Assembling Hardtop

WARNING: This page is about a different car, the 2012 Porsche Boxster, 2011 Porsche Boxster, 2010 Porsche Boxster, 2009 Porsche Boxster, and 2008 Porsche Boxster. However, it is still accessible from the selected car via links, so may be relevant.

Set the hardtop down on the assembly fixture on the outer roof panel.
Information
- Please observe the colored installation position of the expander nuts!
- 1A = yellow
- 1B = white
- 1C = green
- 2A = red
- 2B = white
Press expander nuts into the hardtop body.
1. 2.1. Beginning in the direction of travel going left
2. 2.2. One red -2A- expander nut
3. 2.3. Three yellow -1A- expander nuts
4. 2.4. One green -1C- expander nut
5. 2.5. One white -1B- expander nut
6. 2.6. Press three green -1C- expander nuts into the hardtop body.
7. 2.7. Beginning in the direction of travel going right
8. 2.8. One white -2B- expander nut
9. 2.9. Three yellow -1A- expander nuts
10. 2.10. One green -1C- expander nut
11. 2.11. One white -1B- expander nut
12. 2.12. Press three green -1C- expander nuts into the hardtop body.
13. 2.13. Press the expander nuts at the front -1B- into the hardtop body in the direction of travel.
  
  Fig 1: Identifying Hardtop Body And Expander Nuts
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit wiring harness for rear window heater.
1. 3.1. Position wiring harness with the hardtop locking mechanism, rivet the flat connector -3- onto the hardtop body -1- with a 3.2 mm tubular rivet and connect the plug connection -4- .
  
  Fig 2: Locating Rear Window Heater Wiring Harness
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Stick sound absorber on the hardtop body.
1. 4.1. Position the self-adhesive sound absorber -2- in the hardtop body -1- and press firmly into place.
  
  Fig 3: Sticking Sound Absorber On Hardtop Body
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit locking lever.
1. 5.1. Position locking lever -2- on hardtop body -1- and secure with fastening screws -3- . Tightening torque → Tightening torque: 10 Nm (7.5 ftlb.)
  
  Fig 4: Locating Locking Lever Mounting Screw
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Engage roof liner at rear and transverse struts.
1. 6.1. Insert transverse struts -2- with plastic sleeves -3- into the hardtop body -3- .
2. 6.2. Pull back plastic strip -4- of roof liner -5- and engage in groove of hardtop body -1- .
  
  Fig 5: Locating Roof Liner At Rear And Transverse Struts
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Information
- 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.
Engage roof liner at sides.
1. 7.1. Engage roof liner -1- at the left and right sides in the sheetmetal clips -2- .
  
  Fig 6: Locating Roof Liner
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit roof liner at front.
1. 8.1. Position front retaining strip -2- of roof liner -1- and clip it in.
  
  Fig 7: Locating Front Retaining Strip And Roof Liner
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit sealing rubber.
1. 9.1. Insert self-adhesive sealing rubber -2- at the ends of the roof frame seal -1- .
2. 9.2. Remove protective film of the sealing rubber and press firmly into place at the rear on all sides.
  
  Fig 8: Locating Rubber Seal
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Affix Nito tape to the hardtop body.
1. 10.1. Stick a 2 cm wide strip of Nitto tape -2- on the hardtop body -1- at the front left and right.
  
  Fig 9: Identifying Strip Of Nitto Tape Applying Area On Hardtop Body
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit roof frame seal and retaining strip.
1. 11.1. Engage roof frame seal in the hardtop body at the corners and fasten with the fastening screw -1- . Tightening torque → Tightening torque: 10 Nm (7.5 ftlb.)
2. 11.2. Position retaining strip -2- and screw down using the fastening screws -3- .
  
  Fig 10: Locating Retaining Strip And Fastening Screws
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit seal at sides of roof frame.
1. 12.1. The seal at the sides of the roof frame -1- is in two parts. Position lower seal with retaining strip -2- on roof frame -1- and fasten with fastening screws -3- .
2. 12.2. Press upper seal -4- into the profile of the retaining strip -5- .
  
  Fig 11: Fitting Seal At Sides Of Roof Frame
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install hardtop locking mechanism. → Installing Convertible Top Lock
Information
- Once a trim panel has been clipped in, the old plastic clips are no longer usable and must always be replaced.
Fit interior lining.
1. 14.1. Clip lining -28- at the sides, front and rear into the hardtop body -1- .
  
  Fig 12: Fitting Lining
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Apply putty at roof ends.
1. 15.1. Apply putty at roof ends front and rear.
  
  Fig 13: Locating Putty Applying Area At Roof Ends
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Information
  - Once a trim panel has been clipped in, the old plastic clips are no longer usable and must always be replaced.
Clip in roof strip clips and cover strips.
1. 16.1. Fit roof strip clips -30- .
2. 16.2. Fit cover strip seal on the cover strip -31- .
3. 16.3. Position cover strip on hardtop body -1- and press into the roof strip clips.
  
  Fig 14: Locating Roof Strip Clips And Cover Strips
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.