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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)) >> Replacing convertible-top covering with flexible rear window >> Installing the convertible-top covering

Installing the convertible-top covering

WARNING: This page is about a different variant/trim than selected.
CAUTION: Damage (tearing) to the zip fastener connection on the convertible-top covering!
  • The adhesion (hot-melt process) between the rear window and the convertible-top covering must be implemented before the first closure or calibration of the convertible top.

All pins and screw joints must be checked for tightness before the convertible-top covering is installed. See ASSEMBLING CONVERTIBLE-TOP FRAME .

The tension strap must be replaced before fitting the convertible-top covering. See INSTALLING TENSION STRAP .

  1. Fastening convertible-top covering at the main bow

    Lay the convertible-top covering on the convertible-top frame, fit the front tightening strip -16-  of the convertible-top covering in the groove of the main bow -17-  and centre.

    Fig 1: Fastening Convertible-Top Covering At Main Bow
    G03055620Courtesy of PORSCHE OF NORTH AMERICA, INC.
  2. Fitting convertible-top covering at the corner bow
    1. Press tightening strip centre (notch marking) into groove of the corner bow (centre of the corner bow is identified by a hole).

      The tightening strip is secured by tapping in the seal -arrow B-  . See Fig 2.

    2. Coat the cloth covering with adhesive and stick it inside around the corner bow -inset A-  . See Fig 2.
    Fig 2: Fitting Convertible-Top Covering At Corner Bow
    G03055621Courtesy of PORSCHE OF NORTH AMERICA, INC.
  3. Fastening holding strap of the convertible-top covering
    1. Position holding strap at the right on convertible-top frame 3 on the inside and press in the clip.
    2. Fig 3: Fastening Holding Strap Of Convertible-Top Covering
      G03055622Courtesy of PORSCHE OF NORTH AMERICA, INC.

    On the left side, the holding strap is fastened with the fastening clip of the wiring harness.

  4. Fastening the fastening strap at the main bow
    NOTE:
    • As a model year 2000, an altered main bow will be installed. The convertible-top covering connection on the main bow is screwed in position with a shaped sheetmetal part. In vehicles built before model year 1999, the two upper bores -arrow C- must be re-drilled into the shaped sheetmetal part.
    Fig 4: Fastening Strap At Main Bow
    G03055623Courtesy of PORSCHE OF NORTH AMERICA, INC.

    Converting shaped sheetmetal: 

    1. To do so, mount the shaped sheetmetal part on to the main bow by the two lower screwed points.
    2. Mark the position of the new drill-holes through the upper holes in the main bow with a marking tool.
    3. Remove the shaped sheetmetal part and drill at both markings with a diameter 6 mm drill bit.

      Fastening the fastening strap at the main bow: 

    4. Turn the vertical fastening strap of the convertible-top covering inward around the main bow, and place it on the shaped sheetmetal part. Screw in with the oval-head screws -arrows A-  T15 M3.5. See Fig 4.

      Tightening torque 1.7 Nm (1.5 ftlb.) 

    5. Position wedge on the main bow and screw in place with the fastening screws T25 M5 -B-  . See Fig 4.

      Tightening torque 2.8 Nm (2.0 ftlb.) 

  5. Fastening the convertible-top covering at the sides of the roof frame 1
    1. Lay the convertible-top covering to the front and guide the shaped sheetmetal part -14-  into the roof frame -15-  from above. See Fig 5.
    2. Fasten the convertible-top covering with the fastening screws -13-  starting from the rear bottom side of the roof frame. See Fig 5.

    Tightening torque 5 Nm (3.5 ftlb.) 

    Fig 5: Fastening Convertible-Top Covering At Sides Of Roof Frame 1
    G03055624Courtesy of PORSCHE OF NORTH AMERICA, INC.
  6. Fastening convertible-top covering at front

    A cardboard strip and a self-adhesive strip are affixed at the front of the convertible-top covering.

    1. Pull the protective film off the Teflon adhesive tape.
    2. Fold the convertible-top material around the roof frame edge without wrinkles. The convertible-top covering is initially held with fixing clips.
    Fig 6: Folding The Convertible-Top Material Around The Roof Frame Edge
    G03055625Courtesy of PORSCHE OF NORTH AMERICA, INC.
  7. Fastening the retaining rail and convertible-top seal on the roof frame 1
    1. Remove the fixing clips.
    2. Insert convertible top seal -12-  at the front corners into roof frame 1 in -direction of arrow-  and tighten with torx screws T25 -11-  . See Fig 7.

      Tightening torque: 1.7 Nm (1.5 ftlb.) 

