GM Lumina/Grand Prix/Cutlass Supreme/Regal 1988-1996

Convertible Top Cover and Rear Window Assembly

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REMOVAL & INSTALLATION



See Figures 1 and 2

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Fig. Fig. 1: Convertible top listing pockets



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Fig. Fig. 2: Convertible top stay pads and rear window assembly

This is a fairly complicated procedure, and ultimate success depends largely on practice and skill. Hence, a professional convertible repair shop is the best place to take your car, should it need repair. But, if you want to attempt it yourself, here's the procedure.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove inner headliner by pulling loose all fastening tape strips from around all side windows, header, and rear, and screws in No. 4 bow.
  4.  
  5. Using a grease pencil, mark the locations of all attaching holes on the top cover material. Remove the quarter and rear belt moldings.
  6.  
  7. Cover all painted surfaces on the rear compartment lid and quarter panels.
  8.  
  9. Remove the front rail and No. 1 seal and retainers.
  10.  
  11. Remove the welt assembly and top cover from No. 1 bow.
  12.  
  13. Remove the screw and spring from the rear of each side retention cable and pull the cable toward the front to remove.
  14.  
  15. Remove the screw, spring, and plate from the lower end of each retention cable and pull the cables through the listing pockets from the upper end.
  16.  
  17. Remove the screws securing the listing pocket and retainer to No. 2 bow, and remove the retainer.
  18.  
  19. Note the location and spacing of the staples securing the cover at the top of the No. 3 bow, and remove them.
  20.  
  21. Remove the rod that holds the backlite to the cover at the top.
  22.  
  23. Note the location and spacing of the staples and remove the top cover from the rear belt tacking strips.
  24.  
  25. Mark the location of the backlite outer panels along the balance of the belt tacking strips.
  26.  
  27. Disconnect the wires to the rear defroster.
  28.  
  29. Double-check the tacking strip marking locations on the backlite assembly, and remove the backlite assembly from the rear belt tacking strip.
  30.  

To install:
  1. If replacing the backlite assembly, transfer the reference marks from the removed backlite assembly to the new one as follows:
    1. Place the new backlite assembly in a clean covered surface with the inner surface facing down.
    2.  
    3. Position the removed backlite assembly over the new one and carefully align them together.
    4.  
    5. While holding both together securely, carefully lay out and trim the material and transfer the backlite assembly reference marks along the bottom portion of the tacking strips.
    6.  
    7. Reverse the backlite assemblies by placing the new assembly over the old one as described above.
    8.  
    9. Recheck the locations of the reference marks. If any difference is noted, the average between the two is now the correct reference to use. Mark the corrected reference clearly. Trim off excess material beyond 1 / 2 in. (13mm) along the bottom and transfer the center mark from the bottom center of the removed backlite assembly to the new one. Transfer of reference marks must be done correctly for best results and minimum rework.
    10.  
    11. Position and center the new backlite assembly according to the reference marks.
    12.  

  2.  
  3. Install the backlite assembly to the backing strip using heavy duty 3 / 8 in. staples. Apply downward pressure to the backlite assembly at each point of staple installation. Staple from the center to the ends.
  4.  
  5. After the backlite has been properly secured, trim OFF all excess material at the rear below the tacking strip.
  6.  
  7. Connect the rear defroster wires.
  8.  
  9. Transfer the reference marks from the old top cover to the new one as follows:
    1. Place the new cover on a clean surface with the inner surface of the cover facing down.
    2.  
    3. Position the removed top cover over the new one.
    4.  
    5. Carefully align the backlite opening upper corners, rear quarter upper corners and rear quarter upper corners of both covers. Secure both covers together at these locations.
    6.  
    7. Transfer location marks for tacking strip.
    8.  
    9. Position the top cover over the top stack in the raised position. The cover may require some lateral stretching along the rear bow to achieve the proper fit of the quarter flaps to the rear side rails and to remove fullness from the top cover valance over the backlite.
    10.  

