Folding Top Cover
Figures 1 through 5
Remove or Disconnect
1. Rear seat cushion and seatback. Refer to Section 10-10 of the Service Manual.
2. LH and RH quarter trim panels. Refer to Section 10-7 of the Service Manual.
3. Nuts securing upper corners of stowage compartment to LH and RH rear side rails.
4. Nuts and bolts securing lower corners of stowage compartment to quarter inner panels.
5. Peel LH and RH portions of stowage compartment off quarter inner panels.
6. LH and RH quarter belt reveal molding nuts.
7. Screws securing rear window drain panel sight shield and remove shield.
8. Screws securing rear window lower reveal molding and pull moldings away while sliding off of quarter belt reveal moldings.
9. Molding retainer screws and lower reveal molding retainers.
10. LH and RH quarter belt reveal molding screws and pull moldings away from quarter panels to release studs of moldings from sheet metal.
11. Using a sharp pencil, mark location of complete rear belt tack strip (upper edge) on outer surface of folding top cover.
12. Mark location of finished edge of each sail panel on rear window at tack strip. Marks will aid in locating sail panels over tack strip during installation.
13. Release folding top front latches to relieve cover tension.
IMPORTANT:
Only remove staples retaining sail panels to tack strip. It is not necessary to remove staples retaining stowage compartment and window to tack strip.
14. Staples retaining sail panels to tack strip. Note location and spacing of staples.
15. Separate bottom edge of each sail panel from butyl tape at tack strip.
16. Pull LH and RH sail panels over cover to expose No.4 bow.
17. If cover is stapled to NO.4 bow, remove staples securing cover while noting location and spacing of staples on tack strip of bow.
18. Mark location of all reveal molding attaching holes on lower edge of tack strip or body.
19. Raise top off windshield header to suitable working height and remove folding top front seal assembly. Refer to the appropriate procedure in Section 10-9 of the Service Manual.
20. Front seal assembly retainer screws and separate LH and RH retainers from foam tape.
21. With top fully lowered, remove staples securing windshield header welt assembly and remove welt assembly from No.1 bow.
22. Screws securing retention cables to No.1 bow. If original cover is to be reinstalled, attach a length of wire or string to end of each cable. This step will aid in pulling cables through cover if cable ends become trapped within material.
23. Staples securing cover to No.1 bow, then peel cover from bow and front side rails to expose attachments to rail.
24. Raise top to windshield header, remove screws securing retainers to No.2 and No.3 bows and remove retainers.
25. Screws and nuts securing LH and RH rear side rail weatherstrips and peel weatherstrips from retainers.
26. Rear side rail weatherstrip retainer screws and separate LH and RH retainers from foam tape.
27. Screws securing cable ends to rear side rails. To ease removal of screws, raise top off windshield header. If replacing cover, pull cables through material using previously attached string or wire.
28. Peel cover from rear side rails.
29. If cover is secured to No.4 bow with integral plastic locking mechanism and wedged shaped retainer, fold cover back over rear compartment lid to access No.4 bow.
IMPORTANT:
Use care not to damage locking mechanism, cover or window during removal of retainer.
30. Using a hammer and a long narrow metal rod or wooden dowel, drive retainer out of No.4 bow. Note position of retainer within bow during removal.
31. Carefully release locking mechanism from slot in No.4 bow and remove cover from vehicle.
Install or Connect
1. If replacing cover, transfer reference marks made on original cover to replacement cover as follows:
a. Position replacement cover on a clean surface with exterior surface up.
b. Position original cover over replacement cover.
c. Carefully align rear window opening upper corners and quarter window upper corners of both covers.
d. Secure covers together at these locations.
e. Carefully lay out sail panels of both covers.
f. Transfer tack strip reference marks.
g. Recheck location of reference marks.
2. Pull cables through replacement cover by attaching previously installed string or wire to a length of welding rod or other rigid material. Once cables have been pulled through cover material, disconnect welding rod. Leave string or wire attached to cable ends.
3. Add butyl tape as necessary to tack strip to ensure complete sealing of sail panels to stowage compartment.
4. If cover is secured to No.4 bow with plastic locking mechanism, follow Steps 5-11. If cover is stapled to No.4 bow, skip Steps 5-11 and proceed with Step 12.
