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Cover, Convertible: Installation

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GC0157719Courtesy of CHRYSLER GROUP, LLC
  1. Fold headliner material (1) over and secure with a binder clip (2), clothes pin or equivalent.
    NOTE:

    This will help hold the headliner material (1) out of the way during installation.

    GC0157700Courtesy of CHRYSLER GROUP, LLC
  2. Fold the folding top cover (1) as shown.
  3. With help from an assistant, on the opposite side, lift the folding top cover by the two lift up springs (2) on each side.
    NOTE:

    While moving and positioning, take care not to let rear area of cover fall or flop over. For ease of installation keep the cover in the folded position

    GC0157874Courtesy of CHRYSLER GROUP, LLC
  4. Insert the left and right front roof bow slider blocks (1) into the left and right rail channel ends (2) simultaneously.
  5. Slide the cover up the rails and insert the second set of roof bow slider blocks into the rails simultaneously.
  6. Keeping the cover in the folded position, slide the cover up into the center of the roof opening.
    GC0157615Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    To prevent damage to the stow slider block screw, use an appropriate flat bladed tool.

    NOTE:

    Use a flat bladed tool (2) that fits properly into the thickness of the center slot of the screw head on the folding top stow slider block (1). Due to the small size of the screw, it will be tempting to use a small flat bladed tool. A smaller flat bladed tool most likely will not have enough thickness on the blade to fill the center slot in the screw head properly. Using to small of a flat bladed tool may strip the head of the screw.

  7. Insert the right folding top stow slider block into rear of the folding top rail. Left and right are not interchangeable. They can be identified by an inboard side forward facing arrow.
  8. There is a notch on the top of the rail in the C-pillar area, align the stow slider block (1) to the slot.
  9. Turn the right side folding top stow slider block front screw a half turn counter clockwise, while gently moving the folding top stow slider bracket slightly back and forth, to engage the arm into the roller assembly.
  10. Position the left folding stow slider block to the notch on the top of the rail in the C-pillar area, align the folding top stow slider bracket to the slot (1).
  11. Turn the left side folding top stow slider block front screw a half turn clockwise, while gently moving the folding top stow slider block slightly back and forth, to engage the arm into the roller assembly.
    GC0157648Courtesy of CHRYSLER GROUP, LLC
  12. Position the rear stop block into to the rear of the rail.
  13. Install the fastener (2) securing the rear stop block (1). Tighten the fastener to 3 Nm (27 lbf-in).
  14. Repeat on the opposite side.
    GC0153515Courtesy of CHRYSLER GROUP, LLC
  15. Position and engage the rear track cover (1) by inserting the outboard edge of the cover and rolling the track cover outward and down. Hand tap to seat properly. Repeat on the opposite side
  16. Attach the seal end (2) at the bottom of the rear track cover (1).
    GC0157866Courtesy of CHRYSLER GROUP, LLC
  17. Position the linkage arm (2) end with the O-ring bushing (1) in place, into the hole in the folding top stow slider block (3).
  18. Repeat on the opposite side.
    GC0157722Courtesy of CHRYSLER GROUP, LLC
  19. Manually cycle the cover to 3/4 closed position, using the 17 mm hex head under the rear shelf.
    NOTE:

    Caution- To prevent damage to the folding top motor, never use power tools to turn the folding top manual operation hex head gear.

  20. Insert the cover into the second bow retainer (1) by inserting the bow end cap into the end of the lift up spring (2) fully.
    GC0157611Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Be certain that the white strip on the tension belts are always facing up toward the cover and that there are no twists in the belt.

