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Home >> Porsche >> 2003 >> 911 Carrera 4S, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 22 (Convertible Top, Hardtop) >> Replacing convertible top frame >> Assembling convertible-top frame

Assembling convertible-top frame

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Removal tool for removing and fitting retaining clips -19-. See TEST AND ADJUSTING VALUES  .

  1. Placing the roll-over bar on assembly fixture

    Place the roll-over bar outside the vehicle on a workbench or assembly fixture and secure.

    Fig 1: Placing Roll-Over Bar On Assembly Fixture
    G03155101Courtesy of PORSCHE OF NORTH AMERICA, INC.
  2. Fitting the adjusting piece and strips of adhesive tape
    1. Insert the adjusting piece -2-  , which is used to brace the tension bow, into the guides of the roll-over bar -1-  and fasten the adjusting piece -2-  with the fastening screw -3-  . See Fig 2 .
    2. Affix two strips of double-sided adhesive tape -4-  in the area of the convertible-top support fastening point. See Materials and tools  .
      3. Fig 2: Fitting Adjusting Piece And Strips Of Adhesive Tape
      G03155102Courtesy of PORSCHE OF NORTH AMERICA, INC.

    The strips of tape are used to fasten the water collection tray.

  3. Installing water collection tray

    Position the hole pattern of the water collection tray -5-  on the hole pattern -Arrows-  of the roll-over bar -1-  and press the tray onto the two strips of double-sided adhesive tape -4-. 

    4. Fig 3: Installing Water Collection Tray
    G03155103Courtesy of PORSCHE OF NORTH AMERICA, INC.
  4. Installing convertible-top support

    Position the convertible-top support -6-  on the roll-over bar and fasten it with the fastening screws -7-.  Make sure that when tightening, the convertible-top support is pressed in the direction of arrows -A and B-. 

    Fig 4: Installing Convertible Top Support
    G03155104Courtesy of PORSCHE OF NORTH AMERICA, INC.

    See TIGHTENING TORQUES  .

  5. Install seat belt.

    Position the belt reel at the bottom -8-  and the deflector at the top -9-  on the roll-over bar -1-  and fasten with the fastening screws -10,11-  . See TIGHTENING TORQUES  .

    Fig 5: Installing Seat Belt
    G03155105Courtesy of PORSCHE OF NORTH AMERICA, INC.
  6. Fitting stop buffer on the roll-over bar

    Position bracket (stop) -12-  on the roll-over bar and tighten with the fastening screws -13-  . See TIGHTENING TORQUES  .

    7. Fig 6: Fitting Stop Buffer On Roll-Over Bar
    G03155106Courtesy of PORSCHE OF NORTH AMERICA, INC.
  7. Joining drive lever to the B-pillar
    NOTE:
    • When inserting the push bar-Arrow- of the roof frame into the roof frame, make sure that it is routed through the rubber strap of the B-pillar!
    • Use assembly grease when fitting the pins!
    1. Press in Teflon bushings -14-  in the bores of the push bar and drive lever on both sides. See Fig 7 .
    2. Position the drive lever -16-  on the B-pillar -15-  and join it with the pin, -18-  8 x 45. See Fig 7 .
    3. Position the push bar -17-  on the drive lever -16-  and join it with the pin, -18-  8 x 45. See Fig 7 .
    4. Press the retaining clips -19-  into the pins -18-8  . See Fig 7 .
    8. Fig 7: Joining Drive Lever To B-Pillar
    G03155107Courtesy of PORSCHE OF NORTH AMERICA, INC.
  8. Joining convertible-top support to the B-pillar
    NOTE:
    • Use assembly grease when fitting the pins!
    1. Press in Teflon bushings -14-  in the bore of the drive lever on both sides. See Fig 8 .
    2. Position the B-pillar -15-  on the convertible-top support -5-  and join it with the pin -18  8 x 45. See Fig 8 .
    3. Press the retaining clips -19-  into the pins -18  . See Fig 8 .
    9. Fig 8: Joining Convertible Top Support To B-Pillar
    G03155108Courtesy of PORSCHE OF NORTH AMERICA, INC.
  9. Installing main bow
    NOTE: Use assembly grease when fitting the pins!
    1. Position the main bow -20-  on the convertible-top support -5-  and drive lever -16-  . Then join with the pins, 8 x 70 -21-  and 8 x 45 -18-  . See Fig 9 .
    2. Press the retaining clips -19-  into the pins -18-  , -21-  . See Fig 9 .
    10. Fig 9: Installing Main Bow
    G03155109Courtesy of PORSCHE OF NORTH AMERICA, INC.
  10. Fitting the roof frame on the B-pillar
    NOTE:
    • Use assembly grease when fitting the pins -18-  ! See Fig 10 .
    1. Press in Teflon bushings -14-  in the bore of the B-pillar and push bar on both sides. See Fig 10 .
    2. Fit the pre-assembled B-pillar -15-  in the roof frame -22-  and connect with the pins 8 x 45 -18-  . See Fig 10 .
    3. Secure the pin -18-  with a clip -19-  . See Fig 10 .
    Fig 10: Fitting Roof Frame On B-Pillar
    G03155110Courtesy of PORSCHE OF NORTH AMERICA, INC.
  11. Fitting convertible-top lock
    1. Position convertible-top lock -23-  in roof frame -22-  and fasten with the fastening screws -24-  . See TIGHTENING TORQUES  .
      2. Fig 11: Fitting Convertible Top Lock
      G03155111Courtesy of PORSCHE OF NORTH AMERICA, INC.
    2. Lock the convertible-top frame.
  12. Fitting centring pins
    1. Position centring pins -25-  on the roof frame -22-  on the left and right and fasten with the fastening screws -26-  .