  10.  
  11. Install the rod holding the backlite to the top cover; insert through the support strips.
  12.  
  13. Install the No. 2 bow top cover retainer into the new top cover listing pocket.
  14.  
  15. Install the side retention cables into the cover side rail listing pockets. If needed, a wire may assist you in pulling them through.
  16.  
  17. Install the Nos. 2 & 3 bow top cover listing pockets to their bows.
  18.  
  19. Raise the top slightly OFF of the windshield header.
  20.  
  21. Install the side retention cables to the springs and rear rails with the screws.
  22.  
  23. Install the rear retention cables into the rear listing pockets. Secure the lower ends of the the cables to the quarter belt line brackets with the screws.
  24.  
  25. Lock the top to the windshield header. Pull the top cover straight forward at seams to the desired top fullness, and align the center of the top cover with the center rivets in the No. 1 bow. While maintaining tension on the cover over the top of No. 1 bow, make a pencil mark on the cover outer surface along the forward edge of the No. 1 bow.
  26.  
  27. Raise the top OFF of the header to a comfortable working height.
  28.  
  29. Install the cover to No. 1 bow using staples after pulling 1 / 4 in. (6mm) past the reference mark. Trim excess material.
  30.  
  31. Raise the top and lock to the windshield header. Check appearance of the top trim. If additional tension is needed, pull the cover further forward. Staple and recheck for satisfactory appearance.
  32.  
  33. Install the welt assembly to the No. 1 bow using staples.
  34.  
  35. Install the No. 1 bow seal retainer and front rail retainers.
  36.  
  37. Apply weatherstrip adhesive to the inner surface of the retainer. Attach the front rail and the No. 1 bow seal assembly to the front rail retainer and across No. 1 bow. Secure the seal to the bow with the attaching screws.
  38.  
  39. Install the top cover to the belt tacking strips starting at the rear and working rearward. Apply downward pressure to the top cover at each point of staple installation.
  40.  
  41. To prevent water leaks, cover all staples with preheated butyl tape, then heat the tape again to seal to the staples. Cover the butyl tape with duct tape.
  42.  
  43. Cut or pierce holes in the cover and along the backlite assembly along the tacking strip for belt molding attaching studs.
  44.  
  45. Install the rear belt and quarter belt moldings.
  46.  

When complete, the top cover should be completely free of wrinkles, tucks and draws. Make whatever adjustments are necessary in order to make the top look perfect. There's nothing worse than a ragtop poorly installed!

  1. If everything is satisfactory, install the inner headliner.
  2.  
  3. Clean the top and car as needed.
  4.  
  5. Connect the negative battery cable and check the top for proper operation.
  6.  

MOTOR/PUMP ASSEMBLY REPLACEMENT



See Figure 3

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Fig. Fig. 3: Venting the convertible top motor/pump

  1. Operate the top to its full up position. Disconnect the negative battery cable.
  2.  
  3. Remove the rear seat and seatback to gain access to the pump. If removing the lift cylinder, remove the quarter trim panel to gain access to it.
  4.  
  5. Disconnect the wiring harness from the motor.
  6.  
  7. Place absorbent rags below the hose connections at the end of the reservoir.
  8.  


CAUTION
Failure to vent the unit prior to line disconnection may spew fluid into your face or on the cars painted surfaces.

  1. Remove the fill plug slowly to vent the unit. Then re-install the plug.
  2.  
  3. Disconnect the hydraulic lines and cap them.
  4.  
  5. Remove the mounting nuts and remove the motor/pump assembly.
  6.  

To install:
  1. Fill the reservoir with Dexron®II automatic transmission fluid.
  2.  
  3. Make sure that all threaded parts have their sealing ring in place, and connect the hydraulic lines.
  4.  
  5. Connect the wiring harness.
  6.  
  7. Connect the negative battery cable and operate the top through several up and down cycles until movement is consistently smooth indicating that all air has been bled from the system.
  8.  
  9. Check all connections for leakage and recheck the fluid level by removing the full plug.
  10.  
  11. Install previously removed interior parts.
  12.  

 
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