Toyota Celica 1986-1993 Repair Guide

Convertible Top

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TOP REPLACEMENT




CAUTION
On models with an air bag, wait at least 30 seconds from the time that the ignition switch is turned to the lock position and the battery is disconnected before performing any further work.

1986-89 Vehicles
  1. Remove the headliner (See Headliner).
  2.  
  3. Remove front rail weather-strip and front rail weather-strip retainer assemblies by unlatching the top and lowering it halfway. Remove the two nuts/washers and screw and remove the front rail weather-strip retainer.
  4.  



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Fig. Fig. 1 Convertible top components1986-89 vehicles



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Fig. Fig. 2 Quarter and back belt moldings1986-89 vehicles



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Fig. Fig. 3 Location of No. 1 bow1986-89 vehicles



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Fig. Fig. 4 Location of No. 2 and 3 bows1986-89 vehicles

  1. Remove top cover retainer assembly.
  2.  
  3. Detach top cover from No. 1 bow, pulling top cover to break cement bond.
  4.  
  5. Detach top cover flaps from front rails, pulling flaps to break cement bond.
  6.  
  7. Remove top cover retainers from No. 2 and No. 3 bow listing pockets, removing the six screws on each bow. Push top cover away from No. 2 and No. 3 bows. Slide top cover retainers out of listing pockets to remove them.
  8.  



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Fig. Fig. 5 Location of No. 4 bow1986-89 vehicles



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Fig. Fig. 6 Backlight assembly components1986-89 vehicles



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Fig. Fig. 7 Quarter trim panel components1986-89 vehicles

  1. Remove side retention cable from front side rail, by removing the screw.
  2.  
  3. Remove rear weather-strip assemblies, by raising the top to the windshield header, and removing the four nuts and washers.
  4.  
  5. Detach top cover quarter flaps from the rear rails.
  6.  
  7. Remove side retention cable from the top cover by pulling the cable back through the top cover side listing pocket.
  8.  
  9. Remove belt tacking strip assembly, by removing the twelve nuts and four bolts. Pull both forward ends of the belt tacking strips inboard to clear the quarter mounting studs. Pull the complete tacking strip assembly forward to clear the rear mounting studs. Push the tacking strip assembly to one side to allow clearance. Raise one corner of tacking strip from the body. Then lift the remainder of the tacking strip assembly above the belt line.
  10.  
  11. Use a suitable sharp pencil to accurately mark the location of the complete belt tacking strip assembly. Mark the upper and lower edge and ends on the outer surface of the top cover. Mark the location of the inner vertical edge of the top cover backlight opening on the belt tacking strip assembly.
  12.  
  13. Detach top cover from belt tacking strip assembly, using an awl to remove staples.
  14.  


WARNING
Before removal, note location and spacing of staples.

  1. Remove top cover from No. 4 bow:
    1. Fold top cover (rear sail material) back over the No. 4 bow.
    2.  
    3. Remove No. 4 bow feature strip outer isolator by pulling it out of the No. 4 bow feature strip retainer.
    4.  
    5. Remove No. 4 bow feature strip insert by pulling the insert out of the No. 4 bow feature strip retainer.
    6.  
    7. Detach top material from the No. 4 bow by pulling the No. 4 bow feature strip out of the No. 4 bow feature strip retainer.
    8.  
    9. Remove top cover.
    10.  

  2.  

To install:

  1. Transfer reference marks from removed top cover to new top cover:
    1. Place new top cover on a suitable clean surface, such as on a clean roof of a car to provide proper contour and fullness with inner surface of cover down.
    2.  
    3. Position removed top cover over new one.
    4.  
    5. Carefully align backlight opening upper corners and rear quarter upper corners of both covers. Secure both covers in position.
    6.  
    7. Carefully lay out trim material of quarter area of both covers. Using a sharpened pencil, transfer location marks for tacking strip from old top to new top.
    8.  
    9. Reposition new top cover over old top cover to check reference mark locations.
    10.  

  2.  
  3. Install top cover to No. 4 bow:
    1. Position new top cover over top stack framework.
    2.  
    3. Fold top cover quarter sail material back over the No. 4 bow.
    4.  
    5. Align the No. 4 bow feature strip to the No. 4 bow feature strip retainer.
    6.  
    7. Engage the No. 4 bow feature strip into the No. 4 bow feature strip retainer, starting at one end working toward the other.
    8.  

