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Home >> Mitsubishi >> 1999 >> Eclipse Spyder GS-T L4-1997cc 2.0L DOHC Turbo MFI >> Repair and Diagnosis >> Body and Frame >> Roof and Associated Components >> Convertible Top >> Service and Repair >> Top Cover Assembly

Top Cover Assembly




REMOVAL AND INSTALLATION

REMOVAL SERVICE POINTS




[A] TOP COVER REMOVAL FROM NO.1 BOW
Detach the top cover from the No.1 bow.
1. Create a No.1 bow reference line on the top cover. Mark the leading edge of the No.1 bow on the top cover which will be used to align the top cover (old or new) to the No.1 bow.

NOTE: If the old top cover will be reinstalled, use a marking utensil that can be easily wiped off the top cover leaving no residue.

2. Peel the top cover from the length of the No.1 bow and the end flaps.
3. Using an 1/8 in. drill, remove the rivet securing the side retention cable at both sides of the topstack.

[B] TOP COVER REMOVAL FROM NO.2 AND 3 BOWS
Pull the top cover listing strip material from the bows.

[C] TOP COVER REMOVAL FROM NO.4 BOW
Pull the top cover listing strip material from the bow.

[D] TOP COVER REMOVAL FROM REAR RAILS
Pull the top cover sail panel material from the rear rails.




[E] TOP COVER REMOVAL FROM NO.5 BOW
Detach the top cover from the No.5 bow.
1. From inside the convertible top assembly, accurately mark the top edge of the bow on the the inside surface of the top cover.
2. Use an awl to remove the staples.




NEW TOP COVER PRE-INSTALLATION SERVICE POINT
Prepare the new top cover assembly.
1. On a suitable, clean work surface, cut the old top cover material just ahead of the backlite seam. The old backlite portion will be used to make a template.




2. On the old top cover, on the No.5 bow reference line, accurately cut on the line.

NOTE: At this time, do not discard the thin strip of top cover material. When installing the new top cover, use it for determining quantity and location of staples.




3. On the old top cover, at the No.1 bow leading edge reference line, accurately cut on the line. Discard the thin strip of top cover material.




4. Place the new top cover, outside surface face-up, on a clean, flat work surface. The backlite portion must be flat.
5. Position and align the old backlite portion over the same portion of the new top cover. Be sure the backlite openings and seams are aligned. Clamp, hold or place weighted bags on the top covers to keep them aligned.
6. Create the tackstrip alignment line for the new top cover. Transfer the line from the old top cover to the new by drawing along the recently cut line and onto the new top cover.

NOTE: Be sure to examine the reference line as you go to ensure it is accurate. Otherwise, the top cover may have wrinkles (too loose), or may cause excessive latching effort (too tight), and/or the backlite may bind or catch on the back belt moulding as it exits or enters the topstack well area during operations.

7. Repeat the above procedure for reference line at the No. 1 bow using the front portion of the top cover.

INSTALLATION SERVICE POINTS

[A] TOP COVER TO NO.1 BOW INSTALLATION

NOTE: If the top cover is off the vehicle, lay it in position on the topstack.

Check that the top cover side retention cables are in their top cover pockets. If they are not, attach a length of stiff wire to them and fish them back through the top cover pockets.
1. Attach the cable to the front rail with a 0.125 in. x 0.500 in., protruding head, stainless steel rivet.
2. Inspect the No.1 bow and the old top cover (if it is being reinstalled) for adhesive tape that may been damaged during removal. Use weather strip adhesive to attach the top cover where the tape is missing. Clean the top cover mounting areas of the No.1 bow with isopropyl (rubbing) alcohol and a clean cloth.

NOTE: Depending on the condition of the adhesive tape on the old top cover, it may be reusable. Do not attempt to reinstall the old top cover if the tape is contaminated with dirt or by touching it with the fingers. If the tape is contaminated, it must be removed, and weather strip adhesive used in its place.

3. Pull the top cover forward and over the No.1 bow. Align the reference line on the top cover to the leading edge of the No.1 bow. To verify if the top cover is centered to the bow, fold over the end flaps and check side-to-side, and adjust as necessary.
4. At the No.1 bow material flap, peel off the tape's protective backing (new top cover only), pull the material to the reference mark, and press firmly in place to the bow. Repeat the process for the end flap material. For the old top cover with contaminated tape, use weather strip adhesive.
5. Using a small-width, hand-held roller, firmly press (by rolling) the top cover to the No.1 bow ensuring that all the tape and/or adhesive is pressed.

NOTE: In the event the top cover needs to be removed (for adjustment purposes), the factory-installed, pressure-sensitive tape can be repositioned safely for up to several hours after rolling it. The tape takes approximately five (5) days to completely cure/bond to the bow.

6. Using a sharp knife or single-edge razor blade, trim the excess top cover material at the No.1 bow.
7. Reinstall the front top cover retainer immediately.




