Service Manual Supplement

1995 Volume 3

FOREWORD

This Service Manual Supplement has been prepared with the latest service information available at the time of publication. It is subdivided into various service groups that are unique to the retractable hardtop. Each section may contain one or more of the following: diagnosis, disassembly, repair, installation procedures, specifications, and tightening references. Service groups that are not specific to the retractable hardtop can be found in Volumes 1 & 2. Use of this manual will aid in properly performing any servicing necessary to maintain or restore the high levels of performance and reliability designed into these outstanding vehicles.

WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION THROUGH

AUTOMOTIVE SERVICE EXCELLENCE

Mitsubishi Motors Corporation and Mitsubishi Motor Sales of America, Inc. reserve the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to install them on its products previously manufactured.

© 1995 Mitsubishi Motor Sales of America, Inc. Printed in U.S.A.

MSSP-1 01 B-95

GROUP INDEX

General ..

Electronic Control ..

Suspension (I:CS)

Service Brak'es .

Body .

Exterior .

Interior .

Chassis Electrical .

Heater, Air Conditioning ..

and Ventilation

Alphabetical Index ..

Quick Refere!nce Chart ..

Hatchback-lio-Convertible Wiring Harness Connector Changes

WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES

WARNING!

(1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver (from rendering the SRS inoperative).

(2) If it is possible that the SRS components are subjected to heat over 93°C (200°F) in baking or in drying after painting, remove the SRS components (air bag module, SRS diagnosis unit, front impact sensors) beforehand.

(3) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer.

(4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS) and GROUP 00 - Maintenance Service in Volume 1, before beginning any service or maintenance of any component of the SRS or any SRS-related component.

NOTE

Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.

I TSB Revision

00-1

GENERAL

CONTENTS

GENERAL DATA AND SPECIFICATIONS 28

GENERAL INFORMATION ABOUT THE

RETRACTABLE HARDTOP SYSTEM 7

HOMELlNKTM UNIVERSAL TRANSMITTER.. 22

INTRODUCTION 2

LUBRICATION AND MAINTENANCE 29

PRECAUTIONS BEFORE SERVICE 27

QUICK TROUBLESHOOTING GUIDE HARD

TONNEAU 11

QUICK TROUBLESHOOTING GUIDE HARDTOP

AND HARD TONNEAU 14

RECOMMENDED LUBRICANTS AND

LUBRICANT CAPACITIES 30

SPARE TIRE, JACK AND TOOL

SET STORAGE 22

SPYDER CLEANING RECOMMENDATIONS .. 21

VEHICLE IDENTIFICATION 5

VEHICLE WASHING 22

00-2

GENERAL - Introduction

GENERAL INFORMATION INTRODUCTION

The addition of a retractable hardtop feature creates changes to several other systems and components. These changes are summarized below. Detailed information can be found on the reference pages.

GROUP # GROUP DESCRIPTION CHANGE SUMMARY
33 Front Suspension • Spyder-unique coil spring rate
33B Electronic Control • Relocation of ECS control unit
Suspension (ECS) • Wiring harness changes
• Coupe's ECS control unit mounting bracket modified to accommodate Spyder
• Available modified as a service part
34 Rear Suspension • Spyder-unique coil spring rate
35 Service Brakes • Relocated ABS electronic control unit
• ECU must be removed to perform system diagnostics
• Spyder-unique proportioning valve
42 Body Body Structure:
• Incorporation of additional body strengthening components
• Major body modifications
Doors:
• Spyder-unique due to strengthening components
• Hole must be drilled in new service part to accept wire harness
Door Windows:
• Incorporate "Express-Down" feature when operating retractable hardtop
• Automatic raising feature when pressing and holding retractable hardtop
"CLOSE" switch
• Operates normally using switches when not operating hardtop
• Wiring harness changes
• Drivers and passenger side window has 2 additional relays
• Passenger side is controlled through hardtop ECU
Front Fenders:
• Spyder-unique
• Lower portion modified to accommodate additional lower A-pillar structure
• Lower mounting changed
• RH fender has hole for mounting motor antenna
Hardtop "CLOSE"/"OPEN" and hard tonneau "CLOSE"/"OPEN" switch
replace Active Aero switch in center console
Hard Tonneau:
• Hard tonneau replaces liftgate
• Forward opening, rear hinged
• Powered by electro-hydraulic system
• Driver's liftgate release lever is used for hard tonneau manual release
• Twin, cable-actuated, gear motor-released latches with integrated limit switches
• Tonneau hinge-mounted hardtop down-stop lock prevents hardtop
movement
Quarter Windows:
• Power instead of fixed
• Non-independent operation
Roof:
• Steel roof and liftgate replaced by two-piece retracting composite roof
• Powered by electro-hydraulic system
• Spyder-unique heated rear window replaces heated liftgate glass
• Uses coupe timer and switch
Weatherstrips:
• Spyder-unique
Windshield Header:
• Electro-mechanical header latch system
• Single motor-driven assembly with dual latches with integrated limit switches
• Manual override release/latch feature I TSB Revision

GENERAL - Introduction

00-3

GROUP # GROUP DESCRIPTION CHANGE SUMMARY
42 Body (continued) • Wiring harness changes
51 Exterior Drip Moulding
• Modified coupe part
Hard Tonneau Spoiler:
• Spyder-unique
• Non-moveable design with integrated high-mount stop light
Liftgate Lock Cylinder:
• Not used for Spyder
• Replaced by emblem cover
Rear Bumper Decal (LH):
• MITSUBISHI decal is carry-over part without diamond star
• Spyder-unique location
Rear Bumper Decal (RH)
• SPYDER VR4 and SL decal are Spyder-unique
• Spyder-unique location
Rear Bumper Upper Extensions:
• LH and RH modified to accommodate Spyder-unique body structure
Side Air Dam:
• Modified to accommodate Spyder-unique body structure
52 Interior Front Pillar Trim:
• Modified coupe part
Front Seats:
• Seat belt guides Spyder-unique
• Seat recline angle restricted
Headlining:
• Hard, molded, vinyl wrapped, multi-section
• AlC in-car temperature sensor relocated to center headlining
Luggage Compartment Floor Boxes:
• Modified coupe parts (LH) & (RH)
Luggage Compartment Trim:
• Spyder-unique (soft trim)
• Floor board replaced by an object-in-trunk sensor
• Carry-over cargo lamp assembly, new switch and location changes
• Wiring harness changes
Quarter Trim:
• Spyder-unique
• Courtesy lights carry-over coupe parts
Rearview Mirror:
• Spyder-unique, self-dimming, lighted
• Spyder-unique mounting location and mounting button
• Coupe's mounting button may be existing but is not used and is covered by
a garnish
Rear Seatbacks and Locking System:
• Spyder-unique
Seat Belts (Front and Rear):
• Spyder-unique
• Mounting points relocated
Sunvisors:
• Spyder-unique
54 Chassis Electrical CD (Ccmpact-Disc) Auto Changer:
• CD changer cover deleted
• Location is in same proximity as coupe
• Spyder-unique front and rear mounting brackets
• Surrounded by Spyder-unique body structure
• Accessible through door in body structure behind RH rear seatback
• Can be serviced by removing rear-facing body structure cover [TSB Revision

00-4

GENERAL -Introduction

GROUP # GROUP DESCRIPTION CHANGE SUMMARY
54 Chassis Electrical (continued) HomeLink™ Universal Transmitter:
• All-new unit
• Located in center of windshield header garnish
• Must be removed to access header latch manual override
• Wiring harness changes
Motor Antenna:
• Relocated from rear fender to front fender
• Spyder-unique mounting hardware (some relocated coupe parts)
• Relocated relay is mounted in passenger compartment, behind glove box
• Wiring harness changes
Radio Amplifier:
• Spyder has a different amplifier
• Externally appears the same as coupe
• Internally modified for better bass
• Same attaching hardware
Rear Combination Lights:
• LH and RH modified to accommodate Spyder-unique body structure
• Not available as a service part modified for the Spyder
• Modify prior to installation
Theft Alarm System:
• Relocated light automatic shut-off unit
• Relocated keyless entry antenna and receiver
• Coupe's keyless entry receiver mounting bracket modified to accommodate
Spyder, available modified as a service part
55 Heater, Air Conditioning, and Climate Control Temperature Sensor:
Ventilation • Located in rear headlining section
• See page 55-1 in this Manual for information on operating the system
when the hardtop is open
• Wiring harness changes
Spare and Full Size Tire Spare Tire:
• When not in use, should be stored in well, same as coupe
Full Size Tire:
• When not in use, cannot be stored in spare tire well; reinstall object-in-trunk
sensor, and place tire far left to clear hardtop down-stop I TSB Revision

GENERAL - Vehicle Identification

00-5

<1995 MODELS>

1st 2nd
Digit Digit
Country Make Vehicle
type
J- A- 3-
Japan Mitsubishi Passenger
Car A-

Driver

and Passenger Air Bag

M-

3000GT FWD

N-

3000GT AWD

V-

3000GT FWD Convertible W-

3000GT AWD Convertible

VEHICLE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER LOCATION The vehicle identification number (V.I.N.) is located on a plate attached to the top of the instrument panel.

VEHICLE IDENTIFICATION CODE CHART PLATE All vehicle identification numbers contain 17 digits. The vehicle number is a code which tells country, make, vehicle type, etc.

Model Plant Serial
year number
1 R- Y- 000001
2 1994 Nagoya to
3 Year Plant 999999
s-
1995
Year
9
X 4- J-

3-door 3.0 drn '

Hatchback (181.4 cu. in 5- [DOHC-MFll Convertible K-

3.0 drn' (181.4cu. in. [DOHC-MFI Turbo)

5-

Sports

6- Premium 7- Ultimate

NOTE

'''Check digit" means a single number or letter X used to verify the accuracy of transcription of vehicle identification number.

V.I.N. (except sequence number) Brand Engine displacement Models code
JA3AV65JoSY Mitsubishi 3000GT 3.0 drn" (181.4 cu. in.)
<FWD> [DOHC-MFI) Z11ABRPML7M
(Spyder SL)
JA3AW75Ko SY Mitsubishi 3000GT 3.0 drn" (181.4 cu. in.)
<AWD> [DOHC-MFI-TURBO) Z16ABJGFL7M
(Spyder VR4) I TSB Revision

00-6

GENERAL - Vehicle Identification

Theft protection label

For original parts

For replacement parts

LOCATIONS

Target area (A: for original equipment parts, B: for replacement parts)

Tonneau

THEFT PROTECTION

In order to protect against theft, a Vehicle Identification Number (VIN) is attached as a label to the hard tonneau.

In addition, a theft-protection label is attached to replacement parts for the hard tonneau.

Caution regarding tonneau repairs:

1. When repainting original tonneau do so after first masking the theft-protection label, and, after painting, be sure to peel off the masking tape.

2. The theft-protection label for replacement parts may be covered by masking tape, so such parts may be able to be painted as is. If masking tape is not on the label, be sure to cover it. The masking tape should be removed after painting is finished.

3. The theft-protection label should not be removed from original parts or replacement parts.

I TSB Revision

GENERAL - Retractable Hardtop and Hard Tonneau Operation Information

00-7

GENERAL INFORMATION ABOUT THE RETRACTABLE HARDTOP SYSTEM

•

This car has a "one-touch" (or single-switch) system, with a built-in delay safety feature, for operating the retractable hardtop, hard tonneau, windshield header latches, quarter windows and power door windows sequentially. The delay feature only works when closing the hardtop; it stops the hardtop several centimeters (inches) from the windshield in case there is something between the hardtop and where it secures to the windshield header. Releasing and pressing the hardtop switch on the "CLOSE" side will resume operation.

The hardtop system also has another feature called an automatic "all-window glass-closed and up" feature. This feature allows the operator to raise the door glass, and close the quarter windows simultaneously, but only after the hardtop has closed and the hard tonneau has fully latched. For more information and important precautions on this feature and all the power windows, refer to POWER QUARTER WINDOWS AND DOOR WINDOWS in this section.

While the hardtop is being opened or closed (which includes the automatic opening and closing of the hard tonneau) a chime will sound and the red indicator lamp to the left of the hardtop switch will flash at the normal rate of 1 flash per second. The vehicle MUST NOT be driven until the chime and indicator turn off. (Note that the hard

tonneau indicator will not light when operating the hardtop.)

