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CONVERTIBLE TOP
TABLE OF CONTENTS
page CONVERTIBLE TOP DIAGNOSIS AND TESTING - HYDRAULIC SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS ADJUSTMENT - CONVERTIBLE TOP .... ADJUSTMENT - HYDRAULIC MOTOR/PUMP BLEEDING PROCEDURES . . . . . . . . . . . . ADJUSTMENT - TOP FRAME CAM . . . . . . ADJUSTMENT - BALANCE LINK . . . . . . . . ADJUSTMENTS - DOWEL PIN . . . . . . . . . . SPECIFICATIONS - CONVERTIBLE TOP TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . FOLDING TOP COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . TOP HEADLINING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . HYDRAULIC CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . HYDRAULIC LINES REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . HYDRAULIC MOTOR/PUMP ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . CONVERTIBLE TOP REAR WINDOW REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . CONVERTIBLE TOP STORAGE REMOVAL . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . page . . . . . . . . 18 . . . . . . . . 19 . . . . . . . . 19 . . . . . . . . 19 . . . . . . . . 19 . . . . . . . . 20 . . . . . . . . 20 . . . . . . . . 20 . . . . . . . . 21 . . . . . . . . 22 . . . . . . . . 22

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CONVERTIBLE TOP
DIAGNOSIS AND TESTING - HYDRAULIC SYSTEMS The power convertible top hydraulic system consists of: Two hydraulic cylinders Hydraulic lines Electric hydraulic pump and reservoir Dual relays
HYDRAULIC SYSTEM TESTS
NOTE: The convertible top will raise slowly or make abnormal noise if the hydraulic fluid level is low.

(1) Remove rear seat cushion and back. (2) With the top down, remove motor assembly from the floor panel. (3) Remove the reservoir fill plug (4) Visually inspect fluid level. The fluid level should be at least at the bottom edge of fill hole, when motor bracket is held on a level (flat) surface. If low, inspect for leak in hydraulic system. (5) Motor/Pump: (a) Put reservoir fill plug back in place. Apply power to the motor and listen for operation. If the

motor fails to run, check the voltage to the connector (10.5 to 16 volts required). Voltage below 12.6 volts will cause top to operate slowly. (b) Check the motor/pump for evidence of fluid leak. If leakage is seen and fittings/hoses and cylinders dont have any leaks, then replace the motor/pump. (6) Cylinders: (a) Check cylinder tubes for dents. (b) Check cylinders for leaks. Leaks are indicated by hydraulic fluid running down the cylinders. Small oil residue accumulation at seal is normal. (7) Repair or replace components, as necessary. (8) Bleed the motor/pump (Refer to 23 - BODY/ CONVERTIBLE TOP - ADJUSTMENTS - HYDRAULIC MOTOR/PUMP BLEEDING PROCEDURES). (9) Secure motor/pump assembly into floor panel mounts. (10) Raise top. (11) Lower top and verify fluid level per step three. If low, add Dexron III Automatic Transmission Fluid as necessary. Do not overfill reservoir. (12) Install rear seat back and cushion making sure these components do not cause hydraulic line pinches and/or kinks. (13) Verify system operation.

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ing cylinder shafts to top linkage). Cylinders will be extended. (4) Remove motor from floor panel. Keep motor connected to wire harness. (5) Hold cylinders upside down (cylinder rod pointing down). (6) Hold motor/pump assembly with reservoir up. The rubber fill plug will be at the top. (7) Raise motor/pump assembly to at least 2 inches above the horizontal rear seat back reinforcement. (8) Cycle system at least once, making sure cylinders can extend without obstruction. Allow for two to three seconds stall. There may be a percolating or gurgling sound, which indicates that the procedure is working. (9) Hold cylinders in normal position and cycle system at lease once, making sure cylinders can extend without obstruction. Allow for two to three seconds stall. There may be a percolating or gurgling sound, which indicates that the procedure is working.

ADJUSTMENTS

ADJUSTMENT - CONVERTIBLE TOP Refer to (Fig. 1) to determine which adjustment is required. Refer to the appropriate procedure for more information. ADJUSTMENT - HYDRAULIC MOTOR/PUMP BLEEDING PROCEDURES After replacing any component of the power lift mechanism or if convertible top does not start to raise within 2 seconds after the switch is activated, bleed the convertible top motor/pump assembly. (1) Raise the top to the full up position. Do not latch folding top. (2) Remove the rear seat cushion, seat back and quarter trim panels. (3) Completely detach cylinders from attachment points (mounting bracket nuts and pivot bolts attach-

Fig. 1 ADJUSTMENT LOCATIONS

1 - TOP HEADER 2 - DOWEL PIN 3 - SET SCREW 4 - FRONT 5 - FRONT-TO-CENTER RAIL ADJUSTING SCREW 6 - TURN DART TOWARD REAR (HEADER MOVES FORWARD AND UP) 7 - CAM 8 - TURN DART TOWARD FRONT (HEADER MOVES REARWARD AND UP) 9 - BALANCE LINK 10 - SERRATED PLATE

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At this point, any air in the system has migrated to the reservoir. (10) Retract cylinders completely and remove the rubber fill plug from reservoir. Fluid level may be low. (11) Remove the rubber fill plug from reservoir. Fluid level may be low.
CAUTION: THE MOTOR/PUMP ASSEMBLY MUST REMAIN IN THE CURRENT POSITION UNTIL THE RUBBER FILLER PLUG IS REINSTALLED.

