Frame, Folding Top: Installation
Always use Urethane to bond Folding Top Fame to the vehicle. Never use products such as Silicone or other types of adhesives, as this will jeopardize the integrity of the roof system
Failure to follow these instructions may result in serious or fatal injury
Protect all exposed painted and trimmed surfaces from coming in contact with urethane and primers
- If re-using the original body side apertures, headers or the folding top frame, it will be necessary to remove the remaining urethane bead (1) down to a maximum height of 1mm. Use a gasket scraper (2) or equivalent to trim as close as possible to the part without cutting into the part or damaging the paint.
- Place replacement weatherstrip (1) face down on a clean and dry surface.
- Alcohol wipe (2) entire weatherstrip mating surface (bottom) and allow to dry for one minute.
- Clean top surface of folding top frame with wax and grease remover, per manufacture recommendations.
- Alcohol wipe the entire folding top frame area that the weatherstrip will make contact. Allow to dry for one minute.NOTE:
It is crucial that there are no skips or voids in the butyl bead.
- Apply 4 mm of butyl (3) to the entire perimeter of the weatherstrip (2) mating surface. Butyl is to be placed between guide lines (1).NOTE:
Right side shown, left side typical.
- Apply a 3-4 mm bead of weatherstrip adhesive to the outboard edge next to the butyl. From the front corners, the adhesive is to extend inward 300 mm (12 in) and 500 mm (20 in) rearward.NOTE:
Right side shown, left side typical.
NOTE:Care should be taken to avoid any contact with the adhesive and butyl areas of the weatherstrip.
- With the aid of an assistant, place the folding top frame positioned with the top down over the weatherstrip.
- Insert the weatherstrip alignment square tab (2) located on the right and left side of the weatherstrip (1) into the alignment square holes (3) located on the left and right rear corners of the folding top frame (4).
- Tuck the front corners (1) of the weatherstrip onto the folding top frame (3).
- Working toward the center, tuck the outer lip of the weatherstrip (2) onto the outer edge of folding top frame (1).
- Repeat until the right, left and front areas have been completed.
- Inspect the entire perimeter of the folding top frame to be certain the lip of the weatherstrip is properly seated.
- Gently remove the protective tape from the butyl.NOTE:
A small wooden roller (2), or equivalent, should be used to aid in evenly compressing the butyl.
CAUTION:THIS STEP IS CRITICAL, if not done correctly leaking may occur
- Firmly compress the weatherstrip, starting at the ends and working towards the center.NOTE:
Weatherstrip installation is complete, continue with prepping of vehicle and folding top frame.
NOTE:Any areas with an existing urethane bead should be trimmed down to no more than 1 mm, as explained in the folding top frame removal procedure.
- Allow the weatherstrip adhesive to cure per manufacturer recommendations.
- Use alcohol wipes (2) to clean the roof opening perimeter mating surfaces.
- Alcohol wipe (2) the folding top frame (1) mating surface where urethane bead is to be applied.
- Alcohol wipe the body side aperture, front header and rear header.
- Allow areas that have been treated with alcohol wipes to dry for 1 minute.NOTE:
Follow the urethane primer manufacturer recommendations for application and dry time.
- Apply urethane primer to any paint that may have been damaged on the roof flanges and headers during removal, ONLY within any area that the weatherstrip and frame will cover.
- If the body side apertures or headers have been refinished, apply urethane primer to the mating surfaces.
- If installing a new folding top frame, prime the mating surface area.
Urethane bead placement is as follows:
- Front (2) - 6 mm from edge of curve to edge of urethane
- Sides (3) - 4 mm from edge of weatherstrip to edge of urethane
- Rear Center (1) - 10 mm from bevel to edge of urethane
- Rear Sides (4) - 10 mm from bevel to edge of urethane
NOTE:Use Mopar Part # 04864015AB urethane to install the folding top frame. Follow the recommendations for work and handling the urethane.
- Cut a 6 X 11 mm. notch in the urethane tube nozzle (1) as shown.
- Apply a 8 X 13 mm bead of urethane to the pre-primed area of the frame, using a power caulk gun or equivalent. Start and finish at the rear center of the frame.
- With one person on each corner, carefully place folding top straight and evenly down upon the roof, allow the mounting fastener holes to aid in proper alignment.
- Visually verify that the urethane has made complete touch-down to the roof around the entire perimeter.NOTE:
Proceed to frame fastening procedures before urethane is totally cured.