In order for the closing of the hardtop to be complete, the header latches must have latched the hardtop, the quarter windows and door windows must have fully closed, and the hard tonneau must have fully latched. Otherwise, the chime and indicator will not turn off. The chime will sound for 1 second to indicate the closing of the hardtop is complete. To confirm that the hardtop is latched, push up on the hardtop after the 1 second chime turns off.

If a problem is encountered by the system, such as if an object is detected in the hardtop stowage area, the system will only allow the hardtop to open halfway, and stop. The chime and indicator will flash at twice the normal rate until the problem is resolved.

The switch located next to the hardtop switch is for operating the hard tonneau independently when operating the hardtop is not desired (refer to NORMAL OPERATION - HARD TONNEAU, in this section).

Before operating the hardtop system or hard tonneau the parking brake must be set and the gear selector should be in the "P" (PARK) (automatic transaxle), or neutral position (manual transaxle). Then, start the vehicle.

For complete operating procedures, refer to NORMAL OPERATION - OPENING (or CLOSING) RETRACTABLE HARDTOp, or NORMAL OPERATION - HARD TONNEAU, in this section.

NOTE

Should either the retractable hardtop or the hard tonneau's power systems become inoperable they can be operated manually (refer to MANUAL OPERATION OPENING [or CLOSING] RETRACTABLE HARDTOP, or MANUAL OPERATION - HARD TONNEAU, in this section).

Caution

(1) WHEN OPENING THE RETRACTABLE HARDTOP, always make sure there are no items or packages in the hardtop stowage area. Even a small article could scratch the hardtop's finish or damage the hardtop, glass windows or mechanisms. Personal injury could result.

(2) The retractable hardtop stowage area has an object-in-trunk sensor that will restrict operation of the hardtop system if certain articles are within the top stowage area. Object shape, size, material, weight or placement may affect detection. ALWAYS check the hardtop stowage area for items when opening the hardtop.

(3) When opening or closing the retractable hardtop, keep hands clear from roof panel

~B Revision

00-8

GENERAL - Power Quarter Windows and Door Windows Information

joints and any part of the hardtop or hard tonneau mechanisms.

(4) Keep hands and any part of the body away from moving parts such as power quarter windows, power door windows, and the top of the windshield header where the hardtop secures.

(5) Before and during opening and closing of the hardtop or hard tonneau, make sure that your passengers are aware that you will operate the system. Otherwise, personal injury may result from the quarter windows unexpectedly retracting or closing and the door windows raising or lowering.

(6) Operating the retractable hardtop system without the engine running may discharge the vehicle battery, resulting in hard engine starting or a no start condition.

(7) Once the hardtop is lowered do not place any cargo in or around the hardtop.

(8) Make sure the hard tonneau is closed; driving with the hard tonneau incompletely closed is hazardous.

(9) To avoid damage, do not sit or place excessive weight on the hard tonneau or the trim panels above the rear seatbacks.

(10) Never operate the retractable hardtop or the hard tonneau while the vehicle is in motion. (11) Never press the hardtop "OPEN" switch solely to retract the quarter windows after the hardtop has closed and latched.

(12) Never press the hardtop "OPEN" switch

solely to lower the door windows.

OBJECT-IN-TRUNK SENSOR

The Spyder has an object-in-trunk sensor located in the cargo/hardtop stowage area. The sensor consists of a pressure-sensitive mat bonded to the removable trunk floor board. The sensor is designed to restrict operation of the hardtop system if articles are within the hardtop stowage area. Object size, shape, material, weight and placement may affect detection. ALWAYS check the stowage area for items when opening the hardtop. Even a small article could scratch the hardtop's finish or damage the hardtop, glass windows or mechanisms. Personal injury could result.

To remove the object-in-trunk sensor, raise the front of it, disconnect the wire connector at the luggage compartment floor box, then remove the sensor from the stowage area.

NOTE

When you reinstall the sensor, be sure to reconnect the wire connector, otherwise the hardtop will only open partway and stop, until the sensor is reconnected.

COLD WEATHER DRIVING

Before opening or closing the retractable hardtop be sure to clean off any snow or ice from the vehicle, particularly the hardtop roof and tonneau, which could cause damage when the hardtop and/or tonneau is operated. Cleaning off the hardtop and tonneau will also avoid getting snow and ice in the cargo/hardtop stowage area which could melt and refreeze.

Do not operate the hardtop or tonneau if icing has not allowed either system to function. When icing has occurred, allow the vehicle to stand in a warm area to thaw.

POWER QUARTER WINDOWS AND DOOR WINDOWS

The power quarter windows and door windows are part of the retractable hardtop's "one-touch" system.

Unlike the door windows which have separate drive motors, the quarter windows cannot be operated individually because one motor drives both windows simultaneously. No switch is provided to operate the quarter windows separately. DO NOT use the quarter windows for ventilation; they must remain closed while the hardtop is closed and latched.

When the hardtop opens, automatically the quarter windows retract and the door windows lower. But only when closinq the hardtop, what is called the automatic "all-window glass-closed and up" feature, can be used to close the quarter and door windows simultaneously. This feature can be used for convenience for when you want to secure and lock the vehicle after having the hardtop open.

To use this feature, for instance when closing the hardtop to secure the vehicle, press and hold the hardtop "CLOSE" switch after the safety stop feature stops the hardtop near the windshield. Holding the switch after the header latches latch, and the hard tonneau latches, will close the quarter windows and door windows.

NOTE

1. The quarter windows may be fully closed before the door windows. So continue to

I TSB Revision

GENERAL - Power Quarter Windows and Door Windows Information

00-9

press and hold the "CLOSE" switch until the quarter windows and door windows are closed and the 1 second chime sounds. Then, if you wish, use the door window switches to raise or lower the door windows.

2. Although the door windows can be raised and lowered independently of the quarter windows using the door window switches, they will also operate simultaneously with the quarter windows regardless of what position they are in when the hardtop "OPEN" or CLOSE" switch is pressed.

Caution

(1) DO NOT at any time press the hardtop "OPEN" switch to solely open the windows. Pressing the "OPEN" switch solely to open any of the window glass will, without notice, unlatch the hardtop and hard tonneau, and possibly start opening the hard tonneau and hardtop. DO NOT drive the vehicle with the header latches not fully latched.

(2) Whenever the hardtop "OPEN" switch is accidentally pressed, open the hardtop 101.6 - 152.4 mm (4 - 6 inches) and then close the hardtop.

(3) When opening the hardtop, ALWAYS be sure BOTH quarter windows have retracted. DO NOT open the hardtop if BOTH windows do not fully retract.

(4) The hardtop may not open if the quarter windows do not retract. Therefore, do not attempt to open the hardtop manually until the headlining is removed, and the quarter windows are retracted manually. This can be done using a 5 mm allen wrench. Insert the 5 mm allen wrench into the center of the quarter window motor and turn clockwise to retract both quarter windows.

(5) Do not force the door or quarter windows.

LOW OR DISCHARGED BATIERY

(1) If the vehicle battery voltage is less than 10 volts for more than 2 consecutive seconds, the hardtop ECU will shut down until 10 or more volts is detected.

(2) If the vehicle battery is discharged, the battery must be charged or the car must be started and the battery allowed to recharge before attempting to resume hardtop operation.

(3) If the battery cannot be charged, or the car started, the closing of the hardtop, opening and closing of the hard tonneau or header latches can be operated manually. To do this, refer to the appropriate heading under MANUAL OPERATION - in this section.

OVER-CHARGED BATIERY

The hardtop ECU will instantly shut down whenever 16 or more volts is detected, and turn on after the voltage has dropped below 16 volts. This is a good indication of a faulty charging system.

~SB Revision

00-10

GENERAL - Normal Operation - Hard Tonneau

HARD TONNEAU

Flipper door Hardtop closed

The hard tonneau covers the retractable hardtop when the hardtop is open, or it covers the stowage area, which can be used for cargo only when the hardtop is closed. The hard tonneau may be opened and closed without operating the hardtop, but only when the hardtop is closed and latched. When the hardtop is open the hard tonneau switch is rendered inoperative.

The hard tonneau can be opened and closed several ways:

- automatically with the retractable hardtop operation;

- independently by pressing the hard tonneau switch;

- manually if the power system becomes inoperable.

NORMAL OPERATION - HARD TONNEAU

1. Set the parking brake. Make sure the gear selector lever is in the "P" (PARK) (automatic transaxle), or neutral position (manual transaxle).

2. Start the engine.

Caution

Operating the hard tonneau system without the engine running may discharge the vehicle's battery, resulting in hard engine starting or a no start condition.

3. Press and hold the hard tonneau switch on the "OPEN" or "CLOSE" side of the switch. Momentarily the hard tonneau will operate.

NOTE

When the switch is pressed the red indicator lamp to the right of the switch will flash and a chime will sound until the hard tonneau has closed and latched.

Caution

(1) WHEN OPENING THE RETRACTABLE HARDTOP, always make sure there are no items or packages in the hardtop stowage area. Even a small article could scratch the hardtop's finish or damage the hardtop, glass windows or mechanisms. Personal injury could result.

(2) The retractable hardtop stowage area has an object-in-trunk sensor that will restrict operation of the hardtop system if certain articles are within the top stowage area. Object shape, size, material, weight or placement may affect detection. ALWAYS check the hardtop stowage area for items when opening the hardtop.

(3) Once the retractable hardtop is opened and stowed do not place any cargo in or around it.

(4) Make sure the hard tonneau is closed and latched; driving with hard tonneau incompletely closed is hazardous.

(5) To avoid damage, do not sit or place excessive weight on the hard tonneau or the trim panels above the rear seatbacks.

(6) When opening or closing the hard tonneau keep hands and any part of the body away from moving parts, such as the flipper doors (located at the front ends of the hard tonneau) and along where the hard tonneau seals to the vehicle body.

I TSB Revision

GENERAL - Quick Troubleshooting Guide for Operating the Hard Tonneau

00-11

QUICK TROUBLESHOOTING GUIDE FOR THE HARD TONNEAU

(For information and troubleshooting on the hardtop and hard tonneau systems together, see NORMAL OPERATION - OPENING [or CLOSING] RETRACTABLE HARDTOp, in this section. For Diagnostics and Testing refer to GROUP 42.)

DESCRIPTION OF PROBLEM POSSIBLE CAUSE ACTION TO TAKE COMMENTS
Hard Tonneau does not • The gear selector is not in • Set the parking brake and Always apply the parking
operate. "P" (PARK) (automatic trans- place the gear selector in brake before operating the
axle). "P" (PARK) (automatic trans- hardtop or the hard tonneau.
• The gear selector is not in axle), then start the engine.
neutral (manual transaxle), • Set the parking brake and
and the parking brake is not place the gear selector in
applied. neutral (manual transaxle),
then start the engine.
Hardtop is open and hard Normal operation: tonneau In an emergency hard ton-
tonneau will not open using switch is electrically locked- neau can be opened
the hard tonneau switch. out. manually (refer to MANUAL
OPERATION - HARD
TONNEAU in this section).
Hardtop appears to be closed, Hardtop IS not fully latched. Open the hardtop 101.6 - • Service the vehicle.
but hardtop chime and 152.4 mm (4 - 6 in.) then close • In an emergency, the
indicator sound and blink at the hardtop again using the header latches can be
twice the normal rate, and hardtop "CLOSE" switch. operated manually (refer to
the hard tonneau will not Release the switch when the MANUAL OPERATION -
open or close using the hard chime and indicator turn off. HEADER LATCHES in this
tonneau switch. Wait for the 1 second chime, section.
then push up on the hardtop
to be sure it has latched.
Hard tonneau will not open Vehicle battery is discharged • Recharge battery. Make sure all accessories are
or close without engine to less than 10 volts. • Start the car and allow the off, and do not operate hard-
running. battery to recharge. top or hard tonneau while
battery is recharging.
Vehicle battery is over- Turn on some or all Could indicate possible
charged 116 or more volts). accessories to lower the charging system malfunction.
battery voltage below 16
volts.
Hard tonneau will not open, • Pump's bypass valve may Turn the bypass valve to the If turning bypass valve does
or opens slowly, with engine not be fully in the "POWER" "POWER" position until it not solve problem, service
running, but pump can be position. stops. the vehicle.
heard running. • Low pump pressure.
Hard tonneau's chime and Indicates that hard tonneau Open hard tonneau and Service the vehicle if you
indicator sounding and is not fully closed and check to see that nothing is have to push down on the
blinking at twice the normal latched. preventing the hard tonneau hard tonneau to get it to
rate, will not turn off when from closing, then close the latch.
the tonneau appears to be hard tonneau. ~thetonneau
closed. still will not latch, push
down on both front ends of
the tonneau to engage
latches.
Only one hard tonneau latch Latch mechanisms may DO NOT continue to operate • Service the vehicle.
releases and tonneau does require service. tonneau or hardtop. • In an emergency, the
not open. tonneau can be opened
manually (refer to MANUAL
OPERATION - HARD
TONNEAU in this section).
Hard tonneau's chime and May indicate a general DO NOT operate the hardtop • Service the vehicle.
indicator sound and blink at malfunction. or hard tonneau. • In an emergency either
twice the normal rate, but system can be operated
does not appear to be manually (refer to the appro-
associated with any notice- priate heading under
able problem. MANUAL OPERATION in
this section). I TSB Revision

00-12

GENERAL - Normal Operation - Opening Retractable Hardtop

RETRACTABLE HARDTOP

NORMAL OPERATION - OPENING RETRACTABLE HARDTOP

1. Set the parking brake. Make sure the gear selector lever is in the "P" (PARK) (automatic transaxle), or neutral position (manual transaxle).

