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Home >> Porsche >> 2003 >> 911 Carrera 4S, Standard >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 5 (Convertible Top, Hardtop - 911 CARRERA (996)) >> Disassembling and assembling hardtop >> Assembling hardtop >> Positioning the hardtop

Positioning the hardtop

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Set the hardtop down on the assembly fixture on the outer side of the roof.

  1. Pressing expanding nuts into the hardtop body
    Fig 1: Pressing Expanding Nuts Into Hardtop Body
    G03055585Courtesy of PORSCHE OF NORTH AMERICA, INC.
    NOTE:
    • Please observe the coloured installation position of the expanding nuts!
    • 1A = yellow
    • 1B = white
    • 1C = green
    • 2A = red
    • 2B = white
    1. Beginning in a leftward direction of travel

      One red -2A-  expanding nut. See Fig 1.

      Three yellow -1A-  expanding nuts. See Fig 1.

      One green -1C-  expanding nut. See Fig 1.

      One green -1B-  expanding nut. See Fig 1.

      Press three green -1C-  expanding nuts into the hardtop body. See Fig 1.

    2. Beginning in a rightward direction of travel

      One white -2B-  expanding nut. See Fig 1.

      Three yellow -1A-  expanding nuts. See Fig 1.

      One green -1C-  expanding nut. See Fig 1.

      One green -1B-  expanding nut. See Fig 1.

      Press three green -1C-  expanding nuts into the hardtop body. See Fig 1.

    3. Press the expanding nuts at the front -1B-  into the hardtop body in the direction of travel. See Fig 1.
  2. Fitting harness of the rear window heater

    Position wiring harness with the hardtop locking element, rivet the flat connector -3-  onto the hardtop body with a 3.2 mm tubular rivet -1-  and connect the flat connector to the cable lug -4-  .

    Fig 2: Fitting Harness Of Rear Window Heater
    G03055586Courtesy of PORSCHE OF NORTH AMERICA, INC.
  3. Fitting hardtop locking element
    1. Screw in and tighten fastening screws -5-  into the hardtop lock element -6-  .

      See TIGHTENING TORQUES .

    Fig 3: Fitting Hardtop Locking Element
    G03055587Courtesy of PORSCHE OF NORTH AMERICA, INC.
  4. Sticking felt strips on inside of window aperture

    Stick a felt strip -7-  approx. 2 cm wide along the window aperture on the rivet joints of the hardtop body -1-  .

    Fig 4: Sticking Felt Strips On Inside Of Window Aperture
    G03055588Courtesy of PORSCHE OF NORTH AMERICA, INC.
  5. Sticking insulation on the hardtop body

    Position the self-adhesive insulation -8-  in the hardtop body -1-  and press firmly into place.

    Fig 5: Sticking Insulation On Hardtop Body
    G03055589Courtesy of PORSCHE OF NORTH AMERICA, INC.
  6. Fitting locking lever
    1. Position the locking lever -11-  on the hardtop body -1-  and tighten with the fastening screws -12-  . See TIGHTENING TORQUES .
    Fig 6: Fitting Locking Lever
    G03055590Courtesy of PORSCHE OF NORTH AMERICA, INC.
  7. Sticking in foam strips and foam pads
    1. Position the foam strips -13-  on the B-pillar -A-  , rear roof -B-  and on the front centring peg -C-  or foam pad -14-  to the left and right and press in firmly.
    Fig 7: Sticking In Foam Strips And Foam Pads
    G03055591Courtesy of PORSCHE OF NORTH AMERICA, INC.
  8. Engaging roof liner at rear and transverse struts
    1. Insert the transverse struts -15-  with the plastic sleeves -16-  into the hardtop body -1-  . See Fig 8.
    2. Pull back the plastic rail -17-  of the roof liner -18-  and engage in the groove of the hardtop body -1-  . See Fig 8.
    Fig 8: Engaging Roof Liner At Rear And Transverse Struts
    G03055592Courtesy of PORSCHE OF NORTH AMERICA, INC.
  9. Engaging roof liner at sides
    1. Engage roof liner -18-  at the left and right sides in the sheetmetal clips -19-  .
    2. Fig 9: Engaging Roof Liner At Sides
      G03055593Courtesy of PORSCHE OF NORTH AMERICA, INC.
    NOTE:
    • If the hardtop body is new, the sheetmetal clips on the left and right must be bent over to the outside using a plastic hammer.
  10. Fitting roof liner at front
    1. Position the front retaining rail -20-  of the roof liner -18-  and clip it in.
    Fig 10: Fitting Roof Liner At Front
    G03055594Courtesy of PORSCHE OF NORTH AMERICA, INC.
  11. Fitting rubber seal
    1. Insert self-adhesive rubber seal -22-  at the ends of the roof frame seal -21-  .
    2. Fig 11: Fitting Rubber Seal
      G03055595Courtesy of PORSCHE OF NORTH AMERICA, INC.
    3. Remove backing of the rubber seal and press firmly into place at the rear on all sides.
  12. Affixing Nito tape to the hardtop body
    1. Stick on a 2 cm wide strip of Nito tape -23-  at the front left and right of the hardtop body -1-  .
    Fig 12: Affixing Nito Tape To Hardtop Body
    G03055596Courtesy of PORSCHE OF NORTH AMERICA, INC.
  13. Fitting roof frame seal and retaining rail
    1. Engage roof frame seal in the hardtop body -1-  at the corners and fasten with the fastening screw -24-  . See Fig 13. See TIGHTENING TORQUES .
    2. Position retaining rail -25-  and screw down using the sheetmetal screws -26-  . See Fig 13.
    Fig 13: Fitting Roof Frame Seal And Retaining Rail
    G03055597Courtesy of PORSCHE OF NORTH AMERICA, INC.
  14. Fitting seal at sides of roof frame
    1. The seal on the roof frame -27-  at the sides consists of two parts. Position the lower seal with the retaining strip -28-  on the roof frame -27-  and fasten with the fastening screws -29-  . See Fig 14.
    2. Press the upper seal -30-  into the profile of the retaining rail -31-  . See Fig 14.
    Fig 14: Fitting Seal At Sides Of Roof Frame
    G03055598Courtesy of PORSCHE OF NORTH AMERICA, INC.
  15. Fitting interior trim parts
    NOTE:
    • Once an interior trim part has been clipped in once, the old plastic clips are no longer usable and must always be replaced.
    1. Clip interior trim parts -32-  at the side, front and rear into the hardtop body -1-  .
    Fig 15: Fitting Interior Trim Parts
    G03055599Courtesy of PORSCHE OF NORTH AMERICA, INC.
  16. Fitting centring pegs
    1. Position the centring peg -9-  on the hardtop body -1-  and tighten with the fastening screws -10-  . See TIGHTENING TORQUES .
    Fig 16: Fitting Centring Pegs
    G03055600Courtesy of PORSCHE OF NORTH AMERICA, INC.
  17. Clipping in roof strip clips and cover strips
    1. Fit the roof strip clip -34-  . See Fig 17.
    2. Fit cover strip seal on the cover strip -33-  . See Fig 17.
    3. Position cover strip on the hardtop body -1-  and press into the roof strip clips. See Fig 17.
    Fig 17: Clipping In Roof Strip Clips And Cover Strips
    G03055601Courtesy of PORSCHE OF NORTH AMERICA, INC.