- Accessing from the vehicle interior, loosely install the front fastener (1) securing the frame to the vehicle. Repeat on the opposite side.
- Loosely install the two fasteners (1) located under the package tray securing the package tray/frame to the vehicle.
- Accessing from the vehicle interior, loosely install the fastener (1) located in the lower C-pillar area just above the package tray that secures the frame to the vehicle. Repeat on the opposite side.
- Accessing from the vehicle interior, loosely install the fastener (1) located in the upper C-pillar area securing the frame to the vehicle. Repeat on the opposite side.
- Install the three fasteners (1) securing the lower rear portion of the frame to the body.
- Tighten all frame fasteners to 8 Nm (71 lbf-in).
- Allow the urethane to cure per manufacturer recommendations.
- Using appropriate tools, carefully install the windshield (1) to the vehicle.WARNING:
To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment.
WARNING:To avoid serious or fatal injury when removing a deployed airbag, rubber gloves, eye protection, and a long-sleeved shirt should be worn. There may be deposits on the airbag unit and other interior surfaces. In large doses, these deposits may cause irritation to the skin and eyes.
WARNING:To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the side curtain airbag, or becoming entrapped between the side curtain airbag cushion and the headliner. Failure to observe this warning could result in occupant injuries upon airbag deployment.
NOTE:At no time should any source of electricity be permitted near the inflator on the back of a non-deployed airbag or seat belt tensioner. When carrying a non-deployed airbag, the trim cover or airbag cushion side of the unit should be pointed away from the body to minimize injury in the event of an accidental deployment. If the airbag unit is placed on a bench or any other surface, the trim cover or airbag cushion side of the unit should be face up to minimize movement in the event of an accidental deployment.
NOTE:The Side AirBag Inflatable Curtain (SABIC) is color-coded for the side of the vehicle onto which it will be installed. The left side SABIC will have blue tape at the rear end of the cushion and a blue label beneath the inflator. The right side SABIC will have red tape at the rear end of the cushion and a red label beneath the inflator.
NOTE:Be certain that the airbag cushion is not twisted during installation. A black stripe extends along the entire inboard length of the cushion. If this stripe is visible anywhere along the outboard length of the cushion, the SABIC is twisted and must be untwisted before it is secured to the roof side rail.
- Position and insert the T-tab at the front of the SABIC inflator (5) into the slotted hole in the inner roof side rail (1).
- Engage the hook of the bracket at the back of the SABIC inflator into the slotted hole in the inner roof side rail.
- Align and insert the locating hooks of the metal mounting tabs on the SABIC into the locating holes in the inner roof side rail. Check that the black stripe along the inboard length of the cushion faces inboard to confirm the cushion is not twisted.
- Align and insert the plastic push-in fastener through the mounting tab on the SABIC front tether (2) and into the inner A-pillar (3) until it is fully seated.
- Loosely install three screws. One goes through the bracket at the back of the inflator into the inner roof side rail and two (1) go through the metal mounting tabs forward of the inflator into the inner roof side rail.
- Align and insert the anti-rotation tab at the end of the front tether into the hole in the inner A-pillar and loosely install the screw that secures it.
- Tighten the four screws in the following sequence to 9 Nm (80 lbf-in).
- Bracket at the back of the inflator.
- Mounting tab at the front of the B-pillar.
- Mounting tab over the door window opening.
- Tab at the end of the front tether.
- Align and insert the locating hook of the metal mounting tab on the SABIC behind the inflator into the locating hole in the inner C-pillar. Check that the black stripe along the inboard length of the cushion faces inboard to confirm the cushion is not twisted.
- Loosely install the screw that secures the metal mounting tab to the inner roof side rail.
- Align and position the mounting tab at the end of the rear tether over the stud on the inner C-pillar.
- Install and tighten the nut that secures the rear tether mounting tab to the inner C-pillar. Tighten the nut to 9 Nm (80 lbf-in).
- Tighten the screw that secures the metal mounting tab on the SABIC behind the inflator to the inner roof side rail. Tighten the screw to 9 Nm (80 lbf-in).
- Reconnect the body wire harness connector for the SABIC to the connector receptacle at the back of the inflator. Be certain the connector is fully engaged and locked.
- Reinstall the headliner into the vehicle. Refer to HEADLINER, INSTALLATION .
- Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) Verification Test procedure should be performed following service of any SRS component. Refer to SUPPLEMENTAL RESTRAINT SYSTEM VERIFICATION TEST
.
