Body - Convertible Top Deck Lid Malfunctions
NUMBER: 23-042-03GROUP: Body
DATE: October 18, 2004
SUBJECT:
Decklid Will Not Open
MODELS:
2005 (ZH) Crossfire Roadster
DISCUSSION:
The decklid may not open due to a failure in the convertible top relating to the following conditions:
^ The decklid latch is inoperative.
^ The fifth bow is latched and the hydraulic system is inoperative.
^ The convertible top is in the closed (up) position.
If the technician has verified that all three conditions are present, this bulletin provides a procedure to gain access to the trunk so that the technician may diagnose and repair the condition that caused the decklid to not open.
NOTE:
If the convertible top is in the open (down) position or if the fifth bow is not latched, perform Step # 12 through Step # 28 to gain access to the trunk.
PARTS REQUIRED
SPECIAL TOOLS/EQUIPMENT REQUIRED
PROCEDURE TO GAIN ACCESS TO THE TRUNK:
1. Remove the B-pillar trim on each side of the vehicle, by removing the three screws (Fig. 1).
2. Tilt both of the seat backs forward and move both of the seats to the forward position.
3. Remove the umbrella hooks by removing the screws (Fig. 2).
4. Remove the seat belt bezel on each side by pulling the front sports bar trim out slightly and sliding the seat belt bezel upward.
5. Remove the front sports bar trim panel by removing the two plastic retainers (Fig. 2).
6. Remove the M bracket on the left sports bar (2 fasteners) (Fig. 3).
NOTE:
In order to gain access to and release the fifth bow latch you must cut a hole in the rear sports bar trim panel. After the decklid is opened the rear sports bar trim panel must be replaced.
7. Using the template (Fig. 4), mark the rear sports bar trim panel behind the left sports bar (Fig. 5).
8. Using duct tape, wrap the left Sports Bar to protect the finish during the next step.
9. Insert a 7 mm (9/32 in.) drill bit into the chuck of the drill motor and tighten the chuck. Place a piece of 8 mm (5/16 in.) I.D. rubber hose over the drill bit so that only about 13 mm (1/2 in.) of the drill bit is exposed at the tip of the drill bit. The rubber hose will act as a depth stop while drilling the holes. Drill a series of holes close together around the lines marked on the Rear Sports Bar Trim Panel (Fig. 6).
10. Using the drill & drill bit, connect the drilled holes until the piece separates (Fig. 7).
NOTE:
The next step is a blind operation. The technician will have to locate the latch release without being able to see what he is doing. The latch is located 559-610 mm (22-24 in.) from the Rear Sports Bar Trim Panel.
11. Using a 6 mm allen (hexagon) wrench from behind the left seat, reach through the cut out in the rear sports bar trim panel and unlatch the fifth bow for the convertible top (Fig. 8).
12. Lift the fifth bow to the upright position. Using two 76 mm (3 in.) wide strips of masking tape; up the entire back window around the fifth bow and up to the windshield, secure the top in the upright position (Fig. 9).
13. Using the multi-function tool, supplied with the vehicle, unlock the tonneau cover (Fig. 10).
NOTE:
If the multi function tool is not available, a thin 178 mm (7 in.) long 10 mm open end wrench will also work. For example a Snap-On combination wrench, p/n 0EXLM10B.
14. Open the tonneau cover. Using two 76 mm (3 in.) wide strips of duct tape (or equivalent), secure the tonneau cover in the upright position (Fig. 11).
NOTE:
Place the duct tape so that the decklid may be opened without moving the duct tape (Fig. 11).
15. Vacuum the debris from the top storage area and from behind the left seat.
16. Lift the trunk separator, move it slightly rearward and let it come down and fold the trunk separator twice, into the forward most position to get access to the decklid lid trim panel (Fig. 12).
17. With the technician laying on his back in the top storage area, reach through from the top storage area, loosen and remove the Torx head screw (size T20) behind the emergency release handle (Fig. 13).
18. Remove the decklid trim fasteners (11) (Fig. 13).
19. Move the decklid trim panel to gain access to the decklid latch.
20. With the technician laying on his back in the top storage area; reach through from the top storage area and reposition the deck lid latch blocker by pushing the blocker toward the passenger side with a screwdriver (Fig. 14).
21. Remove the duct tape and lower the Tonneau cover. Lock the tonneau cover using the multi function tool provided with the vehicle (Fig. 15).
22. Lower the convertible top fifth bow.
23. Open the decklid.
24. Diagnose and repair the condition that caused the decklid latch blocker to stick.
25. Install the decklid trim panel.
26. Using the 6 mm allen (hexagon) wrench, reaching through the trunk from the rear of the vehicle, latch the fifth bow.
27. Close the decklid.
28. Remove the duct tape that was placed on the Sports Bar in Step # 8.
29. Replace the rear sports bar trim panel, p/n 1AW36XDVAA, that was cut in Step # 9 by removing the rear sports bar trim panel bolts from between both Sports Bars and the single bolt under the Tonneau cover near the latch.(Fig. 12).
POLICY:
Information Only
Disclaimer
This bulletin is supplied as technical information only and is not an authorization for repair.