    3. Position the retaining rail -10-  on roof frame 1 and tighten using T25 Torx screws -9-  . See Fig 7.

      Tightening torque: 3.5 Nm (2.5 ftlb.) 

    4. Fig 7: Fastening Retaining Rail And Convertible-Top Seal On Roof Frame 1
      G03055626Courtesy of PORSCHE OF NORTH AMERICA, INC.
  8. Fastening seals and retaining strip at the sides of the roof frame

    The seal on the roof frame at the sides consists of two parts.

    1. Position the upper seal -6-  onto the retaining strip -7-  in -direction of arrow A-  and screw on to roof frame with the Torx screws T15 -8-  . See Fig 8.

      Tightening torque: 2.8 Nm (2.0 ftlb.) 

    2. Press the lower seal -5-  into the profile of the retaining strip -7-  . See Fig 8.
    3. Fig 8: Fastening Seals And Retaining Strip At Sides Of Roof Frame
      G03055627Courtesy of PORSCHE OF NORTH AMERICA, INC.
  9. Fastening tension cable of the convertible-top covering

    Position the tension cable eyelet -3-  on the main bow and fasten with the T25 -4-  Torx screw.

    Fig 9: Fastening Tension Cable Of Convertible-Top Covering
    G03055628Courtesy of PORSCHE OF NORTH AMERICA, INC.

    Tightening torque: 7 Nm (5 ftlb.) 

  10. Fastening convertible-top covering on the tension bow
    NOTE: As from the Vehicle Identification Number 99 XS 65 5 883, cutouts have been integrated to the right and left of the additional seal. These cutouts can also be integrated retroactively into the additional seal by cutting out.
    1. Cut out the additional seal parallel to the tension strap -C-  on the right and left using a knife. See Fig 10.
    2. Press tightening strip centre (notch marking) -inset A-  into the lower groove of the tension bow -inset B-  (centre of the tension bow is identified by a hole) -inset A-  . See Fig 10.
    3. The reference overlap seams of the convertible-top covering must be positioned and centered in the additional seal -arrow C-  cutouts on the left and right. See Fig 10.
    4. Secure the convertible-top covering by tapping in the seal -inset D-  . See Fig 10.
  11. Fig 10: Fastening Convertible-Top Covering On Tension Bow
    G03055629Courtesy of PORSCHE OF NORTH AMERICA, INC.
  12. Fitting tension bow seal
    1. Press tension bow seal into the lower groove of the tension bow and fasten at both ends with the T25 Torx screws -2-  .
    2. Fig 11: Fitting Tension Bow Seal
      G03055630Courtesy of PORSCHE OF NORTH AMERICA, INC.

    Tightening torque: 5 Nm (3.5 ftlb.). 

  13. Fastening pull strap at the main bow
    1. Pull the restraining strap through the fabric pocket on the main bow.
    2. Engage both ends of the restraining straps into the tension spring -arrow A-  . See Fig 12.
    3. Position fabric pocket on the main bow and fasten with the T 10 -1-  Torx screws. See Fig 12.
    Fig 12: Fastening Pull Strap At Main Bow
    G03055631Courtesy of PORSCHE OF NORTH AMERICA, INC.
  14. Inserting flexible rear window
    1. Refer to REMOVING AND INSTALLING FLEXIBLE REAR WINDOW OF CABRIOLET .
      CAUTION: Damage (tearing) to the zip fastener connection on the convertible-top covering! The adhesion (hot-melt process) between the rear window and the convertible-top covering must be implemented before the first closure or calibration of the convertible top.
    2. End service position.
    3. Calibrate the convertible top. To do this, connect the Porsche System Tester 2 to the diagnostic socket. Switch on ignition to carry out this test. Select menu item Convertible top  , and select menu item Calibrate  in the command line which then appears. Start calibration with the "F7" key. Calibration can be started irrespective of whether the convertible top position is open or closed. The latching hook in roof frame 1 does not close during calibration.
    4. Fig 13: Inserting Flexible Rear Window
      G03055632Courtesy of PORSCHE OF NORTH AMERICA, INC.
    NOTE:
    • If the convertible-top covering is very taut (with new convertible-top covering), close the convertible top and heat the convertible-top covering evenly using an infra-red radiator.
    • Ensure that the convertible-top covering is not heated for longer than 1 hour. Maintain a minimum distance from the infra-red radiator of 100 cm and a temperature range of approx. 60°C (140 Fahrenheit), then leave the vehicle overnight with the convertible top closed.
    • The same effect can be achieved if the vehicle is exposed to direct sunlight.
    • See MATERIALS AND TOOLS .