2. Be sure that the exterior of the hardtop is

completely clean and dry.

3. Start the engine.

Caution

Operating the retractable hardtop system without the engine running may discharge the vehicle battery, resulting in hard engine starting or a no start condition.

Caution

(1) WHEN OPENING THE RETRACTABLE HARDTOP, always make sure there are no packages in the hardtop stowage area. Even a small article could scratch the hardtop's finish or damage the hardtop, glass windows or mechanisms. Personal injury could result.

(2) The retractable hardtop stowage area has an object-in-trunk sensor that will restrict operation of the hardtop system if certain articles are within the hardtop stowage area. Object shape, size, material, weight or placement may affect detection. ALWAYS check the hardtop stowage area for items when opening the hardtop.

(3) When opening the hardtop, ALWAYS be sure BOTH quarter windows have retracted. DO NOT open the hardtop if BOTH windows do not fully retract until the headlining is removed, and the quarter windows are retracted manually. This can be done using a 5 mm allen wrench. Insert the 5 mm allen wrench into the center of the quarter window motor and turn clockwise to retract both quarter windows.

4. Press and hold the hardtop "OPEN" switch to open the hardtop.

NOTE

(1) When the hardtop "OPEN" switch is pressed sequentially the quarter windows retract and door windows lower, and the header latches unlatch, and the hard tonneau unlatches and begins to open along with the hardtop.

(2) If the hardtop only opens halfway and stops, and the chime and indicator flash and sound at twice their normal rate, that is an indication that:

• an object has been detected by the objectin-trunk sensor or,

• the object-in-trunk sensor is not connected.

Remove the object or reconnect the sensor, then go to Step 5.

5. Press and hold the hardtop "OPEN" switch.

Release the switch after the hard tonneau has closed and latched and the chime and indicator have turned off. The chime will sound for 1 second to indicate the opening of the hardtop is complete.

NOTE

If the hardtop stops and reverses direction and stops at the halfway closed position, that is an indication that:

• an object that was not detected earlier (due to size, shape, material, weight or placement) has now been detected by the object-in-trunk sensor, or;

• an item has just been placed in the top stowage area while the hardtop was being opened.

Remove the object and resume opening the hardtop.

6. If desired, raise the door window glass using

the door window switches.

AIR CONDITIONING - WHEN HARDTOP IS OPEN When the hardtop is open, the in-car temperature sensor for the air conditioning is now reading the temperature inside the hardtop stowage area. Therefore, when using the AlC set the "MODE" to the desired selection and select the fan speed using "FAN". Set the temperature control ("TEMP") to a comfortable setting as required. The AlC system is not designed to cool the vehicle with the hardtop open.

NORMAL OPERATION - CLOSING RETRACTABLE HARDTOP

1. Set the parking brake. Make sure the gear selector lever is in the "P" (PARK) (automatic transaxle), or neutral position (manual transaxle).

2. Start the engine.

Caution

Operating the retractable hardtop system without the engine running may discharge the battery, resulting in hard engine starting or a no start condition.

3. Press and hold the hardtop switch on the "CLOSE" side until the hardtop stops near the windshield header, then release the switch.

NOTE

The hardtop has a safety stop feature that stops the hardtop near the windshield .

4. Make sure there is nothing atop the windshield header where the hardtop secures .

5. Press the "CLOSE" switch and release it only

I TSB Revision

GENERAL - Normal Operation - Opening Retractable Hardtop

00-13

after the quarter windows and door windows have fully closed, the hard tonneau has closed and latched, and the chime and indicator have turned off. The chime will sound for 1 second to indicate closing of the hardtop is complete.

NOTE

(1) The quarter windows may be fully closed before the door windows. If you wish, use the door window switches to lower the door windows.

(2) Although the door windows can be raised and lowered independently of the quarter windows using the door window switches, they will also operate simultaneously with the quarter windows regardless of what position they are in when the hardtop "OPEN" or "CLOSE" switch is pressed.

Caution

(1) DO NOT at any time press the hardtop "OPEN" switch to solely open the windows. Pressing the "OPEN" switch solely to open any of the window glass will, without notice, unlatch the hardtop and hard tonneau, and possibly start opening the hard tonneau and hardtop. DO NOT drive the vehicle with the header latches not fully latched.

(2) Whenever the hardtop "OPEN" switch is accidentally pressed, open the hardtop 1 01.6 - 152.4 mm (4 - 6 inches) and then close the hardtop.

6. To confirm that the hardtop is latched, push up on the front of the hardtop.

If the hardtop is not latched, open it 101.6 - 152.4 mm (4 - 6 inches), then repeat Steps 5 and 6.

NOTE

If you still cannot latch the hardtop, operate the latches manually (refer to MANUAL OPERATION - HEADER LATCHES, in this section).

Caution

In an emergency, do not force the windows. If the quarter windows do not close, service the quarter window system.

NOTE

Although the rear compartment area is primarily intended for hardtop stowage, it may be used as a trunk or luggage compartment when the hardtop is in the closed position. Before lowering the hardtop, any item in this area must be removed.

Caution

Make sure there are no items or packages in the cargo/hardtop stowage area when you open the hardtop. Even a small article could scratch the hardtop's finish or damage the hardtop, glass windows or mechanisms.

ROOFTOP CARRIER AND LUGGAGE RACK

A rooftop or lumJage carrier of any type or design MUST NOT be used on the Spyder's retractable hardtop or hard tonneau. This includes, but is not limited to ski, bicycle or luggage racks. Damage to the retractable hardtop and/or hard tonneau may result.

THEFT-ALARM SYSTEM NOTE

1. The theft-alarm system operates as described in the Owner's Manual, with the exception where references to the hatchback are made; the Spyder's hard tonneau replaces the hatchback. The hard tonneau cannot be unlocked by key.

2. The theft-alarm system is fully functional when the hardtop is open.

3. When the hardtop is open and the alarm is armed, the hard tonneau can still be manually opened and closed without activating the alarm.

I TSB Revision

00-14 GENERAL - Quick Troubleshooting for Operating Hardtop and Hard Tonneau

QUICK TROUBLESHOOTING GUIDE FOR THE HARDTOP AND HARD TONNEAU

(For information and troubleshooting on the hard tonneau system alone, see NORMAL OPERATION - HARD TONNEAU, in this section. For Diagnostics and Testing refer to GROUP 42.)

DESCRIPTION OF PROBLEM POSSIBLE CAUSE ACTION TO TAKE COMMENTS
Hardtop or tonneau do not • The gear selector is not in • Set the parking brake and Always apply the parking
operate. "P" (PARK) (automatic place the gear selector in brake before operating the
transaxle). "P" (PARK) (automatic hardtop or the hard tonneau.
• The gear selector is not in transaxle), then start the
neutral (manual transaxle), engine.
and the parking brake is not • Set the parking brake and
applied. place the gear selector in
neutral (manual transaxle),
then start the engine.
Hardtop is open and hard Normal operation; tonneau In an emergency hard
tonneau will not open using switch is electrically locked- tonneau can be opened
the hard tonneau switch. out. manually (refer to MANUAL
OPERATION - HARD
TONNEAU, in this section).
Hardtop appears to be Hardtop is not fully latched. Open the hardtop 101.6 - In an emergency, the
closed, but hardtop chime 152.4 mm (4 - 6 inches), header latches can be
and indicator sound and blink then close the hardtop again operated manually (refer to
at twice the normal rate, and using the hardtop "CLOSE" MANUAL OPERATION -
the hard tonneau will not switch. Release the switch HEADER LATCHES, in this
open or close using the hard when the chime and section).
tonneau switch. indicator turn off. Wait for
the 1 second chime, then
push up on the hardtop
to be sure it has latched.
Hardtop and/or tonneau will Vehicle battery is discharged • Recharge the battery. Make sure all accessories are
not open or close without to less than 10 volts. • Start the car and allow the off and do not operate the
engine running. battery to recharge. hardtop or hard tonneau
while the battery is
recharging.
Vehicle battery is over- Turn on some or all acces- Could indicate possible
charged (16 or more volts). sories to lower the battery charging system malfunction.
voltage below 16 volts.
Hard tonneau and/or hardtop • Pump's bypass valve(s) may Turn the bypass valve to the If turning bypass valve does
will not open, or opens not be fully in the "POWER" "POWER" position until it not solve the problem,
slowly, with engine running, position. stops. service the vehicle.
but pump(s) can be heard • Low pump pressure.
running.
Hard tonneau's chime and Indicates that hard tonneau is Open hard tonneau and check Service the vehicle if you
indicator sounding and not fully closed and latched. to see that nothing is pre- have to push down on the
blinking at twice the normal venting the hard tonneau hard tonneau to get it to
rate, will not turn off when from closing, then close the latch.
the tonneau appears to be hard tonneau. If the tonneau
closed. still will not latch, push down
on both front ends of the
tonneau to engage latches.
Only one hard tonneau latch Latch mechanisms may • DO NOT continue to operate In an emergency, the
releases and tonneau does require service. tonneau or hardtop. tonneau can be opened
not open. • Service the vehicle. manually (refer to MANUAL
OPERATION - HARD
TONNEAU, in this section).
Hardtop stops at halfway • Object-in-trunk sensor • Reconnect object-in-trunk
open position while opening, disconnected. sensor.
and chime and indicator • Object detected by object- • Remove detected object.
sound and blink at twice the in-trunk sensor.
normal rate. I TSB Revision

GENERAL - Quick Troubleshooting for Operating Hardtop and Hard Tonneau 00-15

Hardtop opens, but then • Object detected by object- Remove detected object.
reverses direction, and stops in-trunk sensor.
halfway closed. • An object has been placed in
the stowage area while the
hardtop was being opened.
Hardtop stops several inches Normal operation. Release the switch, make sure Normal condition; hardtop
from the windshield header nothing is between the has a safety feature that
while closing. header and the hardtop, and allows you to check that
press the switch again. nothing is between the
header and the hardtop.
Hard tonneau or hardtop's May indicate a general • DO NOT operate the hardtop In an emergency either
chime and indicator sound malfunction. or hard tonneau. system can be operated
and blink at twice the normal • Service the veh icle, manually (refer to the
rate, but does not appear to appropriate heading under
be associated with any Manual Operation, in this
noticeable problem. section). I TSB Revision

00-16

GENERAL - Retractable Hardtop and Hard Tonneau Manual Operation

GENERAL INFORMATION ON MANUAL OPERATION OF THE RETRACTABLE HARDTOP SYSTEM

Power header latch system

Hard tonneau system pump

The retractable hardtop system consists of two separate hydraulic systems; one powers the retractable hardtop and the other powers the hard tonneau. There is also a power latch system located in the windshield header.

If one or more systems become inoperable, refer to the appropriate heading or combinations of headings, depending on the circumstances:

• NORMAL OPERATION - OPENING (or CLOSING) RETRACTABLE HARDTOP

• NORMAL OPERATION - HARD TONNEAU

• MANUAL OPERATION - OPENING (or

CLOSING) RETRACTABLE HARDTOP

• MANUAL OPERATION - HARD TONNEAU

• MANUAL OPERATION - HEADER LATCHES

NOTE

(1) Before you attempt to operate any system manually, check that nothing was overlooked that might otherwise allow normal automatic operation, such as:

• Make sure the manual bypass valve for each hydraulic pump/motor is in the "POWER" position. The system may not work properly or at all if the valves are not closed all the way.

