Corvette 2005-2008

Convertible Tops

Print

Power Convertible Top



Diagnosis & Testing
  1. Complete the checklist prior to performing the diagnosis:
    1. When the folding top control switch is pressed, check for driver information center (DIC) warning messages.
    2.  
    3. Windows are normalized.
    4.  
    5. Luggage barrier is installed and secured.
    6.  
    7. Vehicle is in PARK.
    8.  
    9. Press the ignition to ACCY or RUN, with the engine OFF.
    10.  
    11. Hydraulic fluid bypass valve in the operating position, turned clockwise, located above the pump motor.
    12.  
    13. Operating temperature is normal.
    14.  

  2.  
  3. When using the scan tool, the folding top cover is referenced as the tonneau.
  4.  
  5. If a repair is made to a signal circuit for a fault to ground, test the component of that circuit for proper operation.
  6.  
  7. Use the scan tool to access the History parameters for the folding top control (FTC) module. The parameters will display the status of the folding top systems last operation.
  8.  

Removal & Installation
Motor

CAUTION
Caution: Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury.


CAUTION
Caution: In order to reduce hydraulic pressure, ensure that the folding top has not been operated for 6 minutes before performing this procedure. Failure to do so may result in personal injury.


CAUTION
Caution: The ignition must be in the off position and all electrical loads must be turned off before servicing any electrical component. Failure to do so may result in personal injury or damage to the vehicle.

  1. Place the folding top with the #1 and #5 bow in the up position.

    Click image to see an enlarged view

    Fig. Place the folding top with the #1 and #5 bow in the up position

  2.  
  3. Folding top will bleed down pressure after approximately four minutes of non use.
  4.  
  5. Open the rear compartment.
  6.  
  7. Disconnect the battery.
  8.  
  9. Place a protective covering over the rear compartment interior and the adjacent body panels.
  10.  
  11. Remove the rear compartment side carpet.
  12.  
  13. Locate the hydraulic pump beneath the carpet in the storage compartment on the passenger side of the rear compartment.
  14.  
  15. Support the rear compartment lid.
  16.  
  17. Remove the electrical connector from the hydraulic pump bracket.
  18.  
  19. Disconnect the 2 electrical connectors from the folding top control module.
  20.  
  21. Remove the nuts from the hydraulic pump bracket.

    Click image to see an enlarged view

    Fig. Remove the nuts (1) from the hydraulic pump bracket

  22.  
  23. Lift the pump up and out of the storage compartment and set the pump on the protective covering.
  24.  
  25. Remove the reservoir filler plug.
  26.  
  27. Remove the bolts from the pump manifold plate.
  28.  
  29. Disengage the cylinder hoses by pulling straight up on the hoses.
  30.  
  31. Carefully lift up on the manifold plate.

    Click image to see an enlarged view

    Fig. Manifold Plate

  32.  
  33. Remove the hoses by pulling the hoses straight up from the pump. Use a clean shop towel to control any hydraulic fluid leakage.
  34.  
  35. Remove the hydraulic pump from the vehicle.
  36.  
  37. Remove the O-ring from each hose.
  38.  

To install:

  1. Install a new O-ring on each cylinder hose.
  2.  
  3. Align the manifold plate bolt holes to the holes on the new pump. This will ensure that the cylinder hoses are placed in the correct port.
  4.  
  5. Align the cylinder hoses into each port and push down until the hoses are seated properly in the hydraulic pump manifold.
  6.  
  7. Install the manifold plate bolts. Do NOT tighten.
  8.  
  9. Push down on the manifold plate and verify that all of the cylinder hoses are seated properly.
  10.  
  11. Tighten the bolts to 89inch lbs.(10 Nm).
  12.  
  13. Install the reservoir filler plug.
  14.  
  15. Position the hydraulic pump to the mounting location.
  16.  
  17. Apply a suitable sealer to the bolts.
  18.  
  19. Install the nuts to the hydraulic pump bracket.
  20.  
  21. Tighten the nuts to 13ft. lbs.(18 Nm).
  22.  
  23. Connect the electrical connectors to the folding top control module.
  24.  
  25. Install the 3 electrical connectors to the hydraulic pump bracket.
  26.  
  27. Add fluid as needed.
  28.  
  29. Install the rear compartment carpet.
  30.  
  31. Remove the protective covering.
  32.  
  33. Connect the battery.
  34.  
  35. Remove the rear compartment lid support.
  36.  
  37. Close the rear compartment.
  38.  
  39. Bleed the hydraulic system.
    1. Inspect the fluid level and add fluid as necessary.
    2.  
    3. Start the vehicle.
    4.  
    5. Cycle the folding top under power through one complete cycle in both directions.
    6.  
    7. Inspect the fluid level again and add more fluid as necessary.
    8.  

  40.  
  41. Inspect the hydraulic system for fluid leaks.
  42.  
  43. Inspect the hydraulic system fluid level and add fluid as needed.
  44.  
  45. Inspect the folding top for proper operation.
  46.  

Convertible Top Fluid Addition Procedure


NOTE
When servicing the hydraulic system do not allow the fluid level to drop below the minimum indicator line on the reservoir.


NOTE
Inspect the hydraulic fluid level with the vehicle parked on a level surface, the folding top in the closed position, and the rear compartment open.


NOTE
When new, the power folding top hydraulic fluid is golden clear. As the system is cycled, it picks up the carbon black from the numerous O-ring seals used in the system. The carbon black acts like a dye and causes the fluid to darken considerably and take on a black appearance. This is a normal occurrence and no repair attempts should be performed, as replacement fluid will also darken.

  1. Park the vehicle on a level surface.
  2.  
  3. Place the folding top in the up position.
  4.  
  5. Open the rear compartment.
  6.  
  7. Locate the hydraulic pump beneath the carpet in the storage compartment on the passengers side of the rear compartment.
  8.  
  9. Place a protective covering over the rear compartment interior and the adjacent body panels.
  10.  
  11. Place a shop towel around the pump motor to control any hydraulic fluid spillage.
  12.  
  13. Remove the reservoir filler plug.
  14.  

  1. Add fluid P/N 89022748 or equivalent, until the fluid level is between the MAXIMUM and the MINIMUM indicator lines on the reservoir.
    1. Install the reservoir filler plug.
    2.  
    3. Tighten the plug to 18 inch lbs. (2 Nm).
    4.  
    5. Remove the shop towel.
    6.  
    7. Remove the protective covering.
    8.  
    9. Close the rear compartment.
    10.  
    11. Cycle the folding top under power through one complete cycle in both directions.
    12.  
    13. Place the folding top in the up position.
    14.  
    15. Open the rear compartment.
    16.  
    17. Inspect the fluid level and add fluid as necessary.
    18.  
    19. Install the carpet over the hydraulic pump.
    20.  
    21. Remove the protective covering.
    22.  
    23. Close the rear compartment.
    24.  
    25. Inspect the folding top for proper operation.
    26.  

  2.  

Switch
  1. Use a flat-bladed tool in order to release the switch from the instrument panel cluster trim plate.
  2.  
  3. Disconnect the electrical connection.
  4.  
  5. Remove switch
  6.  

To install:

  1. Install switch into the instrument panel cluster trim plate.
  2.  
  3. Connect the electrical connection.
  4.  
  5. Install the instrument panel cluster trim plate.
  6.  

 
label.common.footer.alt.autozoneLogo