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(22) Verify system operation.

ADJUSTMENT - TOP FRAME CAM The top frame cam changes forward or rearward position of the top header in relation to the windshield header. The cam turns inside the rear side rail and thrust link (Fig. 2). It may be necessary to lengthen the balance links 1 or 2 serrations after a cam adjustment. The position of the cam high side determines the angle between the center and rear side rails. When the high side is fully forward, the angle is at a minimum, and when turned rearward, the angle is increased. An increased angle increases the forward movement of the top. The cam high side is indicated by a arrow on the cam threaded end.

(12) Fill the hydraulic system by adding Dexron III Automatic Transmission Fluid to the reservoir. The fluid level should be 13 to 20 mm (12 to 34 inch) below the top of the reservoir.
CAUTION: DO NOT OPERATE THE FOLDING TOP SWITCH WHILE FILL PLUG IS NOT INSTALLED ON MOTOR ASSEMBLY.

(13) Install rubber fill plug. (14) Secure motor/pump assembly into floor panel mounts. Extend cylinders. (15) Place the cylinders into original position with hose fittings pointing fitting rearward. (16) Install pivot bolt attaching cylinder shaft to top linkage. Torque properly. Ensure all rod eye components are present (foam, plastic bushing and plastic lock washer). (17) Install cylinder mounting bracket and nut. Torque properly. Ensure all trunnion split bushings are present. Tap folding top switch to adjust cylinder length, if needed.
WARNING: HYDRAULIC CYLINDERS PRODUCE ENOUGH FORCE TO PRODUCE SEVERE INJURY IN CASE OF PUNCHING. KEEP HANDS AND FINGERS AWAY FROM MOVING HYDRAULIC CYLINDERS.

Fig. 2 CAM ASSEMBLY

1 - TORX SCREW 2 - CAM 3 - TURN DART TOWARDS REAR OF CAR HEADER MOVES IN THIS DIRECTION 4 - TURN DART TOWARDS FRONT OF CAR HEADER MOVES IN THIS DIRECTION

(18) Install all hydraulic line clips and secure hydraulic lines to body. (19) Verify system operation. (20) Install the quarter trim panels. (21) Install rear seat back and cushion and ensure that the seat back/seat cushion do not pinch or kick the lines.

TO ADJUST CAM SETTING

(1) Lower top to half down position to remove all possible strain from the cam. (2) Remove Torx head screw. (3) Using appropriate Torx bit, rotate cam as necessary and secure set screw. Tighten Torx bit screw to 5.2 to 7.2 Nm (43 to 67 in. lbs.) torque

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ADJUSTMENT - BALANCE LINK
WARNING: DO NOT PLACE HANDS OVER GAPS IN MOVABLE CONVERTIBLE TOP COMPONENTS DURING SERVICING. PERSONAL INJURY CAN RESULT.

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ADJUSTMENTS - DOWEL PIN (1) Loosen dowel pins (Fig. 4). (2) Position dowel pins to the center of the receiver holes in the windshield header. (3) Tighten dowel pins and verify adjustment.
NOTE: Refer to Cam Adjustment or Balance Link Adjustment paragraphs of this section to adjust forward or rearward position of the top header.

(1) Remove quarter trim panel to gain access to balance link bolts. (2) With the top latched in up position, loosen both bolts just enough to permit moving link up or down (Fig. 3). (3) Push upward in the area of the front to center rail joint. Push rails up by hand as far as possible. (4) With the balance link adjusting bolts loosened, allow the balance link to seek proper position. (5) Tighten top link bolt while rail is held in position to 11.7 to 17.7 Nm (105 to 155 in. lbs.) torque. (6) Tighten bottom link bolt while rail is held in position to 22 to 32 Nm (192 to 288 in. lbs.) torque.

Fig. 4 ROOF LATCH AND GUIDE DOWEL PIN

1 - HEADER 2 - DOWEL PIN 3 - SET SCREW 4 - 25.4 mm MIN 35.56 mm MAX

Fig. 3 BALANCE LINK ADJUSTMENT

1 - SERRATED PLATE 2 - BALANCE LINK