• Be sure the object-in-trunk sensor is connected.

• Make sure the vehicle battery is charged and, if possible, the engine running. If battery voltage is less than 10 volts, the hardtop system may not have enough energy to operate properly or at all.

• Check that the battery is not overcharged; the hardtop ECU will instantly shut off at 16 volts and will not turn on until voltage drops below 16 volts.

(2) Once you are reasonably satisfied that normal operation is not possible then proceed with manual operation.

MANUAL OPERATION - HARD TONNEAU

OPENING THE HARD TONNEAU

1. Set the parking brake. Make sure the gear selector lever is in the "P" (PARK) (automatic transaxle), or neutral position (manual transaxle).

2. Open the veh icle passenger side door. Fold the passenger side rear seatback down to expose the carpeting behind the seats.

The hard tonneau's pump/motor is on the passenger side.

3. Open the passenger side access door on your left, and reach in and rotate the bypass valve handle clockwise 90° to the "MANUAL" position, until it stops.

4. Pull the hard tonneau release lever, located to the left beside the driver's seat, up to release the hard tonneau. Make sure both latches are released.

Caution

Never pull the tonneau release lever, except to operate the hard tonneau manually. Otherwise the tonneau will not be fully closed. Driving with the tonneau incompletely closed is hazardous.

I TSB Revision

GENERAL - Manual Operation - Closing Retractable Hardtop

00-17

5. Standing at the passenger side, grasp the hard tonneau along the side from underneath, with both hands placed near the front and side center. Slowly lift until it is all the way up.

NOTE

Hydraulic back-pressure created in the hard tonneau system prevents the hard tonneau from being raised quickly.

Caution

The hard tonneau may close unexpectedly before you return the bypass valve to the "POWER" position.

6. Immediately reach in and return the bypass valve to the "POWER" position by rotating the handle counterclockwise 90° until it stops. This will keep the hard tonneau up without additional support.

Caution

If the bypass valve is not completely closed after raising the hard tonneau it may slowly close without warning.

CLOSING THE HARD TONNEAU

1" Open the veh icle's passenger side door.

Reach in and rotate the bypass valve handle clockwise 90° to the "MANUAL" position, until it stops.

Caution

The hard tonneau may begin to close immediately when the bypass valve is turned to the "MANUAL" position.

2. Using gentle but firm pressure, push down on

the hard tonneau until it is completely closed.

NOTE

The hard tonneau will not slam closed due to the back-pressure in the hydraulic system. DO NOT APPLY EXCESSIVE FORCE TO CLOSE THE HARD TONNEAU.

3. Using a hand-on-hand method, press down on the hard tonneau to latch it. You should hear a click when it latches. Make sure that it is latched by gently, but firmly, pulling up on the hard tonneau near the front and side center (near the latch). Repeat for the other latch.

Caution

Make sure the hard tonneau is closed and latched before driving.

4. Return the bypass valve to the "POWER" position until it stops.

5. Close access door.

6 Return seatback to its fully upright position and

lock in place.

NOTE

The manual bypass valve must be in the "POWER" position in order to operate the hard tonneau electrically.

MANUAL OPERATION - RETRACTABLE HARDTOP

CLOSING RETRACTABLE HARDTOP Caution

Closing the retractable hardtop requires two individuals. If you encounter any difficulties, do not continue to close the hardtop and seek assistance/help.

1. Set the parking brake. Make sure the gear selector lever is in the "P" (PARK) (automatic transaxle), or neutral position (manual transaxle).

2. Start the engine.

NOTE

If the engine will not start and the battery does not have enough energy to lower the door glass windows, open both vehicle doors.

This will allow the hardtop's seals to mate correctly to the door glass windows when they shut, after the hardtop is closed.

3. Press and hold the hardtop switch on the

"CLOSE" side.

NOTE

At this time the hard tonneau should open revealing the folded hardtop. If it does not open, see MANUAL OPERATION - HARD TONNEAU, in this section.

~SB Revision

00-18

GENERAL - Manual Operation - Closing Retractable Hardtop

4. Fold the driver side rear seatback down to expose the carpeting behind the seatbacks. The retractable hardtop pump/motor is on the driver side.

5. Open the access door on the driver side, reach in and rotate the bypass valve handle clockwise 90° to the "MANUAL" position, until it stops.

NOTE: This procedure requires two people.

For illustration clarity, only one person is shown.

6. With you on one side of the vehicle and your helper on the other, each put one hand under the rear portion of the hardtop, and the other hand under the front portion of the hardtop.

Caution

(1) Keep your fingers clear of the hardtop hinges, mechanism and roof joints.

(2) To avoid risk of personal injury, remove all jewelry (rings, bracelets, wristwatches, etc.) from your hands.

(3) DO NOT lift the hardtop by the quarter windows. Damage to the quarter window system and/or personal injury may result.

NOTE: This procedure requires two people.

For illustration clarity, only one person is shown.

7. Using a constant lifting motion slowly lift the

hardtop approximately halfway up.

NOTE

Hydraulic back-pressure created in the hydraulic system prevents the hardtop from being raised quickly.

I TSB Revision

00-19

GENERAL - Manual Operation - Opening Retractable Hardtop

NOTE: This procedure requires two people.

For illustration clarity, only one person is shown.

8. Push only on the rear portion of the hardtop as shown above; DO NOT PUSH ON THE REAR WINDOW. Push the hardtop forward until it drops into the windshield header latches.

9. Close header latches. Refer to MANUAL OPERATION - HEADER LATCHES, in this section.

10. Close hard tonneau. Refer to MANUAL OPERATION - HARD TONNEAU, in this section.

Caution

(1) DO NOT drive the vehicle if the hardtop is not properly latched to the windshield header. Driving with the top incompletely latched is hazardous.

(2) In an emergency, do not force the windows.

If the quarter windows do not close, remove the headlining, and retract the quarter windows manually. This can be done using a 5 mm allen wrench. Insert the 5 mm allen wrench into the center of the quarter window motor and turn clockwise to retract both quarter windows.

11. Return the bypass valve to the "POWER" position by rotating the handle counterclockwise 90°.

12. Close the access door.

13. Return the seatback to its fully upright posi-

tion and lock in place.

OPENING RETRACTABLE HARDTOP Caution

(1) To prevent damage to hardtop system components (especially the quarter windows), manual operation should only be performed by trained technicians, for the sole purpose of vehicle servicing or repair.

(2) Manual operation of the retractable hardtop requires two individuals.

1. Set the parking brake. Make sure the gear selector lever is in the "P" (PARK) (automatic transaxte). or neutral position (manual transaxle).

2. Start the engine.

3. Open the hard tonneau one of three ways:

• automatically using the hardtop "OPEN" switch;

• automatically using the hard tonneau "OPEN" switch;

• manually, if either system becomes inoperable.

NOTE

When the hardtop "OPEN" switch is pressed sequentially the following may occur: the quarter windows may retract and door windows lower, and the header latches unlatch, and the hard tonneau unlatches and begins to open.

4. Unlatch the hardtop one of two ways:

• autornaticallv using the hardtop "OPEN" switch;

• manually if either system becomes inoperable. (refer to MANUAL OPERATION - HEADER LATCHES, in this section).

Caution

(1) The quarter windows must be fully retracted in order for the header latches to unlatch. If the quarter windows do not retract, remove the headlining, and manually retract the windows. This can be done using a 5 mm allen wrench. Insert the 5 mm allen wrench into the center of the quarter window motor and turn clockwise to retract both quarter windows.

(2) The header latches must be unlatched before opening the hardtop. If the header latches do not unlatch they can be opened manually (refer to MANUAL OPERATION - HEADER LATCHES, in this section).

(3) Remove any items from the hardtop stowage area.

5. Fold the driver side rear seatback down to expose the carpeting behind the seatbacks. The retractable hardtop pump/motor is on the driver side.

[ TSS Revision

00-20

GENERAL - Manual Operation - Opening Retractable Hardtop

6. Open the access door on the driver side, reach in and rotate the bypass valve handle clockwise 90° to the "MANUAL" position, until it stops.

NOTE: This procedure requires two people.

For illustration clarity, only one person is shown.

=

7. Open both vehicle doors. With a person on each side of the vehicle, lift along the side portions of the hardtop front roof panel until the hardtop is halfway open.

NOTE

Hydraulic back-pressure created in the hardtop hydraulic system prevents the hardtop from being lowered quickly.

Caution

Keep your fingers clear of the hardtop hinges, mechanism and roof joints.

NOTE: This procedure requires two people.

For illustration clarity, only one person is shown .

..

8. To move the hardtop into the stowage area, each person must place one hand on the rear portion of the hardtop at the top of the quarter window opening, and the other hand at the front edge of the hardtop. Pull the front portion while pushing the rear portion to get the hardtop moving into the stowage area.

9. Push the hardtop until it is 3/4 open. Then, place both hands under the rear portion ofthe hardtop to slow it to a stop.

Caution

Be sure to keep your hands and arms from getting caught under the hardtop.

10. Return the bypass valve to the "POWER" position by rotating the handle counterclockwise 90° as required.

11. Close the access door.

I TSB Revision

GENERAL - Manual Operation - Header Latches

00-21

12. Return the seatback to its fully upright posi-

tion and lock in place.

13. If necessary, close the hard tonneau manually.

Caution

Make sure the hard tonneau is closed and latched before driving.

MANUAL OPERATION - HEADER LATCHES

NOTE

A special wrench is provided for removal and reinstallation of the HomeLink™ Universal Transmitter, and it is also used to manually operate the header latches. The special wrench is located inside the CD (Compact-Disc) changer access door behind the passenger side rear seatback.

The HomeLink™ Transmitter may also be removed using a standard #2 cross-tip screwdriver. The header latches may also be operated using a standard 1/4" square drive ratchet and extension.

Caution

When operating the header latches manually, always be sure to remove the wrench from the header latch motor immediately. Otherwise, personal injury may result if the tool is not removed and the hardtop switch is pressed.

TO OPEN OR CLOSE HEADER LATCHES

Special wrench

1. Using the special wrench (or a screw driver), remove the screw securing the HomeLink™ Universal Transmitter to the windshield header garnish.

2. Pull HomeLink™ Transmitter down from the header garnish, and move to one side out of your way.

Special wrench

3. Using the special wrench (or a 1/4" square

drive ratchet and extension), insert it into the latch motor and turn the wrench (1) full turn clockwise to close the latches.

4. To confirm that the hardtop is latched, push up on the front of the hardtop. If the hardtop is not latched, tu rn the wrench (1) fu II tu rn counterclockwise and repeat Steps 3 and 4.

5. Remove the special wrench (or ratchet and extension).

6. Tuck the HomeLink™ Transmitter wires up into the header garnish, and reinstall the HomeLink™ with the screw.

7. Return the special wrench to the tray, and return the seatback to its fully upright position and lock in place.

SPYDER CLEANING RECOMMENDATIONS

INTERIOR

HEADLINING

Clean with a mild soap or a reliable vinyl cleaner. Apply a small amount of solution with a clean cloth or sponge, then wipe with a damp cloth. When the lather has been removed, wipe again with a soft, clean cloth.

HARD TONNEAU PAD

Hard tonneau pad

Regularly vacuum the hard tonneau pad to keep it free of dust and dirt.

EXTERIOR

ABOUT THE SPYDER FINISH

The retractable hardtop and hard tonneau have been finished with same high-quality finish as the rest of the vehicle.

I TSB Revision

00-22 GENERAL - Spare Tire, Jack and Tool Set Storage and HomeLink™ Universal Transmitter

WASHING LEFT SIDE

Always make sure the retractable hardtop is closed and latched. Otherwise, water may enter the vehicle's interior, causing damage. As with the rest of the vehicle, wash it out of direct sunlight, using a mild soap and water solution. Start washing from the roof panels, working downward, using a sponge. After washing, wipe with a chamois or soft cloth.

NOTE

When using a high-pressure washer avoid directing high pressure spray at the weatherstrips.

WAXING THE RETRACTABLE HARDTOP AND HARD TONNEAU

The retractable hardtop and hard tonneau should be waxed like the rest of the vehicle. When waxing around the weatherstrip mating surfaces of the retractable hardtop and hard tonneau, be careful not to put any wax on the weatherstrips. If stained with wax the weatherstrip may not maintain a weatherproof seal with other components. If wax is accidentally applied to the weatherstrip, remove it promptly before it dries.

POLISHING THE RETRACTABLE HARDTOP AND HARD TONNEAU

Treat them the same recommended way as you would the rest of the vehicle.