  4.  
  5. Install the No. 4 bow feature strip insert by inserting it into the No. 4 bow feature strip retainer.
  6.  
  7. Install the No. 4 bow feature strip outer isolator.
  8.  
  9. Install side retention cables to the top cover and to front side rails by inserting the end of the cable into the rear end of the top cover side rail listing pocket and pushing the cable through the listing pocket. Lower the top halfway and install the end of the cable into the front side rail with the screw.
  10.  
  11. Install top cover to belt tacking strip assembly as follows:
    1. Position and locate top cover to belt tacking strip according to reference marks.
    2.  
    3. Tack top cover to belt tacking strip starting from top cover inner vertical edge reference mark on tacking strip assembly toward the front.
    4.  
    5. Cut or pierce holes in top cover along belt tacking strip for tacking strip attaching studs, and bolts.
    6.  
    7. Trim off excess material to within 1/2 inch of lower edge of belt tacking strip.
    8.  

  12.  


WARNING
Avoid excessive stretching, but keep material flat during tacking operation.

  1. Install belt tacking strip assembly as follows:
    1. Raise top slightly off windshield header.
    2.  
    3. Lower one corner of belt tacking strip assembly into body.
    4.  
    5. Lower the remainder of the belt tacking strip assembly into the body.
    6.  
    7. Position belt tacking strip assembly to attaching studs and install the twelve nuts and four bolts.
    8.  

  2.  
  3. Install No.2 and No. 3 bow retainers by inserting bow retainers into top cover listing pockets. Position bow retainers to each bow and install the 12 screws.
  4.  
  5. Install top cover to No. 1 bow as follows:
    1. Raise the top and latch it to the windshield header.
    2.  
    3. Pull top cover straight forward at seams to desired top fullness.
    4.  
    5. While maintaining tension on the top cover over No. 1 bow, make a pencil mark on the top cover outer surface along the forward edge on No. 1 bow.
    6.  
    7. Lower the top halfway and carefully apply nitrile cement or neoprene weather-strip adhesive to cementing area of No. 1 bow and front side rails and to corresponding surfaces of top cover and to front corner flaps.
    8.  
    9. Secure top cover to No. 1 bow by pulling top cover reference marks slightly beyond target to that pencil marks will be slightly under front edge of No. 1 bow.
    10.  
    11. Align sides of top cover with side rails and secure top cover flaps to the front rails.
    12.  
    13. Raise the top and latch it to windshield header. Check appearance of top cover, top operation and latching effort of top.
    14.  
    15. Trim off all excess material from No. 1 bow.
    16.  

  6.  


WARNING
If additional tension is needed in top cover, repeat step (e) and pull top cover further forward.

  1. Install front rail weather-strip and front rail weather-strip retainer assemblies by positioning front rail weather-strip retainers to the front side rails and install the two washers/nuts and screw to each retainer.
  2.  
  3. Install top cover quarter flaps to rear rails as follows:
    1. Raise the top and latch it to the windshield header.
    2.  
    3. Apply nitrile cement or neoprene weather-strip adhesive to cementing surfaces of rear rail and to quarter flaps.
    4.  
    5. Align quarter flap seam with edge of rear rail to remove all fullness from top cover.
    6.  
    7. With quarter flap seam aligned with each rail, cement quarter flap securely in place to rear rails.
    8.  

  4.  
  5. Install rear rail weather-strip assemblies by positioning it to the rear rail and installing the four washers and nuts.
  6.  
  7. Install headliner (See Headliner).
  8.  
  9. When complete, clean up top material and car as required.
  10.  

1990-93 Vehicles
  1. Remove the quarter outer and back belt moldings.
    1. Lower the convertible top.
    2.  
    3. Open the luggage compartment lid.
    4.  
    5. Remove the quarter outer and back belt moldings by removing the three screws on each quarter outer belt molding, then removing the seven screws from the back belt molding. Without bending the moldings raise them off the body and disengage them to remove.
    6.  

  2.  
  3. Remove the headliner (See Headliner).
  4.  
  5. Remove the back belt trim garnish.
  6.  
  7. Remove the rear rail weather-strip retainer assemblies.
    1. Unlatch the top and lower it halfway down.
    2.  
    3. Using a suitable releasing agent (e.g., Kent, or equivalent) and a flat bladed tool, grasp the weatherstrip and gently pull forward while inserting the flat bladed tool between the weatherstrip and the weatherstrip retainer to break the cement bond and remove the rear rail weatherstrip.
    4.  
    5. Unhook the headliner strap from the top stack main pivot bracket.
    6.  
    7. Remove the rear rail weatherstrip retainer by removing the two nuts and washers.
    8.  

