GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Convertible Top

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TOP REPLACEMENT



See Figures 1 through 10

  1. Install a spacer stick between the No. 3 and No. 4 bow to keep the No. 4 bow in position.
  2.  
  3. Remove the rear belt moldings by removing the attaching screws from rear compartment drain trough. Remove the quarter belt moldings by unfastening the screws and attaching nuts from the rear compartment and underneath the right and left sides of folding top well.
  4.  



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Fig. Fig. 1: Convertible quarter and back belt moldings



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Fig. Fig. 2: Convertible top tacking strip and quarter flaps



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Fig. Fig. 3: Convertible top cover and welt assembly

  1. Apply a protective cover on the rear deck surface and quarter panel painted areas.
  2.  
  3. Using a sharp grease pencil, mark the location of the complete belt tacking strip (upper edge) on outer surface of top cover.
  4.  
  5. Raise the top to a suitable working height. Remove the front No. 1 bow seal and retainers. Detach welt assembly and top cover from the No. 1 bow.
  6.  



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Fig. Fig. 4: Location of the side retention cables



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Fig. Fig. 5: Exploded view of the convertible seal assemblies

  1. Unfasten the attaching screw from the rear of each side retention cable. Remove the cable forward end from the hole in front rail.
  2.  



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Fig. Fig. 6: Location of the feature strip and strip retainer



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Fig. Fig. 7: Unfasten the listing pocket top retainer screws, then remove the retainers

  1. Remove the screws from the lower end of each rear retention cable and rear listing pocket. To ease the removal of rear retention cable screw, raise the top off windshield header. Pull the cables through listing pockets from the upper end.
  2.  
  3. Raise the top and remove the rear rail seals and retainers.
  4.  
  5. Detach the top cover flaps from front rail and rear rail.
  6.  
  7. Remove the feature strip cap (end), feature strip and retainer. Remove the top cover from the No. 4 bow.
  8.  
  9. At underside of the No. 2 and 3 bows, unfasten the screws securing listing pocket top retainers and remove the retainers.
  10.  



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Fig. Fig. 8: Installation of the rear window assembly in the convertible top



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Fig. Fig. 9: Marking the convertible top cover forward edge



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Fig. Fig. 10: Convertible side stay pads and spacer

  1. Disconnect the top cover from rear belt tacking strip. Note the location and spacing of staples before removing them.
  2.  
  3. Mark the location of rear window outer panels along balance of rear belt tacking strip, and the No. 4 bow (upper and lower edge).
  4.  
  5. Recheck the tack strip location markings on rear window assembly. Remove stay pads and rear window assembly from the rear belt tacking strip and the No. 4 bow. Note the location and spacing of staples before removal.
  6.  
  7. Use a sharp grease pencil and mark the location of all belt molding attaching holes on the lower edge of tacking strip or on quarter panels.
  8.  

To install:
  1. Transfer the reference marks from removed rear window assembly as follows:
    1. Place the new rear window assembly on a clean covered work bench with inner surface down.
    2.  
    3. Position the removed rear window assembly over new one, carefully align the upper window with the lower one.
    4.  
    5. While holding both together securely, carefully lay out the trim material of both and transfer the rear window assembly reference marks along bottom portion of tacking strip.
    6.  
    7. Reverse the rear window assemblies by placing the new rear window assembly over the original as described above.
    8.  
    9. Check the location of reverence marks. If any difference is noted, the average between the two is the correct reference to use. Mark the corrected references clearly. Trim off the excess material beyond the 1 / 2 in. (13mm) allowance along the bottom and transfer the center mark from bottom center of removed rear window assembly to new one. Transfer of the reference marks must be done correctly for best results and minimum rework.
    10.  

  2.  
  3. Lock the top to windshield header and install spacer sticks between the No. 4 bow and and rear rail. Spacer stick should be installed between No. 4 bow and rear rail back face. The purpose of the spacer sticks is to hold the No. 4 bow in its most rearward position, keeping tension on the top stay pads during the rear window assembly and top cover installation to belt tacking strips.
  4.  
  5. Position and center the new rear window assembly to the No. 4 bow according to reference marks and center notch. Using heavy duty 3 / 8 in. (9.5mm) stainless steel staples, staple the rear window assembly to the No. 4 bow. Staple from center to ends. Avoid stretching, but keep the material flat during stapling.
  6.  
  7. Position and center the new rear window assembly to the rear tacking strip according to reference marks and center notch. Staple the rear window assembly to tacking strip as follows:
    1. Pull rear window assembly down over the tacking strip to remove all fullness and staple the rear window assembly to the tacking strip. Staple from center to each end of the rear window assembly.
    2.  
    3. Apply downward tension to the rear window assembly at each point of staple installation.
    4.  

  8.  


WARNING
Excessive heat may cause damage to the rear window. Extreme care should be exercised when following this procedure.

  1. Transfer the reference marks from the removed top cover to the new one as follows:
    1. Place the new top cover on a suitable clean surface, with inner surface of cover down.
    2.  
    3. Position the removed top cover over the new one.
    4.  
    5. Carefully align the rear window opening upper corners and the rear quarter upper corners of both covers. Secure both covers together at these locations.
    6.  
    7. Carefully lay out trim material of quarter area of both covers.
    8.  
    9. Transfer location marks for tacking strip.
    10.  
    11. Then reverse position of the covers by positioning the new cover over the original as described above.
    12.  
    13. Recheck location of reference marks. If any difference is noted, the average between the two is the corrected reference to use. Mark the corrected references clearly.
    14.  