SPARE TIRE, JACK AND TOOL SET STORAGE

The spare tire, jack and tool set are stowed in the cargo/hardtop stowage area. To access them, first close and latch the retractable hardtop, then open the hard tonneau using the hard tonneau "OPEN" switch, or use manual operation.

Caution

Lowering the retractable hardtop part way to open the hard tonneau is not recom'!lended. ~ou could easily scratch the hardtop while removmg the spare tire. Use the hard tonneau "CLOSE/OPEN" switch.

For taking the jack, tire, etc. in and out, first disconnect and remove the object-in-trunk sensor (located in the cargo/hardtop stowage area covering the spare tire, tool set and luggage compartment floor boxes). For information on removal of the object-in-trunk sensor see page 00-9, in this section.

NOTE

It is easier to remove the spare tire from the passenger side (it is closer to you). You. may. ~ant to protect your clothing and the vehicle finish by covering the rear fender.

Full size tire

'-- __ TOP VIEW===

To store the full size tire, reinstall the object-intrunk sensor and reconnect the wire connector, and place the tire to the far left in the stowage area.

Caution

(1) The stowage compartment for the spare tire is intended ONL.Y for the spare, not the full size tire and wheel.

(2) Make sure the hardtop down stop clears the

tire while closing the hard tonneau.

For more information regarding handling the spare, jacking and tire changing, etc., see the Owner's Manual.

HOMELINKTM UNIVERSAL TRANSMITTER

The HomeLink™ Transmitter is located in the center of the windshield header garnish. It provides a convenient way to consolidate the functions of up to three individual handheld transmitters into one built-in device. Once trained, the HomeLink™ Transmitter is designed to repeat both the frequency and the security code of the hand-held transmitters used for garage doors, security gates, or most radio frequency receive.rs. With the optional Lighting Package, home/office lighting systems, and security. systems ~an be operated with the HomeLmk™ Universal Transmitter.

Continuous power is supplied to HomeLink™ Transmitter by the vehicle's battery and charging system.

PROPER TRAINING TECHNIQUE Caution

During this procedure, the system that you are training will be made to operate if it is within range of either the HomeLink™ or the hand-held transmitter. Make sure that people or objects are clear of the garage door, gate, etc. that you are training.

NOTE

The vehicle's engine should be turned off while training the transmitter.

I TSB Revision

GENERAL - Homelink™ Universal Transmitter

00-23

1. If you have previously trained this HomeLink™ Transmitter, proceed to Step 2. Hold down the outside two buttons on the HomeLink™ Transmitter until the red light begins to flash rapidly, then release both buttons.

----

Channel 2

Channel 1

2. Decide which one of the three HomeLink™ channels you want to train.

Red light

Held-held transmitter

3. Hold the end of your hand-held transmitter against the bottom of the HomeLink™ Transmitter so that you can see the red light.

NOTE

In order to train, you must hold the handheld transmitter less than one inch from the HomeLink™ Transmitter.

Slow Flash

Rapid Flash

(Continue holding)

Rapid Flash (Release buttons -

4. Press the desired HomeLink™ button until the red light flashes slowly. Do not release the button. Continue holding the button and press the hand-held transmitter button through Step 5.

5. Hold down both buttons until you see the red light on the HomeLink™ Transmitter flash rapidly (this may take 10-90 seconds). Then release both buttons.

TRANSMITTER COMPATIBILITY

If the HomeLink™ Transmitter has not indicated a successful train, note the brand name, model number, and frequency of the hand-held transmitter and refer to Table 1. Table 1 is a listing of all commonly known garage door opener transmitters, and identifies the different transmitters as compatible or not compatible with the HomeLink™ Transmitter.

If the hand-held transmitter is identified in Table 1, is confirmed compatible to the HomeLink™ Transmitter and does not activate the receiver, refer to the diagnostic steps below.

If the hand-held transmitter is identified in Table 1 and is confirmed not compatible to the HomeLink™ Transmitter, inform the customer of the problem and advise them to call HomeLink™ for product discounts on replacement garage door systems.

If the hand-held transmitter is not identified in Table 1 and has not been successfully trained to the HomeLink™ Transmitter, contact HomeLink™ for technical assistance at 1-800- 355-3515. Make sure you identify the brand name, model number, and frequency of the hand-held transmitter (if possible) for the HomeLink™ operator.

TRAINING PROBLEM DIAGNOSIS

• NO SUCCESSFUL TRAIN INDICATION (INDICA· TOR LIGHT DOES NOT FLASH RAPIDLY) AND HOMELlNKTM TRANSMITTER DOES NOT PROPERLY ACTIVATE RECEIVER

If the HomeLink™ Transmitter does not train, please follow these steps to identify the cause of the problem.

II TSB Revision

00-24

GENERAL - HomeLink™ Universal Transmitter

1. Verify that the system (garage door opener, et~.) operates properly with the original transmitter.

2. Verify that the red light on the HomeLink™ Transmitter glows when any button is pushe~. If the light glows,proceed to Step 4.

3 If the light does not glow, verify that battery power is available at the connector to the HomeLink™ Transmitter, replace the fuse ~nd/or.fix the vehicle wiring. If battery power IS confirmed and the light still fails to operate, replace the HomeLink™ Transmitter with a new unit.

4. Verify that the hand-held transmitter has an effective battery. If a new battery is needed, replace and repeat training sequence.

5. Try reorienting the hand-held transmitter and repeating the training sequence. One effective way of reorienting is to touch a different side of the hand-held transmitter to the HomeLink™ Transmitter during training, i.e. place the opposite end of the handheld transmitter against the HomeLink™ Transmitter.

6. If the hand-held transmitter is confirmed compatible in Table 1 and does not properly activate the receiver after completing the above steps, then the HomeLink™ Transmitter may be defective and should be replaced. If the HomeLink™ has been previously replaced for the same problem, contact HomeLink™ at 1-800-355-3515 for additional assistance.

• SUCCESSFUL TRAIN INDICATION (RAPID FLASH) BUT HOMELlNKTM TRANSMITTER DOES NOT PROPERLY ACTIVATE RECEIVER

NOTE

The effective ranqe of the HomeLink™ Transmitter may differ from that of the original hand-held transmitter.

If the HomeLink™ Transmitter appears to have trained (rapid flash), but does not activate the system receiver, follow these steps to identify the cause of the problern:

1. Verify that the system (garage door opener, etc.) operates properly with the original transmitter.

2. Verify that the hand-held transmitter has an effective battery. If a new battery is needed, replace and repeat training sequence.

3. Try reorienting the hand-held transmitter and repeating the training sequence. One effective way of reorienting is to touch a different side of the hand-held transmitter to the HomeLink™ Transmitter during training, i.e. place the opposite end of the hand-held transmitter against the HomeLink™ Transmitter.

4. If the problem persists, and the hand-held transmitter is confirmed compatible in Table 1, then the HomeLink™ Transmitter may be defective and should be replaced. If the HomeLink™ Transmitter has been replaced for the same problem, contact HomeLink™ at 1-800-355-3515 for additional assistance.

NOTE

Should the vehicle be stolen, advise the customer to immediately retrain all their HomeLink™ programmed receiver codes in all applicable radio frequency appliances with their original hand-held transmitter.

I TSB Revision

GENERAL - Homelink™ Universal Transmitter

00-25

TABLE 1

LIST OF TESTED GARAGE DOOR OPENERS

Brand Name Manufacturer Model # FCCID Frequency Train? Comments Need
MHZ receiver
verification?
Chamberlain Chamberlain G-3684 BYF8GKG3684 390 YES
Chamberlain Chamberlain 66LC 390 YES
Crusader Advance Industries - BSH8YN213 340 YES
Genie Genie AT85-P B808KL 390 YES
Genie Genie AT85 - 390 YES AT85 @ 290M HZ
may have problems
like AD9 below.
Genie Genie AT90 B808KL 390 YES
Genie Genie MAT85 B808KL 390 YES
Genie Genie MAT90 B808KL 390 YES
Genie Genie AT285P B808KL 390 YES
Genie Genie AT95 B808KL 390 YES
Genie Genie AT35A - 390 YES YES
Genie Genie AD9 - 290 NO "Oscillator is FM,
too wide for data
reception **"
Genie Genie AT55 - 290 NO "Oscillator is FM,
too wide for data
reception **"
Genie Genie GWK - 390 YES
Heathkit - - - YES
Jeckson - 47-1001 ELY547-471001-T 315 YES
Lift-A-Dor Genie LDT901 B80GT50 390 YES
Liftmaster Chamberlain G3466 132B873A 290 YES
Liftmaster Chamberlain G3467 132B873A 400 NO Illegal transmit
frequency.
Linear Linear DT-2A CJF793 310 YES
Linear Linear SNTOO016 EF4793 304 YES
Linear Linear EK11T CJF793 290 YES YES
Linear Linear SNTOO016 EF4793 304 YES
Linear Linear D-22B CJF793 304 YES
Linear Linear DT4 CJF794 310 YES
Linear Linear SNTOO048B EFF4SNTOO048B 304 YES
Linear Linear MDT EF4DNTOO052 318 NO Doesn't stay "on"
long enough.
Micom International Dynamics ESP-T9 ESP-T10 312 YES
Micom International Dynamics ESP-T9 ESP-T10 312 YES
CodeAble Multi-Elmac (Stanley) 3010 BX79KG 300 YES
Multi-Elmac 3089 - 300 YES
Multi-Code Stanley - A9K X Multicode - YES
Multi-Code Stanley 3070 BX79KGMICRO-10 300 YES
Multi-Code Stanley 3032 BX79KGT 300 YES
Multi-Code Multi-Elmac (Stanley) 1054 1054 250 NO Illegal transmit
frequency.
Multi-Code - 3034 - 300 YES
Multi-Code Stanley 3033 BX79KGT 300 YES
Multi-Elmac Multi-Elmac (Stanley) 1048 1048 250 NO Illegal transmit
frequency.
Multi-Code Stanley 3060 BX79KGMINI 299 YES
Multi-Code Multi-Elmac (Stanley) 1098 1098 301 YES
Multi-Code Martec MK-1010 10-JCOMK-1010 300 YES
Pulsar Pulsar (Allister) PDX9921 BPB83PXMIT 288 YES
Allister Pulsar (Allister) ADX9931 B0A83XMIT 318 YES
Allister Pulsar (Allister) ADX9932 B0A83XMIT 318 YES
Allister Pulsar (Allister) ADX9933 B0A83XMIT 318 YES
Allister Pulsar (Allister) ADX9934 B0A83XMIT 318 YES
Allister Pulsar (Allister) ADX9935 B0A83XMIT 318 YES
Allister Pulsar (Allister) ADX9936 B0A83XMIT 318 YES I TSB Revision

00-26

GENERAL - HomeLink™ Universal Transmitter

Brand Name Manufacturer Model # FCCID Frequency Train? Comments Need
MHZ receiver
verification?
Allister 20 - 340 NO "Very Subtle FSK,
can not distinguish"
Sears Sears 139-654020 YES
Sears Sears - 139.664953 - YES
Sears Sears - 139.664030 YES
Sears Sears - HBW3CQ139.53738 390 YES
Sears Sears 9B53718 - 390 YES
Sears Sears 9B53708 390 YES
Shima Shima T-18B - 304 YES Must repeat button
push to keep trans-
mitter on.
Shima Shima Style D - 319 YES
Stanley Stanley 2986 - 310 YES
Stanley Stanley 1047 1047 310 YES
Stanley Stanley 1050 1050 310 YES
Stanley Stanley 1076 A9K9KG LMX 310 YES
Stanley Stanley 1079 A9K9KG LMX 310 YES
Stanley Stanley 1016 - - YES
Stanley Stanley - - 310 YES
Stanley Stanley 331-1052 A9K99G TPEN-l 310 YES
Stanley Stanley 1077 A9K9KG LMX 310 YES
Telectron Telectron TP-21 - 230 NO Outside of HomeLink™
operating band width.
Telectron Telectron T-BO - 230 NO Outside of HomeLink™
operating band width.
Telectron Telectron T-BOG - 245 NO Illegal transmit
frequency.
Telectron Telectron T-22A 247 NO Illegal transmit
frequency. YES
Touch-n-Go Advance Industries - BSH8YN205 360 YES "*" Data stream and frequency is compatible, 3 samples found to be un-trainable due to wide band transmission."

