3161, 3162, 3163 Installation 10-10-06_REV 10

3161, 3162, 3163
INSTALLATION
GUIDELINES
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1997-2004
Porsche Boxster Top
3161 Top with Plastic Window. 3162, 3163 Tops with Heated Glass.
Defroster wiring loom and service strap are supplied with 3162. See rear panel for details.
NOTICE: This document is intended for use only by professional installers with sufficient knowledge
and experience to perform automotive convertible top removal and installation. This top is made
with “Helper Straps”. Do Not cut them off, they must be installed. See page 3 for instruction.
See rear panel for important information related to Part # 3162, including wiring loom P/N 3162
POWER LEAD and “service strap” P/N 3162 STRAP.
Installation of this product by novice installers is not recommended.
3161, 3162, 3163 Installation. Rev 10-27-08
©2006 Robbins Auto Top Co., Inc.
AUTO TOP CO, INC.
WARNING
Regarding: Porsche Boxster
Issue: OEM design flaw can cause side tension cables not to slide into side channels (figure 1)
Resolution: Design improvement for 3161/3162/3163 Tops to fit 1997-2004 Porsche Boxster (figures 2, 2a)
This problem is the result of malfunctioning or non-existent OEM sliders on the left and right sides near
the B-pillars, which are intended to support and guide the top into the channels. This issue may also cause
distortion and even tearing of vinyl cable sleeves, which are sewn onto the top. Unfortunately this flaw will
affect any top installed on the vehicle unless the cause is addressed.
We’ve modified our 3161/3162/6163 tops by adding elastic “Helper Straps” to the quarters, which help the
cables pull into the channels when raising the top. To help assure proper operation of the convertible top these
helper straps must be used.
Issue: Cable sleeves/top material hangs up on the exterior channel when operating the top.
Figure 1.
This is a known OEM issue for which
Robbins Auto Top Company is not
responsible. This is not covered by
your Robbins product warranty. For
more information you may obtain a
copy of Technical Service Bulletin #
6128 from a Porsche dealer, or from
AllData.com (requires subscription).
Resolution: Secure the elastic helper straps (L&R) as shown.
Helper Strap installation is shown in sequence on page 3 of instruction booklet.
3161 & 3162: Install “Helper Straps”: remove plastic
rivet from b-pillar slider joint, insert plastic rivet
through elastic strap, then into slider joint.
2a
2
Note: performed this step before
attaching headliner listings.
3163 Only: Install “Helper Straps”: Attach double
locking velcro to floating rear bow, at top of narrow
radius (before bow widens).
The above information can also be found in the Technical Notes section at www.robbinsautotopco.com.
For technical assistance with Robbins products email support@robbinsautotopco.com or phone (877) 404-3200 and press 2
3161, 3162, 3163 1997-2004 Boxster Helper Straps
ROBBINS AUTO TOP CO., INC.™
1997
1997--2004 Porsche Boxster Top Removal
1
2
With top halfway open; Remove header weather-seal
and its metal retainer, followed by side weather-seals
and their retainers. (Torx T25)
Remove metal side channels, which the weather-seal
retainers are mounted into. (Torx T25)
Clamp rail
Slider
Plastic Rivet
3
4
Remove screws that retain sheet metal front quarter
bases to the frame, so front quarters (now held only
with 2-sided tape) can be separated from the frame.
Tip: After removing plastic rivets which secure slider to clamp rail;
use an 8mm socket to close prongs, and release slider from rail.
At bottom of clamp rails: Remove tension cable end
screw and rear screw. Slide edge cord from channel in
clamp rail, then pull edge cord from channel in slider.
Lock Strip
in upper channel
Lock Seal
in mid channel
6
5
Rear weatherstrip channel
At lower rail, remove rear weather-strip, peel topping
away from channel, then remove the rubber lock strip
and lock seal (above) to separate top from rail.
Remove plastic trim panels covering boot hinges.
This will create more room to work.
1
7
8
Pull the top toward the rear, and release the rear listing. Remove the top from the top frame.
Raise rear of top and disconnect cable socket from
ball stud (L&R). Unhook extrusion on well (L&R).
3161, 3162, 3163 Top Installation
1
2
Transfer the left and right front quarter, sheet metal
front quarter bases into new top (with glue) and reattach the spring and cable end.
Lay new top over top frame, position sheet metal
front quarter bases, and punch holes for sheet metal
screws.
Clamp rail
Slider
Plastic Rivet
3
2a
Tip: Place elastic “Helper Strap” against frame, behind slider,
before installing plastic rivets. See next page for detail.
