Convertible Top Chevrolet Cavalier III

DESCRIPTION & OPERATION

Convertible top is controlled electrically by a switch and relay, and is powered by 2 direct-current reversible motors. Convertible top control switch is part of header latch handle assembly and is located in center of windshield header. The 2 front header latch receivers (located at outer corners of windshield header) are used to secure convertible top when in the raised position. When latch handle assembly is rotated up, latch receiver link rod pins are engaged.

Convertible top drive motors are mounted to main pivot bracket assembly at base of rear rails and drive convertible top assembly through gears. (Scheme 4)

With ignition switch in RUN position, voltage is applied to convertible top switch through power accessory fuse. Moving convertible top switch to UP or DOWN position energizes convertible top relay and supplies power and ground to both motors. Voltage to operate motors is supplied by power window circuit breaker, via convertible top relay.

Both left and right-side motors are used to open and close convertible top. These motors are electrically connected together for opening and closing top. Depending on position of convertible top switch, convertible top relay supplies power and ground to either side of motors, depending on desired direction of travel.

Scheme 4

COMPONENT LOCATIONS

COMPONENT LOCATIONS

NO. 1 BOW-TO-HEADER SURFACE

1. Raise convertible top to a suitable working height above windshield header. Using a grease pencil, mark striker location. Loosen striker retaining nuts and remove or add shims to maximum of 4 per side. (Scheme 5) Align striker with marks and snug nuts. DO NOT tighten nuts at this time.
2. Latch convertible top to windshield header. Raise convertible top off of header and tighten nuts to 97 INCH lbs. (11 N.m). Latch convertible top to windshield header. Front edge of No. 1 bow should be flush with windshield header surface.

Scheme 5

STRIKER TO RECEIVER

1. Raise convertible top to a suitable working height above windshield header. Loosen striker retaining nuts and adjust striker to desired position. DO NOT tighten nuts at this time.
2. Insert and latch convertible top to windshield header. Raise convertible top off of header and tighten all nuts to 97 INCH lbs. (11 N.m). Striker latch should drive directly into striker latch receiver. (Scheme 5)

UPSTOP

1. Remove quarter trim panel. Unlatch and lower convertible top. Loosen upstop jam nut and lower upstop. (Scheme 6) Raise and latch convertible top. Raise upstop until it contacts rear rail. Unlatch and lower convertible top.
2. Raise upstop an additional 1/4-1/2 turn and tighten jam nut to 17 ft. lbs. (23 N.m) while holding upstop in position. Raise and latch convertible top. Install quarter panel trim.

Scheme 6

SIDE RAIL CROWN

1. To correct side rail misalignment and/or lack of parallelism to upper edge of door and quarter window glass, unlatch convertible top from windshield header. Operate convertible top to half-lowered position. Turn center rail adjusting screw in to increase or out to decrease side rail assembly crown. (Scheme 7)
2. Return convertible top to windshield header and latch convertible top to check alignment of side rails to door and quarter window glass upper edge. Repeat adjustment as necessary until side rail assembly is parallel to door and quarter window glass. (Scheme 7)
3. Raise and latch convertible top. Note striker-to-receiver contact. Striker should enter receiver enough to allow receiver pin engagement without additional help pulling convertible top down.

Scheme 7

FRONT DOOR GUIDE PIN

Ensure door-to-body alignment is correct before aligning front door guide pin. Close door lightly (do not latch). Door guide pin should be centered to door pin locator. Using grease pencil, mark front door guide pin location on door. Loosen guide pin screws. Move guide pin to desired location. Hold guide pin in place, tighten screws to 97 INCH lbs. (11 N.m).

FRONT DOOR GUIDE PIN LOCATOR

Ensure door-to-body alignment is correct before aligning front door guide pin locator. Close door lightly (do not latch). Using grease pencil, mark front door guide pin locator location on lock pillar. Loosen guide pin locator screws. Note number of shims under guide pin locator. Adjust shim thickness by adding or subtracting shims. Hold guide pin locator in place, tighten screws to 97 INCH lbs. (11 N.m).

DOOR WINDOW TOO HIGH OR TOO LOW IN UP POSITION

Loosen bolt on front upstop channel adjust bracket and adjust as necessary. Loosen bolt on rear upstop channel bracket and adjust as necessary. Rear upstop adjustment may be required to adjust top of door window inboard or outboard. (Scheme 8)and (Scheme 9). Higher adjustment brings top of glass inward. Tighten bolts to 53 INCH lbs. (6 N.m).

Scheme 8

Scheme 9

DOOR WINDOW UPPER INBOARD/OUTBOARD

Loosen rear channel adjusting nut washer. Adjust as necessary by turning double ended stud inward or outward. (Scheme 9) Rear upstop adjustment may be required to adjust top of door window inboard or outboard. Higher adjustment brings top of glass inward. Tighten bolts to 88 INCH lbs. (10 N.m).