I TSB Revision

GENERAL - Precautions Before Service

00-27

,-------------,-----

--------,-------

1---------

I

\

I

PRECAUTIONS BEFORE SERVICE SERVICING THE ELECTRICAL SYSTEM

1. Before proceeding with work on the electrical system, the following must never be done:

Unauthorized modifications of any electrical device or wiring, because such modifications might lead to a vehicle malfunction, over-capacity, or short circuit, that could possibly result in a vehicle fire.

2. When servicing the electrical system, disconnect the negative terminal from the battery.

Caution

1. Before connecting or disconnecting the negative battery terminal, be sure to turn off the ignition switch and the lighting switch.

2. After completion of work steps, reconnect the negative battery terminal, warm up the engine, and allow the vehicle to idle for approximately 5 minutes under the conditions described below. This procedure will allow the vehicle's computer-controlled systems to stabilize.

Engine coolant temperature: 80 - 950 C (176 - 2030 F) Lights, electric fans, accessories: OFF

Transaxle: neutral position

(AfT models: "N" or "P")

Steering wheel: neutral (center) position

SERVICING OR ADJUSTING THE RETRACTABLE HARDTOP SYSTEM

Caution

Mechanical adjustments to, or replacement of components of the retractable hardtop system, with the exception of hard and soft trim, will require that the hardtop ECU be run through "auto-configuration" using the ASC INCORPORATED computerized diagnostic system. When applicable DO NOT perform any adjustment or replacement of those retractable hardtop components without having the latest version of the ASC INCORPORATED diagnostic system.

VEHICLE WASHING

If high-pressure car-washing equipment or steam carwashing equipment is used to wash the vehicle, avoid directing high pressure spray at the weatherstrips.

I TSB Revision

00-28

GENERAL - General Data and Specifications

GENERAL DATA AND SPECIFICATIONS

1

4 1

GENERAL SPECIFICATIONS

Models 3000GT SL 3000GT VR-4
Spyder Spyder
<OOHC> <OOHC>
Items (Non-Turbo) (Turbo)
Vehicle dimensions mm (in.)
Overall length 1 4,565 (179.7) 4,545 (178.9)
Overall width 2 1,840 (72.4) 1,840 (72.4)
Overall height 3 1,285 (50.6) 1,285 (50.6)
Wheelbase 4 2,470 (97.2) 2,470 (97.2)
Tread Front 5 1,560 (61.4) 1,560 (61.4)
Rear 6 1,580 (62.2) 1,580 (62.2)
Overhang Front 7 1,025 (40.4) 1,025 (40.4)
Rear 8 1,050 (41.3) 1,050 (41.3)
Minimum running ground
clearance 9 145 (5.7) 145 (5.7)
Angle of approach degrees 10 12.2° 12.2°
Angle of departure degrees 11 16.9° 16.9°
Vehicle weight kg (Ibs.)
Curb weights
MIT 1,450 (3,197) 1,725 (3,803)*
AIT 1,490 (3,285) -
Gross vehicle weight rating 2,050 (4,519) 2,205 (4,861)
Gross axle weight rating
Front 1,090 (2,403) 1,145 (2,524)
Rear 960 (2,116) 1,060 (2,337)
Seating capacity 4 4
For Engine and Transaxle Specifications,
refer to Volume 1 of the Service Manual. NOTE

* <4WS>

I TSB Revision

GENERAL - Lubrication and Maintenance

00-29

LUBRICATION AND MAINTENANCE

The retractable hardtop system has been designed to provide reliable, maintenance-free service under normal driving conditions. This is accomplished by using specially formulated, selflubricating, long wearing components.

Most of these components do not require lubrication. The only parts requiring periodic lubrication are the header latches, hard tonneau latches, and hard tonneau lifting mechanism slide tracks. Note that lubrication, where it is not required, may actually deteriorate the materials or attract dirt which could cause rapid wear and/or component breakage.

MAINTENANCE SCHEDULES

Due to the virtually maintenance-free design of the retractable hardtop system maintenance schedules are not required. Typically, wiping off the mechanism component with a clean damp cloth to remove dust and dirt is all that is needed.

SEVERE SERVICE

Vehicles operating under severe service conditions will require more frequent cleaning of system components under one or more of the following conditions:

Operation of the vehicle (1) Driving in sandy areas (2) Driving in salty areas

(3) Driving in dusty conditions

HARD TONNEAU AND RETRACTABLE HARDTOP HYDRAULIC SYSTEM FLUID

When it is necessary to re-fill the pump reservoir, hydraulic cylinders, hoses, or the entire hydraulic system, MIL-H-5606 (AVIATION HYDRAULIC FLUID), or equivalent, can be used in the tonneau and hardtop hydraulic systems. Some examples of this aviation hydraulic fluid are Mobil Aero HFA, Aeroshell Fluid 4, or Royco 756. When it is necessary to top-off the reservoir, SAE lOW may be used.

As the name implies, the fluid must be an aviation-type fluid, not an automotive or other type. DO NOT use any other fluid or oils other than what is specified. Other types or weights of fluids or oils may slow operation, particularly during cold weather.

Generally, but not in all instances, if the hardtop ECU detects slower-than-normal operation (in this case due to using the wrong hydraulic fluid), it will set a diagnostic trouble code (DTC). The DTC can only be recovered using the ASC INCORPORATED computerized diagnostic system.

In addition to slowing operation, other oils may not be compatible with system components such as the O-ring seals.

Warning

When servicing the hydraulic system, use protective eyewear. Also, wear gloves and clothing that cannot be penetrated by the hydraulic fluid. If fluid contacts the skin, wash the area thoroughly with soap and water or waterless hand soap. Do not use gasoline, thinner, or solvents to clean the fluid from the skin.

LUBRICANTS - GREASES

Semi-solid lubricants bear the NLGI designation and are further classified as grades 0, 1, 2, 3, etc. Whenever "Chassis Lubricant" is specified, Multi-Purpose Grease, NLGI grade 2, should be used.

I TSB Revision

00-30

GENERAL - Recommended Lubricants and Lubricant Capacities Table

RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE RECOMMENDED LUBRICANTS

Items Recommended Lubricants
Retractable hardtop hydraulic pump/motor System factory-filled with MIL-H-5606 (AVIATION HYDRAULIC
FLUID), or equivalent.
Hard tonneau pump/motor For re-filling the pump reservoir, hydraulic cylinders, hoses, or
the entire hydraulic system use Mobil Aero HFA, Aeroshell
Fluid 4, or Royco 756, or equivalent. When topping-off the
reservoir, SAE 10W may be used.
Quarter windows mechanisms Multipurpose grease NLGI Grade 2
Header latch mechanism
Hard tonneau slide mechanism LUBRICANT CAPACITIES TABLE

Description Metric Measure (drn") U.S. Measure
Retractable hardtop hydraulic .976 drn' (976 ml) 1.03 qt
system
Hard tonneau hydraulic system .614 dm' (614 ml) .65 qt I TSB Revision

338-1

ELECTRONIC CONTROL SUSPENSION (ECS)

CONTENTS

ECS CONTROL UNIT

(SPYDER-UNIQUE RELOCATION) 2

Removal and Installation 2

338-2

ECS - ECS Control Unit

ECS CONTROL UNIT (SPYDER-UNIQUE RELOCATION)

REMOVAL AND INSTALLATION

NOTE

Refer to Volume 1 of the Service Manual for more information.

Original location

Pre-removal and Post-installation Operation

• Removal and Installation of LH Quarter Trim Panel (Refer to GROUP 52, in this Manual.)

• Removal and Installation of Theft Alarm System Automatic ShutOff Unit and Keyless Entry Receiver Assembly (Refer to GROUP 54, in this Manual.)

NOTE

The ECS control unit mounting bracket for the Spyder has been modified. When replacing this part use the Spyder-unique service part.

Removal step

1. ECS control unit

I TSB Revision .

35-1

SERVICE BRAKES

CONTENTS

ABS CONTROL UNIT

(SPYDER-UNIQUE RELOCATION) 2

Removal and Installation 2

35-2

SERVICE BRAKES - ASS Electronic Control Unit

ABS ELECTRONIC CONTROL UNIT (SPYDER-UNIQUE RELOCATION)

REMOVAL AND INSTALLATION

Removal steps

1. Electronic control unit

•• 2. Control unit connector connection

NOTE ~

Refer to Volume 1 of the Service

Manual for more information.

Original location

Pre-removal Operation

• Removal of RH Quarter Trim Panel (Referto Group 52, in this Manual).

Post-installation Operation

• Installation of RH Quarter Trim Panel (Refer to GROUP 52, in this Manual).

• Inspection of A.S.S. (Refer to Volume 1 of the Service Manual).

SERVICE POINT OF REMOVAL

2. REMOVAL OF CONTROL UNIT CONNECTOR

Carefully insert a screwdriver into the lock section as illustrated, and carefully pull out the connector from below.

I TSB Revision

42-1

BODY

CONTENTS

BODY DIMENSIONS AND MEASUREMENT

METHODS 264

BODY STRUCTURE

ASC Incorporated Installed Parts 267

Mitsubishi Installed Parts 266

CHIME MODULE AND TURN-SIGNAL AND

HAZARD FLASHER UNIT 260

DIAGNOSTICS AND TESTING 15

Auto-configuration 17

Circuit Diagrams

Chime Module 144

Data Link Connector (DLC) 148

Driver Door Power Window System 138

Hard Tonneau Latch System 137

Hardtop and Hard Tonneau Control Switch 142

Hardtop and Hard Tonneau Hydraulic Pumps 147

Header Latch System 136

LEDs 145

Object-in-trunk Sensor 143

Passenger Door Power Window System 140

Potentiometers 146

Power Quarter Window 135

Retractable Hardtop Power Distribution and

Control 134

Configuration Diagrams

Interior 24

Luggage Compartment 26

Overa"...................................................................... 23

Diagnostic Trouble Code (DTC) Identification List.... 47 ECU Connector Location and Terminal