  8.  
  9. Remove the front rail weatherstrip assemblies.
    1. Unlatch the top and lower it all the way down.
    2.  
    3. Using a suitable releasing agent (e.g., Kent, or equivalent) and a flat bladed tool, grasp the weatherstrip and gently pull upward while inserting the flat bladed tool between the weatherstrip and the weatherstrip retainer to break the cement bond and remove the front rail weatherstrip.
    4.  
    5. Remove the front rail weatherstrip retainer by removing the screw at each end of the retainer.
    6.  
    7. Raise the top halfway. Remove the nut and washer and remove the front rail weatherstrip retainer.
    8.  

  10.  



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Fig. Fig. 8 Convertible top components1990-93 vehicles



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Fig. Fig. 9 Quarter and back belt moldings1990-93 vehicles



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Fig. Fig. 1 0 Location of No. 1 bow and latch assemblies1990-93 vehicles



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Fig. Fig. 1 1 Location of No. 2 and 3 bows1990-93 vehicles

  1. Remove the top cover front retainer. Lower the top halfway down and remove the 7 screws.
  2.  
  3. Detach the top cover from the No. 1 bow by pulling the cover away to break the cement bond.
  4.  
  5. Detach the top cover flaps from the No. 1 bow by pulling the flaps away from the No. 1 bow to break the cement bond.
  6.  



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Fig. Fig. 1 2 Location of No. 4 bow1990-93 vehicles



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Fig. Fig. 1 3 Side rail assembly components1990-93 vehicles



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Fig. Fig. 1 4 Backlite assembly components1990-93 vehicles



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Fig. Fig. 1 5 Quarter trim panel components1990-93 vehicles

  1. Remove the top cover retainers from the No. 2 and No. 3 bow listing pockets by removing the 3 screws on each bow, pushing the top cover rearward and away from the No. 2 and No. 3 bows. Slide the top cover retainers out of the listing pockets to remove them.
  2.  
  3. Remove the side retention cables from the top cover by removing the screws from the No. 1 and No. 2 bows, then folding the top cover rearward and pulling the cables back through the top cover side listing pocket to remove the cable.
  4.  
  5. Detach the top cover quarter flaps from the rear rails by pulling the top cover quarter flaps away from the rear rail to break the cement bond.
  6.  
  7. Remove the tacking strip.
    1. Remove the 12 screws from the tacking strip.
    2.  
    3. Remove the 8 nuts from the tacking strip.
    4.  
    5. Pull both forward ends of the packing strip inboard to clear the quarter mounting studs.
    6.  
    7. Raise one corner of the tacking strip from the body, then lift the remainder of the tacking strip above the belt line.
    8.  

  8.  
  9. Mark reference points on the top cover assembly. Using a suitable sharp pencil, accurately mark the location of the tacking strip staples on the top cover. Mark a line along the center of the staples to aid in reassembly. Mark the forward edge of the top cover on the tacking strip and mark the rear edge of the top cover on the backlight assembly.
  10.  
  11. Remove the top cover from the tacking strip by using an awl and removing the staples retaining the top cover to the tacking strip.
  12.  


WARNING
Before removal, note location and spacing of staples.

  1. Remove the top cover from the No. 4 bow by folding the top cover rearward over the backlight to expose the top cover No. 4 bow retainer and removing the 6 screws to remove the top cover.
  2.  

To install:

  1. Transfer the reference marks from the removed top cover to the new top cover.
  2.  
  3. Install the top cover to the No. 4 bow.
    1. Position the new top cover over the top stack framework.
    2.  
    3. Fold the top cover back to expose the top cover No. 4 bow retainer.
    4.  
    5. Install the top cover No. 4 bow retainer to the No. 4 bow.
    6.  
    7. Install the 6 screws.
    8.  

  4.  
  5. Install the top cover to tacking strip.
    1. Position and locate the top cover to the tacking strip according to reference marks.
    2.  
    3. Tack the top cover to the tacking strip starting from the rear vertical edge reference mark on the backlight assembly, working toward the front. Avoid excessive stretching, but keep the material flat during tacking operation.
    4.  
    5. Cut or pierce holes in top cover along tacking strip for tacking strip studs.
    6.  
    7. Trim off excess material below the tacking strip. Excess material should not extend more than one half inch beyond the lower edge of tacking strip.
    8.  

