repair operations related to pyrotechnical components | Do not expose pyrotechnical component parts to temperatures above 100°C or 212°F. Disconnect current supply when working on such component parts. |
AS91.00-Z-0008-01A | |
| Risk of injury. Moving parts can pinch, crush or, in extreme cases even sever extremities. | No parts of the body or limbs should be within the operating area of mechanical components when moving components. | AS00.00-Z-0009-01A | |
| Risk of injury caused by scraping or cutting body parts on sharp vehicle parts | Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels. |
AS00.00-Z-0017-01A | |
| Remove/install | |||
| 1 | Remove seat cushion in rear | Model 205.4 except code 248 (Rear seat with integrated child seat) except code P10 (Taxi package Germany) Model 238.4 |
AR91.12-P-1020LW |
| 2 | Remove left and right backrest in rear | AR91.12-P-1721LWR | |
| 3 | Remove left and right shoulder cushion in rear | AR91.12-P-1712LWR | |
| 4 | Remove left and right side trims in rear | Model 205.4 | AR68.30-P-4784LWR |
| Model 238.4 | AR68.30-P-4784LWO | ||
| 5 | Disconnect battery ground line | Model 205.4 | AR54.10-P-0003LW |
| Model 238.4 | AR54.10-P-0003LWO | ||
| 6 | Remove left and right sidebag in rear | Model 205.4 with code 298 (Rear sidebag with belt force limiter) Model 238.4 with code 293 (Sidebags in rear) |
AR91.60-P-0694CLW |
| 7 | Loosen left and right paneling (1) in area of roll bar | ||
| 8 | Remove panel (2) | ||
| 9 | Unscrew left and right screws (3) on crossmember (4) and remove crossmember (4) | ||
| 10 | Unscrew bolt (5) from left and right belt guide (6) | ||
| 11 | Unscrew bolts (7) from left and right connecting panel (8) and remove connecting panels (8) together with belt guides (6) | *BA64.10-P-1001-01D | |
| 12 | Unhook cable (9) on left and right soft top end (10) | ||
| 13 | Move soft top manually to repair position R2 | AR77.30-P-1030LWR | |
| 14 | Remove bolt (15) at top on left and right soft to bow hydraulic cylinder (16) | ||
| 15 | Remove bolt (17) at top on left and right soft top actuation hydraulic cylinder (18) | ||
| 16 | Expose cable (9) on left and right soft top support (14) | ||
| 17 | Remove bolt (20) at bottom on left and right soft top operation hydraulic cylinder (18) | ||
| 18 | Place soft top operation hydraulic cylinder (18) with connected hydraulic lines to one side | ||
| 19 | Lift lower retainer (21) at left and right soft top bow hydraulic cylinder (16) using a suitable screwdriver | Retainer (21) preload can otherwise be lost. |
|
| 20 | Unclip soft top bow hydraulic cylinder (16) at bottom and place to one side with connected hydraulic lines | ||
| 21 | Move soft top manually to repair position R4 | AR77.30-P-1030LWR | |
| 22 | Remove trim piece (22) on left and right side wall | ||
| 23 | Loosen seal (23) in area of left and right side wall | ||
| 24 | Disconnect electrical connector (11) on left and right side of vehicle | ||
| 25 | Disconnect electrical connector (12) from AM amplifier with selection switch (13) and expose wiring harness on soft top support (14) | ||
| 26 | Remove bolts (24) on right and left soft top support (14) | Move soft top to repair position Align soft top supports (14), as shown, with end stops (25) and tighten screws (24). |
AR77.30-P-1030LWR |
| *BA77.33-P-1001-02B | |||
| BA77.33-P-1001-02C | |||
| 27 | Lift soft top out of vehicle | AR77.30-P-1002-04LWR | |
| Fig 1 | |||
| 28 | Remove left and right end stop (25) for soft top supports (14) | When replacing left and right end stop (25) after accident damage or if required. | AR77.30-P-0002LWR |
| 29 | Install in the reverse order |
REAR PANEL
| Number | Designation | Model 205.4 | Model 238.4 | |
|---|---|---|---|---|
| BA64.10-P-1001-01D | Bolt, connecting panel to body | Nm | 20 | 20 |
MECHANICAL SOFT-TOP COMPONENTS
| Number | Designation | Model 205.4 | |
|---|---|---|---|
| BA77.33-P-1001-02B | Bolt, soft top support to body | Nm | 27 |
MECHANICAL SOFT-TOP COMPONENTS
| Number | Designation | Model 238.4 | |
|---|---|---|---|
| BA77.33-P-1001-02C | Bolt, soft top support to body | Nm | 27 |