  21. If necessary, pull the front tension belt (2) through the tension belt clip (1),
  22. Align to the mark (3) on the tension belt (2) to the front edge of the clip (1).
  23. Secure clip (1).
    GC0157657Courtesy of CHRYSLER GROUP, LLC
  24. Inspect the tension belt to be certain it is completely routed.
  25. If the belt has become undone, thread the tension as necessary, rear to front belt sequence - through the slots in the roof bow end cap brackets, through the ear (3) on the front of the headliner (1) and front lift up spring (2).
    GC0157575Courtesy of CHRYSLER GROUP, LLC
  26. Position the tension belt (1) to the lifting arm (2).
  27. Install the rivet (3) and repeat on the opposite side.
    GC0157931Courtesy of CHRYSLER GROUP, LLC
  28. Position the front bow (1) to the lifting arm brackets (2).
  29. Loosely install the front bow bolts (3 and 4). Repeat on the opposite side.
  30. While pushing the center of the front bow forward, tighten the left outer fastener (3) to 9 Nm (80 lbf-in).
  31. Repeat on the right outer fastener.
  32. Tighten the left inner fastener to 9 Nm (80 lbf-in).
  33. Repeat on the right outer fastener.
    GC0157938Courtesy of CHRYSLER GROUP, LLC
  34. Align the center mark on the headliner to the mark on the front bow.
  35. Insert the edge of the headliner (2) into the front roof bow (1).
  36. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, tuck the headliner front edge in fully.
    GC0157933Courtesy of CHRYSLER GROUP, LLC
  37. Loosely install the fastener (1) with sleeve into the four bow end cap (2). Do not tighten at this time. 
  38. Repeat on the opposite side.
    GC0157879Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Caution-

    When re-installing the harness it must hug the pillar and the end of the zip ties must be cut off flush or the headliner will get cut during roof movement.

  39. Route the defroster harness along the bracket.
  40. Install zip ties (1) to the harness. Cut zip tie ends off flush to the head.
  41. Connect defroster wire connector onto the backlight terminal.
  42. Route the harness into the back glass channel.
  43. Install zip ties to the harness. Cut zip tie end off flush to the head.
  44. Repeat on the opposite side.
    GC0157747Courtesy of CHRYSLER GROUP, LLC
  45. Position the headliner tether (1) to the linkage.
  46. Insert the fastener (2) and engage the pin (3) fully.
    GC0157671Courtesy of CHRYSLER GROUP, LLC
  47. Accessing from inside the vehicle, place the three washers (3) between the backlight/glass linkage (2) and the mounting bracket.
  48. Install the nylon washer and fastener (1).
  49. Tighten the fastener to 9 Nm. (80 lbf-in).
  50. Repeat on the opposite side.
    GC0157844Courtesy of CHRYSLER GROUP, LLC
  51. Position the linkage (4) and backlight bracket (3) and insert the pin.
  52. Position the washer (1) and install the C-clip (2).
  53. Repeat on the opposite side.
    GC0157892Courtesy of CHRYSLER GROUP, LLC
  54. Manually close the roof fully.
  55. Insert the tension cable (1) through the rear corner of the folding top frame (3).
  56. Feed the cable (1) through the opening (2).
  57. Repeat on the opposite side.
    GC0157819Courtesy of CHRYSLER GROUP, LLC
  58. Thread the tension cable (1) onto the bracket (2). Repeat on the opposite side.
  59. Position the cable and bracket to the frame and loosely install the fastener.
  60. Repeat on the opposite side.
    GC0157770Courtesy of CHRYSLER GROUP, LLC
  61. Using (special tool #10321, Adapter, Cable Tension) (2), connect the cable tension adapter to the tension cable bracket (1).
  62. Using (special tool #8828A, Spring Gauge) (3), attach the pull gauge to the cable adapter (2).
  63. Set the pull gauge to 18 kg-force. (40 lbs.-force) and pull back until the spec is achieved.
  64. Tighten the fastener (1) securing the bracket (1) to the roof frame to 3 Nm. (26 lbf-in).
    GC0153497Courtesy of CHRYSLER GROUP, LLC
  65. Manually open the roof 20 cm (8 in).
  66. Position the tension bar to the cover.
    GC0153496Courtesy of CHRYSLER GROUP, LLC
  67. Loosely install the fasteners (1) into the tension bar.
  68. Manually close the roof fully.
    GC0157701Courtesy of CHRYSLER GROUP, LLC
  69. Tighten the fasteners (1) securing the linkage (2) to the spoiler reinforcement 9 Nm (80 lbf-in).
  70. Repeat on the opposite side.
    GC0157592Courtesy of CHRYSLER GROUP, LLC
  71. Tighten the fasteners (1), securing the linkage (2) adjustment to 9 Nm (80 lbf-in).
  72. Repeat on the opposite side.
    GC0157919Courtesy of CHRYSLER GROUP, LLC
  73. With the use of a flat bladed tool (3), lift the left side of the spoiler reinforcement (2) approximately 3 mm (1/8 in).
  74. Tighten the left outer fastener (1) to 8 Nm (71 lbf-in).
  75. Repeat on the right side.
  76. Tighten the left side inner fastener to 8 Nm (71 lbf-in).
  77. Repeat on the opposite side
    GC0157933Courtesy of CHRYSLER GROUP, LLC
  78. Tighten the fastener (1), securing the four bow end cap (2), to 9 Nm (80 lbf-in).
  79. Repeat on the opposite side.
    GC0153496Courtesy of CHRYSLER GROUP, LLC
  80. Tighten the tension bar fasteners to 9 Nm (80 lbf-in).
    GC0153495Courtesy of CHRYSLER GROUP, LLC
  81. Feed the spoiler harness in the opening on the cover.
  82. Engage the spoiler harness grommet to the cover and spoiler reinforcement.
  83. With the help of an assistant, align and position the spoiler (1) to the cover.
    GC0157799Courtesy of CHRYSLER GROUP, LLC
  84. Loosely install the four fasteners (1) securing the spoiler to the reinforcement (2).
    GC0158561Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The gap between the roof and the spoiler should be zero. If there is a gap wind noise and water leaks will occur.