5. Locking mechanism into slot in No.4 bow, if utilized. Do not install retainer at this time.
6. Position replacement cover over frame assembly and align finished edge of each sail panel with marks made on rear window at tack strip and press into place. If any draws or wrinkles are present after aligning sail panels, readjust cover at No.4 bow.
7. Secure sail panels to tack strip using 5/16 inch (width) by 1/2 inch (length) stainless steel staples. Apply downward pressure to material at each point of staple installation while working from rear to front of each sail panel.
8. Fold cover back over rear compartment lid to access No.4 bow.
IMPORTANT:
Use care not to damage locking mechanism, cover or window during removal of retainer.
9. Carefully release locking mechanism from slot in No.4 bow.
10. Position cover retainer as noted during removal and insert into No.4 bow.
11. Position locking mechanism into slot of No.4 bow over retainer. Using a rubber mallet, seat entire length of locking mechanism into bow.
12. Position replacement cover over frame and align stapling material of cover with rear edge of No.4 bow tack strip. Center cover over No.4 bow and secure material to bow using 5/16 inch (width) by 1/2 inch (length) stainless steel staples. Apply downward pressure to material at each point of staple installation while working from center to each side.
13. Pull sail panels down over butyl tape and into position with marks made on rear window at tack strip. Align holes for studs of quarter belt reveal moldings in sail panel with holes in tack strip. Press sail panels into place, keeping material flat without stretching.
14. Secure sail panels to tack strip using 5/16 inch (width) by 1/2 inch (length) stainless steel staples. Apply downward pressure to material at each point of staple installation while working from rear to front of each sail panel.
15. Attach cover to rear side rails with weatherstrip adhesive.
16. Attach LH and RH rear side rail weatherstrip retainers to rear side rails with foam tape. Install screws and tighten securely.
17. Attach LH and RH rear side rail weatherstrips to retainers with weatherstrip adhesive. Install screws and nuts and tighten securely.
18. Insert bow retainers through pockets in cover and secure with screws to No.2 and No.3 bows. Tighten screws securely.
19. Raise top to suitable working height over windshield header. Pull cover at seams straight forward over No.1 bow to desired top fullness. While maintaining tension on cover, mark outer surface of cover along forward edge of No.1 bow.
20. Lower top and apply weatherstrip adhesive to cementing area of No.1 bow, front side rails and corresponding surfaces of cover and front corner flaps. Pull cover over No.1 bow, aligning mark on cover with forward edge of No.1 bow, and secure.
21. Staple cover to No.1 bow using 5/16 inch (width) by 1/2 inch (length) stainless steel staples. Apply downward pressure to material at each point of staple installation while working from center to each end of No.1 bow.
22. Raise top and lock to windshield header. Check operation and locking action of top. Inspect cover for proper appearance. If additional tension is needed in cover, remove staples and pull cover farther forward. Staple and recheck cover for proper appearance and operation.
23. Remove string or wire attached to cables and position cable ends to No.1 bow. Install screws and tighten securely.
24. Align windshield header welt assembly to No.1 bow. Fold vinyl flap over welt bulb and staple into position.
25. Apply weatherstrip adhesive to stapled edge of welt assembly and fold vinyl flap back over stapled surface.
26. Replace old foam tape with new foam tape and position front seal assembly retainers to front side rails. Install screws and tighten securely.
27. Front seal assembly. Refer to the appropriate procedure in Section 10-9 of the Service Manual.
28. Studs of LH and RH quarter belt reveal moldings into sheet metal. Install screws and tighten securely.
29. Position molding retainers over tack strip and align screw holes. Install screws and tighten securely.
30. Outer ends of lower reveal moldings over ends of quarter belt reveal moldings while engaging opposite ends together. Align screw holes, install screws and tighten securely.
31. Lower reveal molding escutcheon.
32. Position sight shield over lower reveal moldings and align screw holes. Install screws and tighten securely.
33. LH and RH quarter belt reveal molding nuts and tighten securely.
34. LH and RH portion of stowage compartment to quarter inner panels using vinyl trim adhesive.
35. Nuts and bolts retaining lower corners of stowage compartment to quarter inner panels and tighten securely.
36. Nut securing upper corners of stowage compartment to LH and RH rear side rails and tighten securely.
37. LH and RH quarter trim panels.
38. Rear seat cushion and seatback.
39. Lock top to windshield header, then check appearance of cover and window. Cover should be free from wrinkles and draws.