Body -Convertible Top Weatherstrip Conversion
INFORMATIONBulletin No.: 09-08-67-007
Date: March 18, 2009
Subject:
Plan A to Plan B Convertible Top Weatherstrip Conversion
Models:
2007 Saturn SKY
Built Prior to VIN Breakpoint 7Y103259
Vehicles produced before the above listed breakpoints have a convertible top and sealing system known as Plan A. As the inventory of Plan A weatherstrip service parts is depleting, some service parts are no longer available. If a discontinued weatherstrip is required for service of a Plan A vehicle, the vehicle must be updated to the Plan B weatherstrips sealing system. Use the following steps to revise a vehicle from a Plan A system to a Plan B system.
Important
The following instructions must be followed completely when converting the top sealing system from Plan A to Plan B. Avoiding any of the steps will result in wind and water leaks and a binding condition when operating the top. Do not attempt to mix Plan A and Plan B weatherstrips.
1. Replace the windshield frame weatherstrip. Refer to Windshield Frame Weatherstrip Replacement in SI. The new service part has a square tab molded in the weatherstrip just to the inside of the top pin receiver. This tab is tucked behind the windshield upper garnish molding.
2. Replace the left and right front side door rear weatherstrips. Refer to Front Side Door Rear Weatherstrip Replacement in SI.
- The replacement service part is fastened to the body with a rivet (supplied with the weatherstrip) in the upper door jamb area (1).
- The hole for the rivet should already be in the sheet metal.
- If required, locate and drill the required hole. Seal the hole with Synthetic Lubricant With Teflon (P/N 12371287 [in Canada, P/N 10953437]) in order to prevent corrosion.
3. Remove the left and right front and rear top side weatherstrips. Refer to Folding Top Side Rear Weatherstrip Replacement and Folding Top Side Front Weatherstrip Replacement in SI.
Note
Prior to removing the weatherstrip retainers, mark the bolt heads and retainers with a white paint pen to aid in alignment during reinstallation (1).
4. Remove the left and right front and rear side weatherstrip retainers. Refer to Folding Top Side Front Weatherstrip Retainer Replacement and Folding Top Side Rear Weatherstrip Retainer Replacement in SI. Save the front retainers for reuse.
5. Peel back the top fabric to expose the rear of the 1-2 bow as shown (1).
6. Using a utility knife, score the number 1-2 bow in the areas shown in white (1). Make several passes with the knife to create a deep score line. Do not go past the rivet on the bracket retainer (1).
7. Using vise grip pliers, lock onto the area shown in white and snap off the section of the number 1-2 bow.
Danger
Avoid using power tools. The magnesium top bow material is flammable.
8. Use a flat file to smooth the edges of the new surface.
Important
The old adhesive must be removed, Follow the manufacturer's directions for the new adhesive.
9. Use 3M(TM) trim glue, or equivalent, to glue the top fabric to the number 1-2 bow assembly.
10. Install the right and left front side weatherstrip retainers, using the paint locating marks for alignment. Refer to Folding Top Side Front Weatherstrip Retainer Replacement in SI.
11. Install the new service replacement right and left rear weatherstrip retainers. Do not tighten the fasteners. Refer to Folding Top Side Rear Weatherstrip Retainer Replacement in SI.
12. With the fasteners loose, position the rear weatherstrip retainers as far down as possible on the mountings.
13. Align the front and rear retainers with a gap of 26.5 mm (1.0433 in) plus/minus 0.5 mm (0.0197 in) between the lower edge of the front and rear retainers. Tighten all fasteners to specification (1).
14. Install the new right and left service part rear weatherstrips to the retainer using the new service part top guide pins. Make sure the guide pins are in position on the bottom side of the weatherstrip. The weatherstrip has locating notches that align with the guide pins. If the pins are not installed properly, the weatherstrip will not align.
15. The new rear weatherstrips come with two adhesive seals. A small rectangular seal needs to be installed at the base of the weatherstrip (1). Fold the weatherstrip back to expose the flat spot on the bottom of the weatherstrip. Clean the area and install the seal (1).
16. With the rear weatherstrip still folded back, install the arrow-shaped seal in the retainer with the large edge of the arrow out and the top of the arrow tucked up to the bottom edge of the retainer (1).
17. With the arrow-shaped foam seal installed in the retainer, the head of the arrow will lay across the rear of the rectangular seal installed in Step 16. Fold the weatherstrip up and install it in the retainer. (1).
18. The new rear side weatherstrip service part comes with a plastic cover that is screwed to the top of the weatherstrip. This part needs to be revised (1).
Trim 5 mm (0.20 in) from the leading edge of the cover using a suitable tool. Clean off any rough edges. It is not necessary to follow the curved shape of the original part.
19. Install the cover using the provided fastener.
20. Cycle the top and verify proper function and latching of the folding top rear latches. If adjustment is necessary, refer to Folding Top Adjustment and Door Window Adjustment in SI.
21. Verify the operation and travel of both door glass. Make adjustments as required.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table.
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