WINDOW UNSTABLE IN UP POSITION

With glass in full down position, loosen front lock nut and adjust stabilizer setscrew until door glass stabilizer contacts door window glass. Raise door glass to full up position. Loosen rear lock nut. Adjust stabilizer setscrew until door glass stabilizer contacts door window glass. (Scheme 10) Operate window. Check for binding. Readjust rear stabilizer screw as necessary. Tighten lock nut to 53 INCH lbs. (6 N.m).

Scheme 10

QUARTER WINDOW FORE/AFT, INBOARD/OUTBOARD & UP/DOWN

Ensure door windows are in full up position with correct alignment to "A" pillar and side rail seals. Remove quarter trim panel. Mark locations of adjustment nut washers. Loosen screws enough to disengage quarter window front drive link from quarter window rear drive link. Perform the following adjustments as necessary

Window Is Too Far Forward/Rearward

Loosen nut washers. Adjust quarter window as necessary. Tighten nut washers to 88 INCH lbs. (10 N.m).

Window Is Too High/Low In Up Position

Loosen nut washers. Adjust quarter window as necessary. (Scheme 10) Tighten nut washers to 88 INCH lbs. (10 N.m).

Window Rolls Up Inboard Or Outboard Of Door Glass

Adjust window as necessary by rotating adjustment studs. Start with bottom stud. Turning clockwise moves top of window outboard. Counterclockwise moves top of window inboard. Two top studs adjust window inboard/outboard to quarter panel.

Quarter Window Sash Is Not Parallel To Door Glass Rear Edge

Raise or lower upstop adjustment bolt and/or lengthen or shorten drive link assembly at front-to-rear link connection. Tighten screws to 106 INCH lbs. (12 N.m).

Note. After adjustments are complete, open and close convertible top several times. Check quarter window alignment. Install quarter trim panel.

TROUBLE SHOOTING

Note. Convertible top may also be referred to as folding top.

1. Check PWR ACC fuse (20-amp) by operating power door locks.
2. If PWR ACC fuse blows when replaced, check for faulty convertible top switch or short to ground in Orange wire between fuse block and convertible top switch.
3. Check PWR WINDOW CIRCUIT BREAKER (30-amp) by operating power windows.
4. If PWR WINDOW CIRCUIT BREAKER cycles repeatedly when replaced, check for faulty folding top relay or short to ground in Brown wire between fuse block and folding top relay.
5. Ensure top is not binding or folding unevenly.
6. Check for broken or damaged wiring. Check for proper installation of aftermarket electronic equipment which may affect integrity of other systems.

SYSTEM TESTS

SYSTEM CHECK

1. Turn ignition switch to RUN position. Release convertible top latches and lower all side windows. Remove any items that could obstruct convertible top operation. Move convertible top switch to DOWN position. Top should lower quietly without binding or skewing.
2. Move convertible top switch to UP position. Top should raise quietly and smoothly without binding or skewing.

Note. Check fuses before performing test.

1. Disconnect Natural 3-pin convertible top switch connector located at header latch handle assembly. Turn ignition switch to RUN position. Connect fused jumper wire between switch harness connector terminals "B" (Orange wire) and "C" (Light Blue wire). If top operates, go to next step. If top does not operate, go to step 3 .
2. Replace convertible top switch. Recheck system operation.
3. Disconnect Black, 6-pin convertible top relay connector. Connect test light between convertible top relay connector terminal "A" (Light Blue wire) and ground. Press convertible top switch in DOWN position. If test light illuminates, go to next step. If test light does not illuminate, go to step 5 .
4. Replace convertible top relay. Recheck system operation.
5. Using DVOM, measure resistance of Light Blue wire between convertible top switch harness connector terminal "C" and relay harness connector terminal "A". If resistance is not 0-2 ohms, go to next step. If resistance is 0-2 ohms, go to step 7 .
6. Repair open in Light Blue wire between convertible top switch and relay. See «WIRING DIAGRAMS»(/chevrolet/cavalier/iii-1995-2005/remont/sun-rooft-topconvertible-top/#convertible-top) . Recheck system operation.
7. Using DVOM, check for continuity between ground and convertible top switch connector terminal "C" (Light Blue wire). If continuity exists, go to next step. If continuity does not exist, system is okay.
8. Repair short to ground in Light Blue wire between convertible top switch and relay. See «WIRING DIAGRAMS»(/chevrolet/cavalier/iii-1995-2005/remont/sun-rooft-topconvertible-top/#convertible-top) . Recheck system operation.

Note. Check fuses before performing test.

1. Disconnect Natural 3-pin convertible top switch connector located at header latch handle assembly. Turn ignition switch to RUN position. Connect fused jumper wire between switch harness connector terminals "B" (Orange wire) and "A" (Tan wire). If top does not operate, go to step 3 . If top operates, go to next step.
2. Replace convertible top switch. Recheck system operation.
3. Disconnect Black, 6-pin convertible top relay. Connect test light between convertible top relay harness connector terminal "F" (Tan wire) and ground. Press convertible top switch in UP position. If test light illuminates, go to next step. If test light does not illuminate, go to step 5 .
4. Replace convertible top relay. Recheck system operation.
5. Using DVOM, measure resistance of Tan wire between convertible top switch harness connector terminal "A" and relay harness connector terminal "F". If resistance is not 0-2 ohms, go to next step. If resistance is 0-2 ohms, go to step 7 .
6. Repair open in Tan wire between convertible top switch and relay. See «WIRING DIAGRAMS»(/chevrolet/cavalier/iii-1995-2005/remont/sun-rooft-topconvertible-top/#convertible-top) . Recheck system operation.
7. Using DVOM, check for continuity between ground and convertible top switch connector terminal "A" (Tan wire). If continuity exists, go to next step. If continuity does not exist, system is okay.
8. Repair short to ground in Tan wire between convertible top switch and relay. See «WIRING DIAGRAMS»(/chevrolet/cavalier/iii-1995-2005/remont/sun-rooft-topconvertible-top/#convertible-top) . Recheck system operation.