  2.  
  3. Install the No. 2 and No. 3 bow top cover retainers into the new top cover listing pockets.
  4.  
  5. Install the side retention cables into the new top cover side rail listing pockets. A length of welding rod or equivalent wire can be used to pull the cable through side rail listing pocket.
  6.  
  7. Position the top cover over framework. The top cover may require some lateral stretching along the rear bow to achieve proper fit of quarter flaps to the rear side rails and to remove fullness from the top cover valance over rear window.
  8.  
  9. Secure the No. 2 and 3 bow top cover retainers to the No. 2 and 3 bows.
  10.  
  11. Raise the top slightly off the windshield header. Attach the rear end of side retention cables to the rear side rail with attaching screw. Then apply a forward on the cables and install forward end of cables into the keyhole slots in the front side rail.
  12.  
  13. Install the rear retention cables into the rear listing pockets. Secure the lower ends of the cables and listing pockets to the quarter inner reinforcement with screws.
  14.  
  15. Install the center top cover rear valance over the No. 4 bow. Pull the top cover rear valance over No. 4 bow to remove all fullness from the rear valance. Staple the top cover to the No. 4 bow, starting at center and working towards each end. Avoid excessive stretching, but keep the material flat during stapling. Staples must be installed in a straight line in the center of No. 4 bow. Staples outboard of the seams should not be more than 2 in. (51mm) apart.
  16.  
  17. Apply adhesive to cementing surfaces of the rear side rail and to quarter flaps. Align the quarter flap seam with the edge of rear rail to remove all fullness from the rear top cover. With the quarter flap seam aligned with each rear rail, install a screw at belt tacking strip, then cement the quarter flaps securely in place.
  18.  
  19. Install the side rail seal assembly to help maintain position of the quarter flaps.
  20.  
  21. Lock the top to the windshield header. Pull top cover straight forward at the seams to desired top fullness and align the top cover seams with the notches in No. 1 bow. While maintaining tension on cover over the top of No. 1 bow, make pencil mark on the cover outer surface along the forward edge of top No. 1 bow.
  22.  
  23. Raise the top off header to a suitable working height. Apply adhesive such as 3M 0864 or equivalent, to cementing area of the top No. 1 bow, surface of top cover and to front corner flaps. Pull top cover 1 / 4 in. (6mm) past the reference point over the No. 1 bow and secure.
  24.  
  25. Trim the excess material to retaining screw holes for front rail and No. 1 bow seal.
  26.  
  27. Lower the top and lock to windshield header. Check appearance of the top trim, top operation and locking action of the top. If additional tension is needed in the top cover, repeat step 30 and pull the top cover farther forward. Staple and recheck the top for proper appearance and operation.
  28.  
  29. Align the welt assembly to No. 1 bow. Fold the vinyl flap back over the welt bulb and staple into position.
  30.  
  31. Apply adhesive to the stapled edge of the welt assembly and fold the vinyl flap over stapled surface of welt assembly.
  32.  
  33. Carefully align the front rail retainers. Secure in position with attaching screws.
  34.  
  35. Apply weatherstrip adhesive to the retainer inner surface. Attach the front rail and No. 1 bow seal assembly to the front rail retainer and across the No. 1 bow. Secure the seal to the No. 1 bow with attaching screws.
  36.  
  37. Lock the top to the windshield header. Staple the top cover to the belt tacking strip starting at the rear rail and working rearward. Apply downward pressure to top cover at each point of staple installation. Avoid excessive stretching, but keep the material flat during stapling.
  38.  
  39. Install a pierce hole in the top material and tacking strip at each out board end of the No. 4 bow for feature strip and cap.
  40.  
  41. Install the rear bow feature strip retainer, feature strip and end caps using a clear silicone sealer.
  42.  
  43. Cut or pierce holes in the top cover and rear window assembly along the tacking strip for belt molding attaching studs and install belt moldings.
  44.  
  45. When complete, the folding top cover should be free from wrinkles and draws. Clean up top material and car as necessary.
  46.  

MOTOR REPLACEMENT



See Figure 11

If any parts of the motor and pump assembly are found to be inoperable, it is recommended that the entire unit be replaced with a new motor and pump assembly.

  1. Make sure the convertible top is in the full up position.
  2.  
  3. Disconnect the negative battery cable.
  4.  



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Fig. Fig. 11: Location of the convertible top motor

  1. Remove the partition in the rear compartment to expose the motor/pump unit.
  2.  
  3. Disconnect the wiring harness, then remove the ground wire attaching screw and ground wire.
  4.  
  5. Place absorbent rags below hose connections and at the end of the fluid reservoir.
  6.  
  7. Vent the reservoir by removing then installing the filler plug.
  8.  
  9. Disconnect the hydraulic lines and cap open fittings to prevent leakage of fluid. Use a cloth to absorb any leaking fluid. Remove the motor/pump unit.
  10.  

To install:
  1. Fill the reservoir unit with DEXRON IIE® transmission fluid. Position the motor/pump unit in place.
  2.  
  3. Attach the hydraulic hoses, ensuring that each hose assembly has a seal ring in place. Connect the wiring harness, ground wire and attaching screw.
  4.  
  5. Connect the negative battery cable and operate the top through its up and down cycles until all the air has been bled from the hydraulic circuit.
  6.  
  7. Check connections for leaks and recheck the fluid in the reservoir. Level should be even with fill hole, install plug.
  8.  

 
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