Body - Folding Top Damage Prevention
INFORMATIONBulletin No.: 09-08-67-004
Date: February 17, 2009
Subject:
Prevent Repeat Damage of Folding Top Tonneau Bulkhead and/or Attaching Parts (Panels, Hinges, Cables) - Complete CRITICAL Steps/Adjustments
Models:
2006-2009 Pontiac G6
Attention:
The following CRITICAL steps must be followed to prevent repeat folding top damage when performing the repair procedure in SI titled "Folding Top Stowage Compartment Closeout Panel Link Replacement".
This bulletin addresses any or all of the following conditions that may be present:
^ Folding top is inoperative
^ Multiple DTCs may be set
^ Rear tonneau hinges are broken at the stowage compartment closeout panel link assembly (bulkhead)
^ Front outer tonneau panel (flipper door) cables are broken
^ Front outer tonneau panel (flipper door) brackets are bent
Cause #1
The condition may be the result of cycling the folding top without completing the proper alignments/adjustments of the bulkhead, tonneau panel and flipper doors.
Cause #2
The condition may be the result of a customer having put an object in between the roof panels when the folding top was stowed in the rear compartment. Then, forgetting it was there, may have closed the folding top and the object interfered with the normal operation of the tonneau and/or flipper doors.
Correction
Caution:
If damage is to the extent that the tonneau bulkhead is broken, replace the bulkhead AND both flipper door cables. Though not always visually evident, in cases where the bulkhead is broken, the cables will likely be damaged.
Repair and adjust the bulkhead, cables, tonneau panels and flipper doors following the procedures in SI IN COMBINATION with the critical steps below. DO NOT cycle the folding top until the following critical steps have been completed:
1. With the folding top in the service position, mark the original position (side to side) of the broken bulkhead at the rear corner to main pivot bracket location (1).
Important:
For correct fore/aft positioning of the replacement bulkhead, make sure the front edge of the bulkhead (1) is flush with the main pivot bracket (2) before tightening the four underside bolts (two each side).
2. During installation, ensure the bulkhead is positioned flush with both main pivot brackets AND aligned to the side to side location marked previously. Once positioned, install the four underside bolts (1) and tighten to 28 Nm (21 lb ft).
3. Before reinstalling the side flipper doors, check the following two areas:
1. Inspect for a rubber sleeve under the cable springs as shown above.
Caution:
When starting the sleeve cut, be extremely careful not to nick the cable. Any damage to the cable may cause a future top cycling concern.
2. If a rubber sleeve is present, remove the sleeve from BOTH sides by pushing the spring forward. Start a cut on the sleeve and then pull the sleeve the rest of the way off.
3. Inspect the position of the anti-flutter drive rod (1) on each end of the bulkhead. With the folding top in service position, the drive rod should extend outboard enough to engage with the link (2) AND should be in the vertical position shown above. If adjustment is needed, loosen the set-screw on the stop (3), reposition as shown, then retighten the set-screw.
Important:
If a flipper door cable is replaced, note the position of the cable end rod to the door spring insert. Make sure it is properly inserted and positioned as shown above.
Caution:
The above graphic shows the resulting damage when the cable end rod is not properly positioned and the folding top is cycled.
4. After the bulkhead, center tonneau, side flipper doors and/or cables are installed (and BEFORE the folding top is cycled for the first time), loosen the two main drive rod end bolts for the center tonneau panel until it moves freely. Manually, pull the center tonneau up to its most forward/upright position.
5. With the center tonneau panel in its most forward/upright position, inspect the travel of the flipper doors for the following two conditions:
^ When pulled out, the flipper doors should spring back and return to the v-stop, as shown above. If they do not move back freely, the cable could be binding/broken, or may be out of position at the spring, as noted earlier in Step 4.
^ Ensure that the flipper doors position properly and fully seat into the v-stop. If they are improperly positioned, as shown in above, the door brackets may be bent and require replacement.
^ Caution:
Manually hold the center tonneau panel upward while cycling the folding top, making sure that as the flipper doors extend outward, they do NOT contact the side rail links.
6. Remove the service straps. While manually holding the center tonneau panel in its most forward/upright position, SLOWLY cycle the folding top from the service position to the open position (stowed in rear compartment).
7. Allow the folding top to retract into the rear compartment and stop the cycle just after the rear compartment lid starts its travel to close, approximately 76 mm (3 in) from the full reverse open position. This will allow the center tonneau panel travel to be at its full bottom out position.
8. With the folding top in the open position and the cycle stopped just after the rear compartment lid started its travel to close (as noted above), manually move the center tonneau panel from the full forward/upright position to the full rearward position (horizontal to folding top that is stowed).
9. Set the height of the underside of center tonneau panel to the folding top front roof panel. Manually position the center tonneau panel 73-78 mm (2.87-3.0 in) from the bottom of the center tonneau panel to the top of the roof panel.
Important:
When tightening the two main drive rod ends, you MUST tighten the left (driver side) first and then the right side. If not tightened in this order, the adjustment will not set correctly.
10. Tighten the two main drive rod end bolts. Be sure to tighten the left (driver side) first and then the right side.
Tighten
Tighten to 16 Nm(12 lb ft).
Caution:
Be careful not to crease the headliner along the lower area, as any area not sitting flush may cause an interference issue with the center tonneau panel and cause damage.
11. Inspect the lower edge of rear roof panel headliner for possible missing retainers. If the push pins on both ends are missing, install two push pins (one each side).
Note
This adjustment should allow at least 2 mm (.079 in) spacing between the rear of the panel seal when it swings by the rear roof panel inside trim under the rear window, during folding top cycling.
12. Install the rear upper seat trim and perform center tonneau panel fore/aft adjustments, following the 8-10 mm (0.315-0.394 in) spacing between trim and panel referenced in SI.
13. SLOWLY cycle the folding top closed, and then back to open, making sure the rear tonneau panel/flipper doors do not contact any of the following (all of which may cause damage):
^ Rear interior trim
^ The rear roof panel interior trim under the rear window
^ The side rail links
14. As the folding top cycles, inspect for the following two conditions: When the folding top is cycled closed, verify the rear of the center tonneau panel (1) seats properly into the bottom of the rear roof panel pull up brackets (2).
^ When the folding top is cycled open, just as the rear compartment lid starts to close from the full reverse open position, stop the cycle and verify that the height of the center tonneau panel to the roof panel has not changed from the 73-78 mm (2.87-3.0 in) set previously.
Important:
If the setting has changed, loosen the two main drive rod end bolts and repeat Steps 10 and 11 and verify the setting again. Be sure to tighten the left (driver side) first and then the right side.
15. With the folding top in the full open position, verify/properly adjust the flipper doors to center tonneau panel gaps and height following SI.
Caution:
If cable binding occurs, this could cause the flipper doors to move slowly, creating an interference with the side rail links and cause damage.
16. After adjusting the flipper doors, verify that the doors are moving freely and that the cables are properly routed (as shown above) and not trapped under the rear compartment trim.
17. Properly reinstall the rear upper quarter trim following the procedures in SI.
Warranty Information
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