Removal & Installation

1. Disconnect battery cable. Unlatch convertible top. Remove right and left-side quarter trim panels. Remove headliner retainer screws at quarter inner structure and close-out panel below window. Disconnect rear window defroster electrical connector.
2. Remove bolt, washer and bushing from quarter window drive links and spur gears. Carefully lower quarter windows.
3. Disconnect drive motor harness connectors, noting harness routing. Remove retainers and fold closeout panel trim forward. Remove back belt molding. Remove right and left-side quarter panel belt outer molding. Remove staples retaining top cover and stay pads to quarter belt tack strip.
4. Using an 1/8" drill bit, drill out top cover-to-quarter belt flange rivets. Remove main pivot bracket-to-mounting bracket nut washers. Note and retain shims. With help from assistant, remove convertible top assembly. To install, reverse removal procedure. Ensure quarter window drive links are guided into main pivot bracket.
5. Convertible top assembly should be unfolded or in UP position during installation to allow access to main pivot brackets. Tighten main pivot bracket nut washers to 17 ft. lbs. (23 N.m). Apply Loctite to quarter window drive link bolts. Install and tighten to 18 ft. lbs. (25 N.m).

1. Unlatch and lower top. Disconnect battery cable. Remove windshield molding. Remove retaining screw from receiver pin. (Scheme 11)
2. Disconnect harness connector. Remove header latch handle assembly from windshield frame. Remove switch from header latch handle assembly. To install, reverse removal procedure.

Scheme 11

DRIVE MOTOR ASSEMBLY (TOP DOWN)

Note. This procedure applies to 1999 models only. Information for 2000 models is not available from manufacturer.

Note. If convertible top drive motor has seized and top is lowered, place convertible top by-pass switch (located under shelf panel in driver's side of trunk compartment) into EMERGENCY OVERRIDE (down) position. Using template and instructions provided with new motor, drill holes to access drive motor bolts.

1. Disconnect negative battery cable. Remove quarter trim panel. Remove headliner screws from structure and position headliner aside.
2. Remove No. 4 bow slat-to-pivot bracket bolt and spacer (leave bushing in slat). Remove rear rail pivot bolt and nut at main pivot bracket. Apply Loctite to No. 4 bow slat-to-main pivot bracket bolt and reinstall pivot bracket spacer. Tighten bolt to 17 ft. lbs. (23 N.m).
3. Lift rear rail and spur gear off of convertible top drive motor gear and, with aid of a helper, raise convertible top to closed position. DO NOT latch to windshield header. Apply Loctite to pivot bolt and install to rear rail with nut. Tighten bolt to 17 ft. lbs. (23 N.m). NOTE: Only 3 bolt positions are used. Motor mounting bolts must be installed in same positions as removed.
4. Remove bolts and lock washers retaining drive motor to main pivot bracket assembly. Remove convertible top motor by lowering motor from bottom of main pivot bracket. To install, place by-pass switch in NORMAL OPERATION position and reverse removal procedure. Apply Loctite to motor mounting bolt threads and tighten to 106 INCH lbs. (12 N.m). (Scheme 4)

DRIVE MOTOR ASSEMBLY (TOP UP)

Note. Convertible top must be in raised position to service top drive motor. If convertible top will not raise, see DRIVE MOTOR ASSEMBLY (TOP DOWN) .

1. Disconnect negative battery cable. Unlatch convertible top from windshield header. Remove quarter trim panel. Remove headliner screws at rear rail and quarter panel structure. Fold headliner aside to access convertible top drive motor assembly. Note wire harness routing. Disconnect drive motor connector. NOTE: Only 3 bolt positions are used. Motor mounting bolts must be installed in same positions as removed.
2. Remove bolts and lock washers retaining drive motor to main pivot bracket assembly. Remove convertible top motor by lowering motor from bottom of main pivot bracket. To install, reverse removal procedure. Apply Loctite to motor mounting bolt threads and tighten to 106 INCH lbs. (12 N.m). (Scheme 4)

Raise No. 1 bow off windshield header to a suitable working height. Remove striker mounting nuts, header latch striker and shims. To install, reverse removal procedure. After installation, adjust striker. See STRIKER TO RECEIVER under ADJUSTMENTS. (Scheme 5)

See also:
• WIRING DIAGRAMS
• DRIVE MOTOR ASSEMBLY (TOP DOWN)
• STRIKER TO RECEIVER