- Position the headliner side rail (2).
- Install the fastener (1) securing the tether to the airbag.
- Hand tap the headliner side rail to engage the retaining clips.
- Position the coat hook (1) in the "9 o'clock" position, push in and twist clockwise to the "12 o'clock" position.
- Position the front header cover (1).
- Hand tap the front header cover (1) to engage the retaining tabs.
- Install the rivet (2) located in the dome lamp cavity securing the front header cover (1) to the roof header.
- Install the dome lamp and power top switch. Refer to SWITCH, POWER TOP, FULL OPEN RETRACTABLE ROOF, INSTALLATION .
- Install the visor support and visor (2). Refer to SUPPORT, VISOR, INSTALLATION and VISOR, INSTALLATION .
- Position and slide the rear view mirror (2) downward over the support bracket/button on the inside of the windshield glass until the tab is fully engaged.
- Connect the harness (1) to the rear view mirror (2).
- Install the harness cover (1).
- Install the cover (2) located on the rear of the mirror.multimedia:A supplement to the article is available.
- Position the cover to the vehicle.
- On the folding top cover, fold the 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.
- Fold the folding top cover (1) as shown.
- 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
- Insert the left and right front roof bow slider blocks (1) into the left and right rail channel ends (2) simultaneously.
- Slide the cover up the rails and insert the second set of roof bow slider blocks into the rails simultaneously.
- Keeping the cover in the folded position, slide the cover up into the center of the roof opening.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 slide bracket (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.
- Insert the right folding top slide bracket (1) into rear of the folding top rail. Left and right are not interchangeable. They can be identified by an inboard side forward facing arrow.
- There is a notch on the top of the rail in the C-pillar area, align the folding top slide bracket (1) to the slot.
- Turn the right side folding top slide bracket front screw a half turn counter clockwise, while gently moving the folding top slide bracket slightly back and forth, to engage the arm into the roller assembly.
- Position the left folding top slide bracket to the notch on the top of the rail in the C-pillar area, align the folding top slide bracket to the slot (1).
- Turn the left side folding top slide bracket front screw a half turn clockwise, while gently moving the folding top slide bracket slightly back and forth, to engage the arm into the roller assembly.
- Position the rear stop block into to the rear of the rail.
- Install the fastener (2) securing the rear stop block (1). Tighten the fastener to 3 Nm (27 lbf-in).
- Repeat on the opposite side.
- 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
- Attach the seal end (2) at the bottom of the rear track cover (1).
- Position the linkage arm (2) end with the O-ring bushing (1) in place, into the hole in the folding top slider bracket (3).
- Repeat on the opposite side.
- 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.
- 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.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.
- If necessary, pull the front tension belt (2) through the tension belt clip (1),
- Align to the mark (3) on the tension belt (2) to the front edge of the clip (1).
- Secure clip (1).
- Inspect the tension belt to be certain it is completely routed.
- 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).
- Position the tension belt (1) to the lifting arm (2).
- Install the rivet (3) and repeat on the opposite side.
- Position the front bow (1) to the lifting arm brackets (2).
- Loosely install the front bow bolts (3 and 4). Repeat on the opposite side.
- While pushing the center of the front bow forward, tighten the left outer fastener (3) to 9 Nm (80 lbf-in).
- Repeat on the right outer fastener.
- Tighten the left inner fastener to 9 Nm (80 lbf-in).
- Repeat on the right outer fastener.
- Align the center mark on the headliner to the mark on the front bow.
- Insert the edge of the headliner (2) into the front roof bow (1).
- Using trim stick (special tool #C-4755, Trim Stick) or equivalent, tuck the headliner front edge in fully.
- Loosely install the fastener (1) with sleeve into the four bow end cap (2). Do not tighten at this time.
- Repeat on the opposite side.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.
- Route the defroster harness along the bracket.
- Install zip ties (1) to the harness. Cut zip tie ends off flush to the head.
- Connect defroster wire connector onto the backlight terminal.
- Route the harness into the back glass channel.
- Install zip ties to the harness. Cut zip tie end off flush to the head.
- Repeat on the opposite side.
- Position the headliner tether (1) to the linkage.
- Insert the fastener (2) and engage the pin (3) fully.
- Accessing from inside the vehicle, place the three washers (3) between the backlight/glass linkage (2) and the mounting bracket.
- Install the nylon washer and fastener (1).
- Tighten the fastener to 9 Nm. (80 lbf-in).