Disengagement 19-21

Grounding Locations 18

Inspection and Verification 32

Notes and Terms 16, 17

Pinpoint Tests

No DTCs Present 49

With DTCs Present 75

Recommended Wire Repair 22

Retractable Hardtop Operation 29

Symptom Chart

No DTCs Present 33

With DTCs Present 35

Trouble Shooting Hints

No DTCs Present 41

With DTCs Present 43

Warnings and Cautions 15

Wire Color Codes 28

DOOR LOCATING PIN AND RECEIVER 240

DOOR WINDOW REILAYS 239

FRONT FENDER 219

Lower Fender Bracket 220

GENERAL INFORMt~TION 3

Description

About the Automatic Header Latch System 3

About the Hard Tonneau 3

About the Hardtop and Power Quarter

Windows 3

About the Object-in-trunk Sensor 4

General Precautions 4

Overview 3

HARD TONNEAU 183

HARD TONNEAU HYDRAULIC SYSTEM PUMP/

MOTOR 193

HARD TONNEAU HYDRAULIC SYSTEM PUMP/MOTOR

AND CYLINDERS 190

HARD TONNEAU LJUCH SYSTEM 188

HARD TONNEAU MECHANISM 186

HARD TONNEAU POSITION SENSOR

(POTENTIOMETER) 195

HARD TONNEAU SEQUENCE OF OPERATION

Closing 8

Opening 7

HARDTOP AND HARD TONNEAU CONTROL

SWITCH 257

HARDTOP ELECTRONIC CONTROL UNIT (ECU) 263

HYDRAULIC SYSTEM BLEEDING

Acceptable Levels of Trapped Air Bubbles 215

Hard Tonneau System Bleeding 216

Hardtop System Bleeding 216

Pre-bleeding Notes 215

HYDRAULIC SYSTE:M DIAGRAMS 214

OBJECT-IN-TRUNK SENSOR

261

CONTINUED ON NEXT PAGE

42-2

QUARTER WINDOW 233

Drive Cable 235

Position Sensor 237

Window 233

RETRACTABLE HARDTOP ASSEMBLY 200

RETRACTABLE HARDTOP, FRONT ROOF PANEL 197

RETRACTABLE HARDTOP HYDRAULIC SYSTEM

PUMP/MOTOR 213

RETRACTABLE HARDTOP HYDRAULIC SYSTEM

PUMP/MOTOR AND CYLINDERS 209

RETRACTABLE HARDTOP POSITION SENSOR

(POTENTIOMETER) 207

RETRACTABLE HARDTOP SEQUENCE OF OPERATION

Closing 6

Opening 5

ROOF GLASS 224

General

Glass Wipe, Primers, Adhesive and Glass

Installation Items 221

Replacement of Moulding (Bonding Type) 222

SEALANT AND ADHESIVES

Rear Roof Glass 10

Weatherstrips 10

SERVICE ADJUSTMENT PROCEDURES 149

Door Locating Pin 181

Front Rail Weatherstrip and Holder 170

Hard Tonneau 171

Tonneau Flipper Doors............................................ 179

Tonneau Hinge 171

Tonneau Latches 171

Tonneau Manual Release System 178

Hard Tonneau Position Sensor (Potentiometer) 182

Power Quarter Window 162

Quarter Window 164

Quarter Window Cables, Synchronization of 163

Quarter Window Guiding System (Rudder) 166

Quarter Window Position Sensors 168

Retractable Hardtop Assembly 149

Retractable Hardtop Down Stop 158

Down Stop Height Adjustment 158

Down Stop Lock Adj ustment 159

Retractable Hardtop Position Sensor (Potentiometer) 182

Retractable Hardtop System, Adjustment of 151

Adjustment Points 157

Gap Between Front and Rear Roof Panels 153

Hardtop Flushness to Windshield Header 152

Hardtop Locator Pins 151

Hardtop Roof Crown 154

Hardtop Roof Lock-up Before Closing 152

Ha rdtop U pstops...................................................... 151

Header Latch Garnishes 151

Weatherstrips, All Hardtop Related 151

Windshield Header Power Latch System 160

Latch Actuator Adjustment 160

Latch Height Adjustrnent 161

SPECIAL TOOLS 12

SPECIFICATIONS

9

General 8

Sealants and Adhesives 10

WEATHERSTRIP 242

A-pillar Weatherstrip Holder 242

Front Rail 248

Front Rail Weatherstrip Holder 248

Hard Tonneau 246

Hardtop 250

Hardtop Weatherstrip Holder 250

Quarter Window Sash Seal 244

Rear Rail Inner 252

Windshield Header 242

Windshield Header Weatherstrip Holder 242

WINDSHiElD HEADER POWER LATCH SYSTEM 254

BODY - General Information

42-3

GENERAL INFORMATION DESCRIPTION

Overview

The retractable hardtop system is actually composed of five separate systems that work in unison. The systems are as follows:

• retractable hardtop

• power quarter windows

• automatic header latch system

• hard tonneau

• object-in-trunk sensor (trunk floor)

The hard tonneau and hardtop have their own electric, motor-driven pumps that actuate hydraulic cylinders. An electronic control unit (ECU) controls all electrical functions of the hardtop system. In addition this includes lowering and raising of the door window glass when operating the hardtop.

Manual transaxle-equipped vehicles have the ECU connected to the vehiicle speed sensor and the parking brake switch. This prevents operation of the retractable hardtop or the hard tonneau if the vehicle is moving 3-5 mph or more. Automatic transaxle-equipped vehicles have the ECU connected to the PARK switch and the speed sensor. Operating the hardtop and/or hard tonneau while the vehicle is in motion is hazardous. Never operate the hardtop and/or tonneau while the vehicle is in motion. In addition, always set the parking brake before operating the hardtop or hard tonneau. The retractable hardtop system should only be operated with the ignition switch in the "ON" position and with the engine running.

About the Hardtop and Power Quarter Windows

The retractable hardtop consists of two composite roof panels hinged where the panels join and also at the body. A mechanized rear shelf panel that rests above the rear seatbacks is forward when the hardtop is closed. When the hardtop is open, the shelf panel moves back to cover the gap at the hard tonneau. In an emergency, the hardtop can be closed manually by bypassing the hydraulic pump. Opening the hardtop manually should only be performed by trained service personnel. The retractable hardtop system has a "one-touch" (or single-switch) system, with a built-in delay safety feature when closing the hardtop. This allows the operator to make sure nothing is between the header and the hardtop when it closes.

During operation of the hardtop, the quarter windows automatically retract into the sides of the rear roof panel. The quarter windows cannot be operated independently of hardtop operation; they move to full open (retracted) position when the hardtop is opened, and full closed when the hardtop is closed. The door windows can be operated after the retractable hardtop operation is complete.

About the Automatic Header Latch System

The windshield header contains the automatic latch system. The dual latches are driven by a single electric motor controlled by the ECU. The latches may be manually operated in an emergency by removing the HomeLink™ Universal Transmitter and using a standard 1/4" square drive ratchet and extension to drive the motor. A special combination HomeLink™ Transmitter removal and installation tool/header latch wrench is provided. It is located inside the CD changer compartment. When operating the header latches manually, always be sure to remove the wrench from the header latch motor immediately. Otherwise personal injury may result if the tool is not removed and the hardtop switch is pressed.

About the Hard Tonneau

The hard tonneau covers the hardtop when it is open, and covers the stowage area when the hardtop is closed. The tonneau is a one-piece composite with a serviceable fixed spoiler and center high mount

I TSB Revision

42-4

BODY - General Information

stop light. It is hinged at the rear, opening from the front. Twin, cable-actuated, gear motor-released latches (with manual release), secure the hard tonneau. The hard tonneau may be operated independently of the hardtop by means of the hard tonneau "OPEN"!"CLOSE" switch. It can be operated only with the ignition switch in the "ON" position. The hard tonneau cannot be opened independently if the hardtop is open; the switch is electrically locked-out. The hard tonneau system should only be operated with the engine running.

About the Object-In- Trunk Sensor

The object-in-trunk sensor consists of two electrically conductive grids separated by an insulator, and laminated together to form a pressure-sensitive mat. The mat is bonded to a rigid board and covered with a low-pile carpet. A short pigtail connector on the mat connects to the rear harness in the luggage compartment floor box. The object-in-trunk sensor must be connected for the hardtop system to operate, as the ECU can detect if the sensor is not connected. When the object-in-trunk sensor is disconnected, the hardtop system is restricted.

The purpose of the object-in-trunk sensor is to prevent the hardtop (or objects) from being damaged if an object is within the hardtop stowage area when the hardtop is beinq stowed. When opening the hardtop, and an object is detected in the hardtop stowage area, the hardtop will only open halfway and not proceed until the object is removed. Similarly, if an object is within the stowage area or placed in there while the hardtop is operating, but is not heavy enough to be detected, and the hardtop contacts it while opening, the hardtop will reverse direction and stop halfway closed until the object is removed.

General Precautions

During normal system operation, a chime and visual warning indicator liqhts (next to the hardtop and hard tonneau control switches) alert the vehicle occupants that the hardtop is not fully open or closed, or that the tonneau is not fully closed. When a problem is encountered by the system, the chime and indicators will sound and flash at twice the normal rate. The chime will sound for 1 second to indicate that the opening or closing of the hardtop is complete. When the tonneau closes the chime and indicator turn off (no 1 second chime like the hardtop) to indicate closing of the hard tonneau is complete.

The system should only be operated when the vehicle is stationary, the transmission is in "PARK" (AfT) or Neutral (MfT), the parking brake set, and the engine is idling. If the battery becomes discharged (battery voltage below 10 volts), the system's ECU will not permit the hardtop or hard tonneau to operate. If the battery voltage exceeds 16 volts, the system's ECU will shut down until the voltage drops to 16 or lower.

I TSB Revision

BODY - General Information

42-5

RETRACTABLE HARDTOP SEQUENCE OF OPERATION - OPENING

Conditions:

• Hardtop and hard tonneau completely closed and latched

• Ignition "ON" with engine running at idle

• Transmission in "PARK" (AfT) or "Neutral" (MIT)

• Parking brake set

• Vehicle battery fully charged

• All vehicle accessories off

• All items or packages removed from hardtop stowage area

NOTE

(1) If the hardtop "OPEN" switch is released before the hardtop is fully open, the hardtop stops in midmovement. Pressing the switch a second time causes the hardtop to continue the opening cycle. Whenever the hardtop "OPEN" switch is pressed, released, and pressed again, an audible sound may be heard as the hard tonneau latch motors release and reset.

(2) System operational time may vary due to conditions such as vehicle age and condition, ambient temperature (affecting oil viscosity), battery condition, and level of hardtop ECU software.

Time lapse tolerance +20/-10 seconds

1. Press and hold the "HARDTOP OPEN" switch.
Time Lapse: Operation
0.0 sec to 4 sec: o Chime and indicator light comes on and stays on until the end of the hardtop open cycle.
o Door windows open and quarter windows retract.
4 sec to 11 sec: o Hard tonneau and header latches unlatch.
o Hard tonneau pump/motor starts and raises the hard tonneau to the full open position and turns off.
10 sec to 18 sec: o Hardtop pump/motor starts and moves the hardtop to the fully open position and turns off.
18 sec to 25 sec: o Hard tonneau pump/motor starts and moves the hard tonneau to the fully closed and latched position
and turns off.
o One second chime sounds indicating the completion of the hardtop open cycle.
o Chime and indicator turn off.
2. Release the switch. I TSB Revision

42-6

BODY - General Information

RETRACTABLE HARDTOP SEQUENCE OF OPERATION - CLOSING

Conditions:

• Hardtop completely opened and hard tonneau closed and latched

• Ignition "ON" with engine running at idle.

• Transmission in "PARK" (AfT) or "Neutral" (M(T)

• Parking brake set

• Vehicle battery fully charged

• All vehicle accessories off

NOTE

(1) If hardtop "CLOSE" switch is released before the hardtop is fully closed, the hardtop stops in midmovement. Pressing the switch a second time causes the hardtop to continue the closing cycle.

(2) System operational time may vary due to conditions such as vehicle age and condition, ambient temperature (affecting oil viscosity), battery condition and level of hardtop ECU software.

lime lapse tolerance +20/-10 seconds

1. Press and hold the "HARDTOP CLOSE" switch.
Time Lapse: Operation
0.0 sec to 5 sec: • Chime and indicator light comes on and stays on until the end of the hardtop close cycle.
• Hard tonneau latches release and the hard tonneau opens to the full open position.
5 sec to 16 sec: • Hardtop pump/motor starts and raises the hardtop to the safety stop approximately 270 mm (10 inches)
from the header and stops.
o sec to 6 sec: • Hardtop switch must be pressed a second time.
• Hardtop closes and latches.
• Hard tonneau pump/motor starts the tonneau to the close position.
• Hard tonneau closes and latches.
6 sec to 11 sec: • Quarter windows and door windows extend and close.
• One second chime sounds indicating the completion of the hardtop close cycle.
• Chime and indicator turn off.
2. Release the switch. I TSB Revision

BODY - General Information

42-7

HARD TONNEAU SEQUENCE OF OPERATION - OPENING

Conditions:

• Hard tonneau closed and latched.

• Ignition "ON" with engine running at idle.

• Transmission in "PARK" (A{T) or "Neutral" (MIT)

• Parking brake set

• Vehicle battery fully charged

• All vehicle accessories off

• Hardtop closed (hard tonneau will not operate with the hard tonneau switch if hardtop is stowed)

NOTE

(1) If hard tonneau "OPEN" switch is released before the hard tonneau is fully open, the hard tonneau stops in mid-movement. Pressing the switch a second time causes the hard tonneau system to continue to the open position. Whenever the hard tonneau "OPEN" switch is pressed, released and pressed again, an audible sound may be heard as the hard tonneau Ilatches release and reset.

(2) System operational time may vary due to conditions such as vehicle age and condition, ambient temperature (affecting oil viscosity), battery condition and level of hardtop ECU software.

Time lapse tolerance + 10/-5 seconds

1. Press and hold the "HARD TONNEAU OPEN" switch.
Time Lapse: Operation
0.0 sec to 7 sec: • Chime/indicator light comes on and stays on until the hard tonneau is closed and latched.
• Hard tonneau latches release.
• Hard tonneau pump/motor starts and moves the hard tonneau to the fully open position.
2. Release the switch I TSB Revision

42-8

BODY - General Information

HARD TONNEAU SEQUENCE OF OPERATION - CLOSING

Conditions:

• Hard tonneau completely open

• Ignition "ON" with engine running at idle

• Transmission in "PARK" (AfT) or "Neutral" (MIT)

• Parking brake set

• Vehicle battery fully charged

• All vehicle accessories off

• Hardtop closed (hard tonneau will not operate with the hard tonneau switch if hardtop is stowed)

NOTE

(1) Ifthe hard tonneau "CLOSE" switch is released before the hard tonneau is fully closed, the hard tonneau stops in mid-movement. Pressing the switch a second time causes the hard tonneau to continue the closing cycle.