      See TEST AND ADJUSTING VALUES  .

    2. Affix cover cap -27-  onto the centring pins with Loctite 270.
    Fig 12: Fitting Centring Pins
    G03155112Courtesy of PORSCHE OF NORTH AMERICA, INC.
  13. Fitting the cover on the roof frame

    Insert the cover -28-  on the roof frame -22-  and tighten the fastening screws -29-  .

    Fig 13: Fitting Cover On Roof Frame
    G03155113Courtesy of PORSCHE OF NORTH AMERICA, INC.

    The cover is spring-supported and covers the screw and pivot points on the roof frame.

  14. Fitting the connection-piece with steering lever on the tension bow
    NOTE: Before removal, use a scriber to mark the longitudinal adjustment (from the connection-piece with steering lever to the tension bow) on the connection-piece with steering lever.

    Insert the pre-assembled connection-piece with steering lever -30-  into the tension bow -31-  and fasten with the fastening screws -32-. See TIGHTENING TORQUES  .

    Fig 14: Fitting Connection Piece With Steering Lever On Tension Bow
    G03155114Courtesy of PORSCHE OF NORTH AMERICA, INC.

    The connecting-piece contains a clip in which the pin of the steering lever engages and thereby produces the position "tension bow closed" or "tension bow open" (service position).

  15. Fitting the connection-piece with steering lever LU
    NOTE: Use assembly grease when fitting the pins!
    1. Position the tension bow -31-  with the connection-piece and steering lever -30-  on the main bow -20-  and join with the pin 8 x 25.
    2. Press the retaining clips -19-  into the pins.
    Fig 15: Fitting Connection Piece With Steering Lever
    G03155115Courtesy of PORSCHE OF NORTH AMERICA, INC.
  16. Installing steering lever

    Position the steering lever -30-  on the convertible-top support -5-  and join the parts with the pin 8 x 30. See Fig 16 .

    Press the retaining clips -19-  into the pins. See Fig 16 .

    17. Fig 16: Installing Steering Lever
    G03155116Courtesy of PORSCHE OF NORTH AMERICA, INC.
  17. Installing me tension cable

    Press the ball socket -33-  of the tension cable -34-  into the ball head of the adjusting piece -2-  on the roll-over bar -1-  .

    Fig 17: Installing Tension Cable
    G03155117Courtesy of PORSCHE OF NORTH AMERICA, INC.
  18. Installing tension strap

    See INSTALLING TENSION STRAP (CONVERTIBLE-TOP WITH FLEXIBLE REAR WINDOW)  .

  19. Measuring roll-over bar with convertible-top frame in the vehicle.

    See TEST AND ADJUSTING VALUES  .

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