- Repeat on the opposite side.
- Position the linkage (4) and backlight bracket (3) and insert the pin.
- Position the washer (1) and install the C-clip (2).
- Repeat on the opposite side.
- Manually close the roof fully.
- Insert the tension cable (1) through the rear corner of the folding top frame (3).
- Feed the cable (1) through the opening (2).
- Repeat on the opposite side.
- Thread the tension cable (2) onto the bracket (1). Repeat on the opposite side.
- Position the cable and bracket to the frame and loosely install the fastener.
- Repeat on the opposite side.
- Using (special tool #10321, Adapter, Cable Tension) (2), connect the cable tension adapter to the tension cable bracket (1).
- Using (special tool #8828A, Spring Gauge) (3), attach the pull gauge to the cable adapter (2).
- Set the pull gauge to 18 kg-force. (40 lbs.-force) and pull back until the spec is achieved.
- Tighten the fastener (1) securing the bracket (1) to the roof frame to 3 Nm. (26 lbf-in).
- Manually open the roof 20 cm (8 in).
- Position the five bow/bracket to the cover.
- Loosely install the fasteners (1) into the five bow/bracket.
- Connect the electrical connector to the motor (2) and the module (1).
- Route and secure wiring harness to the rear shelf.
- Align and position the motor cover plate (2).
- Install the four rivets (1) securing the motor cover plate (2).
- Manually close the roof fully.
- Tighten the fasteners (1) securing the linkage (2) to the spoiler reinforcement 9 Nm (80 lbf-in).
- Repeat on the opposite side.
- Tighten the fasteners (1), securing the linkage (2) adjustment to 9 Nm (80 lbf-in).
- Repeat on the opposite side.
- With the use of a flat bladed tool (3), lift the left side of the spoiler reinforcement (2) approximately 3 mm (1/8 in).
- Tighten the left outer fastener (1) to 8 Nm (71 lbf-in).
- Repeat on the right side.
- Tighten the left side inner fastener to 8 Nm (71 lbf-in).
- Repeat on the opposite side
- Tighten the fastener (1), securing the four bow end cap (2), to 9 Nm (80 lbf-in).
- Repeat on the opposite side.
- Tighten the five bow bracket fasteners to 9 Nm (80 lbf-in).
- Feed the CHMSL harness in the opening on the cover.
- Engage the CHMSL harness grommet to the cover and spoiler reinforcement.
- With the help of an assistant, align and position the spoiler (1) to the cover.
- Loosely install the four fasteners (1) securing the spoiler to the reinforcement (2).
- While the assistant applies downward pressure to the spoiler, tighten the four spoiler fasteners (1) to 5 Nm (45 lbf-in).
- Insert the CHSML wiring harness (1) routing clips into the spoiler reinforcement.
- Connect the wiring harness connectors (2).
- Clip the CHMSL wiring connector (2) to the spoiler reinforcement.
- Insert the rear of the headliner (1) into the rear backlight/glass upper retaining channel.
- 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.
- Zip ties must be cut off flush to the head or headliner will get cut during roof movement.
- Repeat on the opposite side.
- Insert the sides of the headliner (1) into the rear window retaining channels.
- Repeat on the opposite side.
- Attach the lower headliner (2) hook and loop fastener to the rear window.
- Position the lower closeout panel aside and secure the headliner strap (2) hook and loop fastener.
- Install the push pin fasteners under the lower package tray closeout panel (3).
- Install the push pin fasteners (1) to the lower headliner.
- Secure the headliner strap (2) hook and loop fasteners on each side.
- Attach the CHMSL wiring harness (1) to the cover.
- Position the C-pillar trim panel (1).
- Hand tap to engage the C-pillar trim panel (1) retaining tabs/clips.
- Install the fastener (2) and tighten securely.
- Repeat on the opposite side.
- Position the B-pillar trim panel (1).
- Hand tap to engage the B-pillar trim panel (1) retaining tabs/clips. Repeat on the opposite side.
- Position the rear shelf (2).
- Install the push pin retainers (3) to the rear shelf.
- Position the bracket (1).
- Install the three fasteners securing the bracket (1) to the rear shelf (2). Tighten the fasteners securely.
- If necessary, install the decklid weatherstrip (1).
- Install the decklid. Refer to DECKLID, CONVERTIBLE, INSTALLATION .
- Connect the negative battery cable.
- 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.
- The cover will need to stay in the closed position for at least 30 minutes to properly stretch.