  6.  
  7. Install the tacking strip by raising the top slightly off the windshield. Install the tacking strip to the quarter mounting studs on both sides and loosely install the 8 nuts. Install the 12 screws on the tacking strip, then tighten the 8 nuts on the tacking strip.
  8.  
  9. Install the side retention cables as follows:
    1. Slide one of the No. 2 or 3 bow retainers into the front end of the top cover side listing pocket.
    2.  
    3. Attach the front eyelet of the retention cable to the retainer and pull the cable through the listing pocket into position.
    4.  
    5. Lower the top halfway and install the ends of the cable to the No.1 and No.2 bows with screws.
    6.  

  10.  
  11. Install the top cover retainers to No. 2 and No. 3 bows by inserting the top cover retainers into the top cover listing pockets and positioning the top cover retainers to each bow then installing the 3 screws to each bow.
  12.  
  13. Install the top cover to No. 1 bow:
    1. Raise the top and latch it to the windshield header.
    2.  
    3. Pull the top cover straight forward at the seams to achieve the desired top fullness.
    4.  
    5. While maintaining tension on the top cover over the No. 1 bow, make a pencil mark on the top cover outer surface along the forward edge of the No. 1 bow.
    6.  
    7. Lower the top halfway down and carefully apply nitrile cement or neoprene weatherstrip adhesive to cementing area of No. 1 bow and corresponding surfaces of the top cover and top cover flaps.
    8.  
    9. Position the top cover to No. 1 bow by pulling top cover reference marks slightly beyond target so that pencil marks will be slightly under the front edge of the No. 1 bow.
    10.  
    11. Align the sides of the top cover with sides of the No. 1 bow and secure the top cover flaps to the No. 1 bow.
    12.  
    13. Secure the top cover to the No. 1 bow pulling the pencil mark slightly beyond the forward edge of the No. 1 bow.
    14.  
    15. Raise the top and latch it to the windshield header. Check the appearance of the top cover, top operation and latching effort of the top. If additional tension is needed in top cover repeat step "e" and pull top cover further forward.
    16.  
    17. Trim off all excess material from No. 1 bow.
    18.  

  14.  
  15. Install the top cover front retainer by positioning the top cover front retainer to the No. 1 bow and installing the 7 screws.
  16.  
  17. Install the top cover quarter flaps to rear rails:
    1. Raise the top and latch it to the windshield header.
    2.  
    3. Apply nitrile cement or neoprene weatherstrip adhesive to cementing surfaces of rear rail and to quarter flaps.
    4.  
    5. Align quarter flap seam with the forward edge of the rear rail to remove all fullness from the top cover.
    6.  
    7. With quarter flap seam aligned with the rear rail, attach quarter flap securely in place to the rear rail.
    8.  

  18.  
  19. Install the front rail weatherstrip assemblies:
    1. Remove all excess adhesive from the front rail weatherstrip retainer.
    2.  
    3. Install the front rail weatherstrip retainer by installing it to the front seal carrier, then installing the washer, nut and screws.
    4.  
    5. Install the front rail weatherstrip assembly: Lower the top all the way down; apply a continuous bead of black weatherstrip adhesive to the channel of the front rail weatherstrip retainer; position and align the weatherstrip to the front rail weatherstrip retainer; using a flat bladed tool, install the weatherstrip into the front rail weatherstrip retainer.
    6.  

  20.  
  21. Install the rear rail weatherstrip assemblies:
    1. Remove all excess adhesive from the rear rail weatherstrip retainer.
    2.  
    3. Install the rear rail weatherstrip retainer by installing the 2 nuts and washers.
    4.  
    5. Hook the headliner strap to top stack main pivot bracket.
    6.  
    7. Install the rear rail weatherstrip assembly: Apply a continuous of black weatherstrip adhesive to the channel of the rear rail weatherstrip retainer; position and align the weatherstrip to the rear rail weatherstrip retainer; using a flat bladed tool, install the weatherstrip into the rear rail weatherstrip retainer.
    8.  

  22.  
  23. Install the back belt trim garnish.
  24.  
  25. Install the headliner (See Headliner).
  26.  
  27. Install the quarter, outer and back belt moldings:
    1. Position the back belt moldings to the body.
    2.  
    3. Engage the quarter outer belt moldings to the back belt molding.
    4.  
    5. Install the 3 screws to each quarter outer belt molding.
    6.  
    7. Install the 7 screws to the back belt molding.
    8.  
    9. Close the luggage compartment lid and raise the convertible top.
    10.  

  28.  
  29. Clean the top to complete installation.
  30.  