At bottom of clamp rails: Insert edge cord into slider
channel, insert lower edge cord into channel in clamp
rail, install tension cable end screw and rear screw.
Attach sheet metal front quarter bases to frame with
sheet metal screws.
2
3161, 3162, 3163 Top Installation Continued
3161 & 3162: Install “Helper Straps”: remove
plastic rivet from b-pillar slider joint, insert plastic
rivet through elastic strap, then into slider joint.
4a
3163 Only: Install “Helper Straps”:
4
Attach double locking velcro to floating rear bow, at
top of narrow radius (before bow widens).
Note: performed this step before
attaching headliner listings.
IMPORTANT
IMPORTANT
22½”
(57.2 cm)
22½”
(57.2 cm)
6
5
Tip: Use small rubber mallet to carefully tap lock strip into upper channel.
Align center seam of top with center line on rail and
insert plastic edging of top in into the upper channel.
Rear deck seams of top must align with pencil marks.
Deck seam alignment: Measure rear rail 22½” (57.2
cm) from center and mark with white grease pencil.
Lock Strip
in upper channel
Lock Seal
in mid channel
Rear weatherstrip channel
7
6a
Push the rear lock seal down into the middle channel
of the rear rail, flush with end.
Apply adhesive to lower flap on the top, and the large
weather strip channel on rear rail.
3
3161, 3162, 3163 Top Installation Continued
8a
8
Align lower flap in channel of rail, making sure seam
is aligned slightly low along edge of rail. Note: If
seam is too high it will be visible when top is closed.
ATTENTION
Note: Make sure seam is slightly low along rail edge.
If seam is placed too high it will show when latched.
10
9
Position the side tension cable ends with clamp rail at
B-pillar and attach with Torx driver.
Secure the clamp rail by pressing against the exterior
of the top, just behind the clamp rails plastic post.
You’ll feel it snap into place. Fasten Velcro traps.
11
12
With glue pre-applied, position and press front of top
to header bow, reinstall front seal starting at corners,
Attach the retaining rail to front with Torx T25.
Reinstall the side seal retaining rails with Torx T15
screws. Insert the lower seal into the channel of the
rail.
4
3161, 3162, 3163 Top Installation Continued
13
14
Reinstall lower rail main weather-seal by inserting
into position on rail. Use putty knife or other tool to
accomplish this.
NOTE: For 3162, perform steps 15-16 before step 14.
Lift rear of top and connect cable socket to ball stud
(L&R). Hook extrusion on well to rear hooks (L&R).
3162 Top Only, Defroster Wiring
Defroster Wiring Loom (Robbins P/N 3162 POWER LEAD) is Supplied with 3162 Top at no additional charge.
15
16
Locate defroster loom socket door in drivers side
quarter, behind shoulder belt. Pull the tab to open the
door. Plug single end of loom into the socket, with
white dot facing forward.
Rout the terminal ends of loom underneath vinyl top
well (hiding them) with long wire toward passengers
side. Rout the ends up to terminals on glass and plug
them onto terminals.
To actuate the heater/defroster use the switch on the dash (shown) which actuates the heated
mirrors. This applies to all 1997-2002 Porsche Boxsters originally sold in the USA market.
We believe the same applies internationally, however, it has not been verified.
With top raised and latched, look the top over for any unfinished items, obstructions, etc. Once satisfied
that everything is in order, cycle the top down completely, then back up. You my want to repeat this a
few times to see that no hidden issues are revealed.
If you have any questions while installing this product please contact Robbins Technical Support, toll free
at (877) 404-3200—then press 2, or email support@robbinsautotopco.com.
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ROBBINS 3162 POWER LEAD
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Textured finger
grip for removal
OEM style push
button release
A power lead is required for the rear defroster to function. Robbins Part# 3162 POWERLEAD is included with each 3162 top shipped from Robbins since February 2007.
The suggested retail price if purchased separately is $98.00 USD.
Alternatively, Porsche’s factory original power lead (Part # 98661231500) is available
from Porsche dealers in the USA for approx. $155.00 USD.
IMPORTANT NOTE:
Glass window decreases the convertible tops
range of opening at rear, and the rear will no
longer stay open (in service position) without
assistance. Robbins service strap; P/N 3162
STRAP can be used to hold the top in the
service position. As of July 11, 2007 Robbins
includes a service strap with each 3162 top
shipped from our plant.
For more information about this item
visit robbinsautotop.com/tech.html
WWW.ROBBINSAUTOTOP.COM