GM Cavalier/Sunfire 1995-2000 Repair Guide

Convertible Tops

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TOP REPLACEMENT



See Figures 1 and 2

  1. Disconnect the negative battery cable.
  2.  
  3. Unlatch the convertible (folding) top.
  4.  
  5. Remove the right and left side quarter trim panels.
  6.  



Click image to see an enlarged view

Fig. Fig. 1: Convertible top assembly-1995 vehicle shown



Click image to see an enlarged view

Fig. Fig. 2: Disassembled view of the convertible top components

  1. Unfasten the screws retaining the headliner at the rear rail and quarter inner structure.
  2.  
  3. Remove the screws retaining the headliner to the closeout panel below the backlite.
  4.  
  5. Detach the heated backlite wire leads.
  6.  
  7. Remove the bolt, washer and bushing from the quarter window drive links and spur gears.
  8.  
  9. Carefully grasp and lower the quarter windows.
  10.  
  11. Make sure the note the wire routing, then detach the drive motor wire harness connectors.
  12.  
  13. Remove the retainers and fold the closeout trim panel forward.
  14.  
  15. Remove the back molding.
  16.  
  17. Remove the right and left side quarter panel belt outer moldings.
  18.  
  19. Unfasten the two staples retaining the convertible cover, backlite and stay pads to the quarter belt tackstrip.
  20.  


CAUTION
Protect eye goggles or safety glasses MUST be worn when drilling out the rivets to reduce the chance of personal injury.

  1. Use a 1 / 8 in. (3mm) drill bit to drill out the four rivets retaining the convertible cover to the quarter belt flange.
  2.  
  3. Note the position of any shims used, then unfasten the three nutwashers retaining the main pivot bracket assembly to the mounting bracket.
  4.  
  5. With the help of an assistant, lift the convertible top assembly from the vehicle.
  6.  

To install:

The convertible top assembly should be unfolded or in the UP position during installation to allow access to the main pivot bracket area.

  1. As the convertible top is lowered into position, the quarter window drive links must be guided into the main pivot bracket to avoid trapping the links. With the help of an assistant, position the convertible top assembly to the vehicle, aligning the main pivot bracket doll pins with the holes in the mounting brackets.
  2.  
  3. If removed, install shims as noted between the mounting bracket and main pivot brackets.
  4.  
  5. Install the nutwashers retaining main pivot bracket assembly to the mounting bracket. Tighten the nutwashers to 17 ft. lbs. (24 Nm).
  6.  
  7. Attach the drive motor wire harness connectors to the body wire harness, routing the wires as noted during removal.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Attach the backlite assembly to the tackstrip. Fasten the heated backlite wire harness connectors.
  12.  
  13. Fasten the topcover and rear stay pads to the tackstrip and quarter panel structure flange.
  14.  
  15. Cycle and latch the convertible top to the windshield header and check the top's appearance and function.
  16.  
  17. Install the right and left side quarter panel belt outer moldings, then install the back belt molding.
  18.  
  19. Fasten the closeout trim panel and secure using the retainers.
  20.  
  21. Apply Loctite® 242, or equivalent, to the bolt threads. Carefully raise the quarter window glass and secure the drive links to the spur gears using the bushing, washer and bolt.
  22.  
  23. Install the screws securing the headliner to the closeout panel below the glass backlite.
  24.  
  25. Fasten the screws securing the headliner to the quarter inner structure and rear rail.
  26.  
  27. Install the right and left side quarter trim panels.
  28.  

MOTOR REPLACEMENT



See Figure 3

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.

Top Up
  1. Disconnect the negative battery cable.
  2.  
  3. Unlatch the convertible top from the windshield header.
  4.  
  5. Remove the quarter trim panel.
  6.  
  7. Unfasten the headliner screws at the rear rail and quarter panel structure. Fold the headliner to access the drive motor assembly.
  8.  



Click image to see an enlarged view

Fig. Fig. 3: Drive motor assembly mounting-1995 vehicle shown

  1. Note the wire routing, then detach the drive motor wire harness connector from the body harness.
  2.  
  3. Unfasten the bolts and lockwashers retaining the motor to the main pivot bracket assembly.
  4.  
  5. Remove the motor assembly by lowering the motor from the bottom of the main pivot bracket.
  6.  

To install:
  1. Position the motor assembly to the main pivot bracket.
  2.  
  3. Apply Loctite® 242, or equivalent, to the bolt threads. Install the bolts and lockwashers retaining the motor to the main pivot bracket. Tighten the bolts to 9 ft. lbs. (12 Nm).
  4.  
  5. Route the motor wire harness over the main pivot bracket and wire harness and attach the wire connector to the body harness.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Check the convertible top motor operation.
  10.  
  11. Fasten the headliner to the rear rail and structure using screws.
  12.  
  13. Install the quarter trim panel.
  14.  
  15. Raise and latch the convertible top.
  16.  

Top Down

If the motor has seized and the convertible top is lowered, place the top bypass switch in the Emergency Override position and proceed as follows.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the quarter trim panel.
  4.  
  5. Unfasten the headliner screw from the structure and position the headliner out of the way.
  6.  
  7. Unfasten the No. 4 bow slat-to-main pivot bracket bolt and spacer. Retain the bushing in the slat.
  8.  
  9. Remove the rear rail pivot bolt and nut at the main pivot bracket.
  10.  
  11. Apply Loctite® 242 or equivalent, to the bolt threads, then reinstall the No. 4 bow slat-to-main pivot bracket spacer and bolt.
  12.  
  13. Lift the rear rail and the spur gear off the motor gear and, with the help of an assistant, raise the convertible to the closed position. Do not latch the top.
  14.  
  15. Apply Loctite® 242 or equivalent, to the bolt threads, then fasten the bolt to the rear rail with the nut.
  16.  
  17. Remove and install the motor assembly, as outlined in the Top Up procedure beginning with Step 4.
  18.  

 
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