MOTOR REPLACEMENT




CAUTION
On models with an air bag, wait at least 30 seconds from the time that the ignition switch is turned to the lock position and the battery is disconnected before performing any further work.

1986-89 Vehicles
  1. Remove left side luggage compartment trim panel.
  2.  
  3. Remove hydraulic motor and pump assembly:
    1. Disconnect wire connector.
    2.  
    3. Remove the bolt attaching the hydraulic motor and pump assembly to mounting bracket.
    4.  
    5. Using a screwdriver, pry the motor and pump assembly up off the mounting bracket.
    6.  
    7. Remove and then install the filler plug on the motor and pump to vent the reservoir.
    8.  

  4.  


WARNING
Venting the reservoir is necessary on this sealed-in unit to equalize the air pressure in the reservoir and the possibility of hydraulic fluid being forced out when disconnecting lines. Place a cloth under motor and pump assembly when disconnecting hydraulic lines to absorb any leaking fluid. Before removal, note the attaching points of each hydraulic line.

  1. Disconnect the hydraulic lines from the motor and pump assembly and cap the open fitting to prevent leakage of fluid.
  2.  
  3. Remove the motor and pump assembly.
  4.  

To install:


WARNING
When installing a new motor and pump assembly, fill the reservoir with sae 10W motor oil prior to installation. This priming operation is necessary prior to performing the following steps in order to avoid drawing an excessive amount of air into the hydraulic system.

  1. Install hydraulic motor and pump assembly:
    1. Connect hydraulic lines to motor and pump assembly.
    2.  
    3. Install motor and pump to mounting bracket.
    4.  
    5. Install the mounting bolt.
    6.  
    7. Connect the wire connector.
    8.  

  2.  
  3. Check reservoir fluid level:
    1. Operate top through its up and down cycles until all air has been bled from the hydraulic system and check hydraulic line connections for leaks.
    2.  
    3. Check the reservoir fluid level. If the fluid level is between the two marks, it is O.K. If the fluid level is low, add more fluid.
    4.  

  4.  
  5. Install left side luggage compartment trim panel.
  6.  



Click image to see an enlarged view

Fig. Fig. 1 6 Removing convertible top motor1986-89 vehicles

1990-93 Vehicles
  1. Remove right side luggage compartment trim panel. Remove motor/pump cover.
  2.  
  3. Remove hydraulic motor and pump assembly:
    1. Disconnect wire connector.
    2.  
    3. Remove the bolt attaching the hydraulic motor and pump assembly to mounting bracket.
    4.  
    5. Using a screwdriver, pry the motor and pump assembly up off the mounting bracket.
    6.  
    7. Remove and then install the filler plug on the motor and pump to vent the reservoir.
    8.  

  4.  


WARNING
Venting the reservoir is necessary on this sealed-in unit to equalize the air pressure in the reservoir and the possibility of hydraulic fluid being forced out when disconnecting lines. Place a cloth under motor and pump assembly when disconnecting hydraulic lines to absorb any leaking fluid. Before removal, note the attaching points of each hydraulic line.

  1. Disconnect the hydraulic lines from the motor and pump assembly and cap the open fitting to prevent leakage of fluid.
  2.  
  3. Remove the motor and pump assembly.
  4.  

To install:


WARNING
When installing a new motor and pump assembly, fill the reservoir with sae 10W motor oil prior to installation. This priming operation is necessary prior to performing the following steps in order to avoid drawing an excessive amount of air into the hydraulic system.

  1. Install hydraulic motor and pump assembly:
    1. Connect hydraulic lines to motor and pump assembly.
    2.  
    3. Install motor and pump to mounting bracket.
    4.  
    5. Install the mounting bolt.
    6.  
    7. Connect the wire connector.
    8.  

  2.  
  3. Check reservoir fluid level:
    1. Operate top through its up and down cycles until all air has been bled from the hydraulic system and check hydraulic line connections for leaks.
    2.  
    3. Check the reservoir fluid level. If the fluid level is between the two marks, it is O.K. If the fluid level is low, add more fluid.
    4.  
    5. If air bubbles remain, bleed the cylinder affected.
    6.  

  4.  
  5. Install motor/pump cover:
    1. Rotate the manual release valve clockwise 90 degrees.
    2.  
    3. Install the motor/pump cover.
    4.  
    5. Rotate the manual release valve counterclockwise 90 degrees.
    6.  

  6.  
  7. Install right side luggage compartment trim panel.
  8.  



Click image to see an enlarged view

Fig. Fig. 1 7 Removing convertible top motor1990-93 vehicles

 
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