]B[ TOP COVER TO NO.2 AND 3 BOW LISTING STRIPS INSTALLATION

NOTE: Before the listing strips can be attached to the bows, the top cover MUST be properly secured to the No.1 bow, the floating tackstrip, and the rear rails. And the topstack must be in the fully closed position (with the front and center rails in their on-vehicle locked-up condition). Otherwise, the top cover will not be centered to the bows. This will cause diagonal top cover wrinkles, and cause the topstack to bind.

1. Clean the old adhesive tape from the bow. Apply new pressure-sensitive tape to the bow(s).
2. Peel the tape's protective backing from the bow(s).
3. With constant, light tension, wrap the listing strip material down and around the back of the bow(s) and up the front. Press the listing strip firmly to the tape. Do not pull the listing strip too much or unevenly. This will cause the top cover to sink or show what is called "read-through" of the bow.




]C[ TOP COVER TO NO.4 LISTING STRIP INSTALLATION

NOTE: Before the listing strip can be attached to the bow, the top cover MUST be properly secured to the No.1 bow, the floating tackstrip, and the rear rails. And the topstack must be in the fully closed position (with the front and center rails in their on-vehicle locked-up condition). Otherwise, the top cover will not be centered to the bow. This will cause diagonal top cover wrinkles, and cause the topstack to bind.

1. Clean off the old adhesive tape from the bow. Apply new pressure-sensitive tape to the bow.
2. Peel the tape's protective backing from the bow.
3. With constant, light tension, wrap the listing strip material down and around the front of the bow and 10 mm (0.39 in.) past the rear of the bow, as shown in the illustration. Press the listing strip firmly to the tape. Do not pull the listing strip too much or unevenly. This will cause the top cover to sink or show what is called "read-through" of the bow.

]D[ TOP COVER TO REAR RAILS INSTALLATION

NOTE: The topstack must be in the fully closed position (with the front and center rails in their on-vehicle locked-up condition). Otherwise, the top cover will not be centered to the topstack. This will cause diagonal top cover wrinkles, and cause the topstack to bind.

1. Inspect both rear rails and the old top cover (if it is being reinstalled) for adhesive tape that may been damaged during removal. Use weather strip adhesive to attach the top cover where the tape is missing. Clean the top cover mounting areas of the rear rail with isopropyl (rubbing) alcohol and a clean cloth.

NOTE: Depending on the condition of the adhesive tape on the old top cover, it may be reusable. Do not attempt to reinstall the old top cover if the tape is contaminated with dirt or by touching it with the fingers. If the tape is contaminated, it must be removed, and weather strip adhesive used in its place.




2. Peel off the tape's protective backing (new top cover only), or apply weather strip adhesive to the rear rail (old top cover), position and align the top cover to the rear rail. Ensure the welt is angled inward, as shown in the illustration at left. Press the top cover firmly in place to the rear rail bow.

NOTE: The top cover welt along the front edge of the rear rails must be angled inward 200 for a distance of 80 mm (3.12 in.) from the bottom of the leading edge. Otherwise, if the welt angles inward too much, this will cause wind noise. However, if it flips outward too much, fraying of the welt will result as it rubs on the belt moulding.
3. Using a small-width, hand-held roller, firmly press (by rolling) the top cover to the rear rail, ensuring that all the tape and/or adhesive is pressed.

NOTE: In the event the top cover needs to be removed (for adjustment purposes), the factory-installed, pressure-sensitive tape can be repositioned safely for up to several hours after rolling it. The tape takes approximately five (5) days to completely cure/bond to the bow.




4. Using an awl, puncture holes through the top cover for the rear rail weather strip retainers.
5. Immediately install the rear rail weather strip. This will help keep the top cover in position.
6. Repeat for the other rear rail.

]E[ TOP COVER TO NO.5 BOW INSTALLATION

NOTE: The topstack must be in the fully closed position (with the front and center rails in their on-vehicle locked-up condition). Otherwise, the top cover will not be centered to the No.5 bow. This will cause diagonal top cover wrinkles, and cause the topstack to bind.

1. Pull the top cover down and over the back of the No. 5 bow.
2. In the center of the No.5 bow, align the reference mark on the inside surface of the top cover to the top of the bow. Ensure there is equal tension either side of center, and secure it in place with one 0.500 x 0.314 in. stainless steel, divergent point staple.
3. Continue securing the top cover to the bow, continually ensuring the reference line on the inside of the top cover follows the tackstrip.

NOTE:
1. If installing a new top cover, refer to the old backlite portion for quantity and location of the staples.
2. If reinstalling the old top cover, do not install staples in the old staple holes. Otherwise, the top cover material may fray, allowing the top cover to come apart.




4. Secure the top cover at each of the forward ends of the No.5 bow with one screw in its original location.
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