  85. While the assistant applies downward pressure to the spoiler (1), tighten the four spoiler fasteners (1) to 5 Nm (45 lbf-in).
    GC0157731Courtesy of CHRYSLER GROUP, LLC
  86. Insert the spoiler wiring harness (1) routing clips into the spoiler reinforcement.
  87. Connect the wiring harness connectors (2).
  88. Clip the spoiler wiring connector (2) to the spoiler reinforcement.
    GC0157818Courtesy of CHRYSLER GROUP, LLC
  89. Insert the rear of the headliner (1) into the rear backlight/glass upper retaining channel.
    GC0157898Courtesy of CHRYSLER GROUP, LLC
  90. With the use of a wire tie (2) attach the headliner sail panel strap (1) and wiring harness (harness is left side only) to the linkage.
  91. Zip ties must be cut off flush to the head or headliner will get cut during roof movement.
  92. Repeat on the opposite side.
    GC0157591Courtesy of CHRYSLER GROUP, LLC
  93. Insert the sides of the headliner (1) into the rear window retaining channels.
  94. Repeat on the opposite side.
  95. Attach the lower headliner (2) hook and loop fastener to the rear window.
    GC0157598Courtesy of CHRYSLER GROUP, LLC
  96. Position the lower closeout panel aside and secure the headliner strap (2) hook and loop fastener.
  97. Install the push pin fasteners under the lower package tray closeout panel (3).
    GC0157579Courtesy of CHRYSLER GROUP, LLC
  98. Install the push pin fasteners (1) to the lower headliner.
  99. Secure the headliner strap (2) hook and loop fasteners on each side.
    GC0153493Courtesy of CHRYSLER GROUP, LLC
  100. Attach the spoiler wiring harness (1) to the cover.
  101. Position the C-pillar trim panel (1).
  102. Hand tap to engage the C-pillar trim panel (1) retaining tabs/clips.
  103. Install the fastener (2) and tighten securely.
  104. Repeat on the opposite side.
    GC0153223Courtesy of CHRYSLER GROUP, LLC
  105. Position the B-pillar trim panel (1).
  106. Hand tap to engage the B-pillar trim panel (1) retaining tabs/clips. Repeat on the opposite side.
    GC0153470Courtesy of CHRYSLER GROUP, LLC
  107. Position the rear shelf (2).
  108. Install the push pin retainers (3) to the rear shelf.
  109. Position the grab handle bracket (1).
  110. Install the three fasteners securing the grab handle bracket (1) to the rear shelf (2). Tighten the fasteners securely.
    GC0153489Courtesy of CHRYSLER GROUP, LLC
  111. Install the decklid weatherstrip (1).
    GC0153450Courtesy of CHRYSLER GROUP, LLC
  112. Install the decklid. Refer to DECKLID, CONVERTIBLE, INSTALLATION .
  113. Connect the negative battery cable.
    GC0153526Courtesy of CHRYSLER GROUP, LLC
  114. With the help of an assistant(s), cycle the cover (1) to the closed position while applying pressure to the front of the cover. Make sure the cover (1) is fully seated. Repeat process if necessary. 
  115. The cover will need to stay in the closed position for at least 30 minutes to properly stretch.
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