Work Procedure
CAMPAIGN WORK PROCEDUREParts:
Each push button repair kit (1YM 898 002 Y20/3PT) contains the following parts:
Special Tools
- Pliers Tool 3392
Section A
Loctite(R) Threadlocker Application and Front Window Adjustment
- Open door and insert flat blade of screwdriver between handle trim -1- and handle and carefully pry trim off handle
- Remove 2 screws -2- from behind trim -1-
- Remove 3 screws -3- at bottom of door trim panel -4-
- Using pliers tool 3392 unclip 6 retainers -6-
- Lift door trim panel upward and out of window slot seal
- Remove rubber grommets from holes -1- in the door inner panel
NOTE: The rubber grommet and hole at the front position is smaller than the rubber grommet and hole at the rear.
- Raise or lower window -4- position so the bolts -2- and -3- are visible through holes -1-
- Ensure that ignition switch is in the "OFF" position
- Open hood and disconnect the ground (GND) cable from the battery
- On the door trim panel, unclip cable guide -1- using the flat blade of a screwdriver -2-, pull cable out of retainer -3- in direction of arrow and unhook cable hook -4-
- Disconnect electrical connectors to window switch, light, etc. and set door trim panel aside
- Loosen nut -5- but do not remove
- Remove the T30 Torx bolts -2- and -3- (bolts on clamps holding window) and add 2 drops of Loctite Threadlocker Blue to bolt threads
NOTE: Be careful not to drop bolt. A magnetic Torx bit or small magnet can help in bolt removal.
- Loosely reinstall Torx bolts -2- and -3-
- Push window -4- down to ensure it is fully into the window clamps
- Slide the window forward or rearward -arrow- until the distance from rear edge of the window to the to the edge of the door is 65 mm±1 (2.52 in. to 2.60 in.) -A-
NOTE: The only position the distance -A- can be measured is when the bolts on the window clamps are visible through the bolt access holes
- Tighten bolt -3- to 8 Nm (71. in. lbs.)
- Reconnect electrical connectors to the door trim panel and reconnect ground GND) cable to the battery
- Lower window completely and raise back to previous position where bolts -2- and - 3- are visible through holes -1-
- Tighten bolt -2- to 8 Nm (71. in. lbs.) then tighten nut -5- to 8 Nm (71. in. lbs.)
NOTE: The X - axis window adjustment has been completed. Check dimension -A-, if not 65 mm±1 (2.52 in. to 2.60 in.) adjust again
- Reinstall rubber grommets into bolt access holes
- Reconnect cable to door lever and clip cable guide in position
- Reconnect remaining electrical connectors to light, lock, etc.
- Reinstall door trim panel -4- onto the door and secure with clips -6-
NOTE: Check door trim clips before reinstalling door trim panel and replace as necessary.
- Secure door trim panel with 3 Torx screws -3- along bottom of door and tighten to 4 Nm (35 in. lbs.)
- Secure door trim panel with 2 phillips head screws -2- and tighten to 4 Nm (35 in. lbs.)
- Reinstall handle trim -1-
- With the door closed and window in the full up position, check to see if the window top rear corner is 1.0 mm (.0.40 in.) outward of the rear window glass
NOTE: This is the Y - axis window adjustment
- If the window is not outboard 1.0 mm adjust the glass as follows:
- On the bottom of the door at the front and rear, remove rubber plugs covering nuts -A-
- Loosen nuts -A- and adjust window in/out position -arrow- equally to achieve the 1.0 mm outward window position and tighten nuts
NOTE: Sliding nuts outward brings the window inward at the top
- Tighten nuts and replace rubber covers when window is in the correct position
- Open door and place 3 pieces of tape along the top of the window as indicated in the illustration -arrows-
- Close door and mark the depth of window entry into the window slot
- Open door and using a scale measure the window entry depth
- Depth needed is 8 mm±1 (.28 in. - .35 in.)
NOTE: This the Z - axis window adjustment
- Remove rubber plugs on the bottom of the door, use a T30 Torx driver and turn screw clockwise to raise window or counterclockwise to lower window to get to the required depth
NOTE: By turning the Torx screw one revolution, the window will move 1 mm (0.04 in.)
- Turn ignition switch to the "ON" position
- Press and release the latch button -arrow 7- and pull the locking handle down
NOTE: DO NOT pull on the latch release button
- Turn the handle -arrow 4- counterclockwise until it stops, then push the convertible top upward, open it slightly and release the handle
- Lift the control switch and partially open the convertible top
- Raise door window and rear window to the top position
- The height -a- of both windows should be the same, otherwise perform the Z - axis adjustment
- The distance -b- (measured horizontally near the top of the windows) must be equal to 9.5 mm±0.5 (0.35 in. - 0.39 in.) otherwise repeat the Z - axis adjustment
NOTE: Illustration is showing the left door window and rear glass
- Reinstall rubber plugs at the bottom of the door
- Repeat procedure on opposite front door
- Tighten the ground (GND) cable to battery to 5 Nm. (44 in. lbs.)
- Perform power restoration procedure
- Proceed to Section B
Section B
Convertible Top Button Replacement
- Unclip roof frame trim panel -1- by prying off rear clips -3- then front clips -2-
- Turn handle 90° and remove roof frame trim panel over handle
NOTE: DO NOT remove handle -4-. It is shown removed for illustrative purposes only
IMPORTANT: Before disassembly, look closely at the position of the button against the adjuster. Also, make note of the button angle and position because it is the position needed for new button installation. Button is under slight spring tension.
- Remove circlip -5-
- Remove pin -6- and latch button -7-
IMPORTANT: When removing the button, two rubber washers -8- and the adjuster -9- also come off. The rubber washers will need to be reinstalled with the new adjuster and button.
- Illustration showing the disassembled single parts:
5 - Clip (new from repair kit)
6 - Pin (new from repair kit)
7 - Button (new from repair kit)
8 - Rubber washers (reinstall parts)
9 - Adjuster (new from repair kit)
- Use the new button, adjuster, pin and clip from the repair kit (1YM 898 002)
- Place and hold the new adjuster with rubber washers in position in the latch bracket so the bottom groove on the adjuster aligns with the latch bar in the release handle
NOTE: The previously removed rubber washers -8- need to be reinstalled. The arrows in the illustration show position of the latch bracket. The rubber washers are inward of the bracket and the adjuster -9- is in the middle.
- To install the new button, hold the new button in the previously noted position before disassembly and rearward of the latch bracket, then move the button forward over the latch bracket and insert the new pin
- Raise the release handle over the new button, press button and check function
- Install new clip on pin
- Reinstall roof frame trim panel
- Turn ignition switch to the "ON" position, press the control switch down and close the top
- Pull down the handle for locking the top, turn the handle counterclockwise as far as the stop, pull the top down and turn the handle clockwise
- Push the handle up into the recess
- Destroy and properly dispose of removed parts as well as the extra part from the repair kit