(2) System operational time may vary due to conditions such as vehicle age and condition, ambient temperature (affecting oil viscosity), battery condition, and level of hardtop ECU software.

Time lapse tolerance + 10/-5 seconds

1. Press and hold the "HARD TONNEAU CLOSE" switch.
Time Lapse: Operation
0.0 sec to 6 sec: • Chime/indicator light comes on and stays on until the hard tonneau is closed and latched.
• Hard tonneau pump/motor starts and moves the hard tonneau to the full closed position.
• Hard tonneau latches latch.
• Chime and indicator turn off.
2. Release the switch I TSB Revision

BODY - Specifications

42-9

SPECIFICATIONS GENERAL SPECIFICATIONS

Items Specifications
Roof (retractable hardtop)
Type 2-piece molded composite, folding, self-storing,
hydraulically actuated (spring assisted) with manual
bypass and rigid headlining
Locking system Two electrically operated, mechanical latches through
retractable hardtop ECU logic interlock
Retractable hardtop "CLOSE OPEN" switch
Type SPDT rocker
Rated load current A 20
Rated voltage DC 12
Retractable hardtop hydraulic pump/motor
Type Permanent magnet type (built-in circuit breaker)
Normal operating voltage DC 10-16
Run current A 25
Bound current A 50
Direction of rotation Clockwise and counter-clockwise
Windshield header latch system
Type Mechanical, single-motor, dual opposing gear racks
Windshield header latch motor
Type Permanent magnet type (built-in circuit breaker)
Run current A 8
Bound current A 18
Direction of rotation Clockwise and counter-clockwise
Hard tonneau
Type 2-piece composite, rear hinged, front opening type,
hydraulically actuated with manual bypass
Locking system Dual, cable actuated latches with electric gear motor
release, and remote manual release, via cable
Hard tonneau "CLOSE/OPEN" switch
Type SPDT rocker
Rated load current A 20
Rated voltage DC 12
Hard tonneau hydraulic pump/motor
Type Permanent magnet type (built-in circuit breaker)
Normal operating voltage DC 10-16
Run current A 13
Bound current A 50
Direction or rotation Clockwise and counter-clockwise
Hard tonneau latch One latch per side, cable-actuated, gear motor-re-
leased with integrated limit switch, and manual re-
lease provision
Door
Locating system (anti-rattle) Spring-loaded pin-in-receiver
Glass installation method
Roof window glass Adhesive
Quarter window glass Fasteners
Glass installation method
Roof window glass Adhesive
Quarter window Fasteners I TSB Revision

42-10

BODY - Specifications

Items Specifications
Glass thickness mm (in.)
Rear roof glass 4.0 ± 0.3 (0.15 ± 0.01)
Quarter window glass 5.0 ± 0.3 (0.19 ± 0.01)
Power quarter window
Type Retracting (beetle-wing style), single switch operation
(with retractable hardtop ECU logic interlock), single
motor drive, dual cable actuated, non-independently
operated (windows synchronized with each other)
Power quarter window motor
Type Permanent magnet type (built-in circuit breaker)
Run current A 8.0
Bound current A 18.0
Direction of rotation Clockwise and counterclockwise I TSB Revision

BODY - Specifications

42-11

SEALANT AND ADHESIVES

Items Specified sealant Remarks
Rear roof glass BETASEAL 57502 urethane USEl only BETASEAL 57502
adhesive urethane adhesive
Weatherstrips 3M SUPER WEATHERSTRIP
ADHESIVE 08008, or equivalent
Butyl tape I TSB Revision

42-12

BODY - Special Tools

SPECIAL TOOLS

ASC tool number and tool name Supersession

Application

ASC pin E-45X8-T005-CXXX Available only

Cable from vehicle to ISO through ASC

convertor box

ASC pin E-4568-T003-8XXX ISO 9141 convertor box

ASC pin E-45X8-T004-CXXX Cable from convertor to PC

ASC pin E-45X8-T002-8XXX PC User's Manual

Personal computer

Digital VOM

Diagnosis and troubleshooting of hardtop electrical system

I TSB Revision

BODY - Special Tools

42-13

AMP tool number and tool name Application
AMP pin 726503-1 ECU connector F-124 large terminal extraction tool
~
AMP pin 726534-1 ECU connector F-124 small terminal extraction tool
==¢===J
AMP pin 872070-1 ECU connectors F-123 and F-125 terminal extraction tool
= I TSB Revision

NOTES

BODY - Diagnostics and Testing Precautions before Service

42-15

Observe ALL Cautions and Warnings in Removal and Installation, and A.djustment procedures.

Warning!

(1) Depending on system malfunction and/or diagnostic procedure, inadvertent operation of the hardtop and/or hard tonneau may occur. For example: if one circuit to hard tonneau pump/motor is shorted to ground or voltage and you connect the other circuit to ground or voltage, hard tonneau may close.

ALWAYS stay clear of hardtop and hard tonneau moving components when diagnosing and/or operating system.

Caution

(1) Make sure both retractable quarter windows are retracted before opening hardtop. DO NOT open the hardtop if BOTH retractable quarter windows do not fully retract.

(2) When opening the retractable hardtop, always make sure there are no items or packages in the hardtop stowage area. Even a small article could scratch the hardtop's finish or damage the hardtop, glass windows or mechanisms. Personal injury could result.

(3) The retractable hardtop stowage area has an object-in-trunk sensor that will restrict operation of the hardtop system if certain articles are within the hardtop stowage area. Object shape, size, material or placement may affect detection. ALWAYS check the hardtop stowage area for items when opening the hardtop.

(4) Once the retractable hardtop is opened and stowed do not place any cargo in or around it.

(5) Make sure the hardtop and hard tonneau are closed and latched; driving with hardtop or hard tonneau partially open is hazardous.

(6) Never operate the retractable hardtop or the hard tonneau while the vehicle is in motion.

(7) To avoid damage, do not sit or place excessive weight on the hard tonneau or the trim panels above the rear seat backs.

(8) When opening and closing the hardtop or hard tonneau keep hands and any part of the body away from moving parts, such as the flipper doors (located at the front ends of the hard tonneau) and along where the hard tonneau seals to the vehicle body.

(9) When MANUALLY operating hardtop and/or hard tonneau the weight and/or the position of the hardtop and/or hard tonneau may cause it to continue movement.

(10) Depending on the nature of the concern when operating hardtop and/or hard tonneau, the weight and/or position of the hardtop and/or hard tonneau may cause it to continue movement. Turning bypass valve to POWER position MAY NOT stop movement of hardtop and/or hard tonneau, for example; if hydraulic system leaks, or if hydraulic cylinders are damaged.

I TSB Revision

42-16

BODY - Diagnostics and Testing

READ ALL OF THE FOLLOWING NOTES AND TERMS BEFORE PROCEEDING.

NOTE:

1. Refer to Volume 2 of the Service Manual General Section for How to Diagnose, How to Read Configuration Diagram, and How to Read Circuit Diagrams.

2. For information that may be needed that is not contained in this Service Manual, Refer to Volume 1 and/or 2 of Service Manual.

3. Make sure hardtop and hard tonneau mechanical adjustments are correct before performing electrical diagnostics.

4. Make sure that the vehicle battery is fully charged and in good condition before performing diagnostics.

5. Inspect system fuses and ground connections before performing diagnostics.

6. If fuses are blown, do not immediately replace them, refer to Inspection and Verification.

7. Intermittent DTCs may occur, DTCs must be active (high-lighted on PC screen) to properly diagnose. It may be necessary to move wiring harnesses and/or individual wires (wiggle) for DTCs to become active. DO NOT replace components if DTCs are not active.

8. When recovering Diagnostic Trouble Codes (DTCs) from the Electronic Control Unit (ECU) using the Personal Computer (PC) write down all DTCs that are in the mernory. Some DTCs may occur as a result of other failures the ECU has seen.

9. Turn ignition switch to the OFF position after each test unless instructed to leave it in the ON position.

10. Manual operation of the hardtop or hard tonneau may be required to gain access to some components for diagnosing.

11. Wire harness and/or component connectors that are identified with pin locations on them, shall use that numbering system, and not the standard Mitsubishi numbering system.

12. Circuit numbers for the retractable hardtop system are on the circuit diagrams listed vertically on the wires.

13. With the ignition switch on, the ECU uses a high reference voltage ("1.7-2.5 vdc, typically 2.1 vdc), and a low reference voltage (0.5-0.9 vdc, typically 0.7 vdc), provided to each of the position switches (this allows the ECU to know which position the switch is in), the ECU must not be in the sleep mode (end of cycle completely up or down) while testing for these voltages. The easiest way to keep the ECU awake is to raise the tonneau. If the tonneau is cycled closed to allow quarter windows to extend, or the header latch motor to latch, the ECU can be awakened by operating the tonneau with the hard tonneau switch.

14. In the Pinpoint Tests, normal testing for the resistance of a good wire with an ohmmeter should

I TSB Revision

BODY - Diagnostics and Testing

42-17

have a value of 3 ohms or less. However, this may vary depending on the ohmmeter used, the length and size of the wire, the use of jumper wires for testing, the amount of connectors in the wire, etc. If a value much larger is found (e.g. 10 ohms), the wire and/or connectors may be suspect to loose connections, corrosion, and/or damage.

15. Under certain fault conditions, it may be necessary to cycle the ignition to the OFF position, and then back to the ON position, to resume hardtop operation.

16. Refer to Quick Reference Chart at the back of this Service Manual for Hatchback to Retractable hardtop wiring harness connector changes.

17. Refer to Configuration diagrams and Removal and Installation procedures for component locations.

DEFINITION OF TERMS

AUTO-CONFIGURATION

Refers to resetting of parameters of hardtop and hard tonneau movement in the ECU by use of a PC and the latest version of the ASC Incorporated software. It may be necessary to service and clear DTCs before auto-configuration can be performed. Refer to PC User's Manual for details on running AutoConfiguration.

DAMAGED

Refers to a mechanically or electrically inoperative component.

RESTORE VEHICLE

Is to install or connect components that were removed or disconnected for testing purpose. DTCs should not be cleared from the ECUs memory until all recorded DTC's have been resolved.

The system MUST be run through AUTO-CONFIGURATION whenever a repair is made or a part is replaced. Refer to PC User's Manual.

RETEST SYSTE M

Is to check for additional concerns after the original concern has been verified and repaired. This may involve checking for DTCs and/or operating the system and checking for proper operation.

I TSB Revision

42-18 GROUNDING LOCATIONS

BODY - Diagnostics and Testing

-

Header latch motor

I TSB Revision

BODY - Diagnostics and Testing

42-19

ECU CONNECTOR LOCATION

F-125

FRONT OF VEHICLE

F-124

HARDTOP' ELECTRONIC CONTROL. UNIT (ECU)

II TSB Revision

42-20

BODY - Diagnostics and Testing

Secondary lock

Primary lock

ELECTRONIC CONTROL UNIT (ECU) CONNECTOR TERMINAL DISENGAGEMENT

ECU CONNECTOR F-125 AND F-123

1. Insert screwdriver into LH side of connector, between lock and connector and rotate screwdriver, then slide lock to LH side to disengage connector.

2. With connector removed, grasp the connector and insert a small screwdriver into an empty cavity and pry sideways to release the secondary lock.

3. Using AMP tool number 0-0872070-1 or equivalent, insert tool straight into face of connector to disengage locking tabs on wire terminal, and pull wire and terminal from connector.

I TSB Revision

BODY - Diagnostics and Testing

42-21

ELECTRONIC CONTBOL UNIT (ECU) CONNECTOR TERMIINAL DISENGAGEMENT

ECU CONNECTOR F-124

1. Insert screwdriver into LH side of connector, between lock and connector and rotate screwdriver, then slide lock to LH side to disengage connector.

2. Using AMP tool number 726534-1 for small terminals, 726503-1 for larger terminals or equivalent, insert tool straight into face of connector to disengage locking tabs on wire terminal, and pull wire and terminal from connector.

I TSB Revision

42-22

BODY - Diagnostics and Testing

RECOMMENDED WIRE REPAIR PROCEDURE

A seal splice can be easily installed using a standard insulated crimp tool and a heat gun. The seal splices are color coded for easy identification of gauge sizes, and are transparent for visual inspection of the final repair.

1. Strip the wire ends 7.6 mm (0.3 inch) and insert into crimp barrel.

2. Push wires firmly into crimp barrel while crimping barrel.

3. Grasp seal splice and wire, and pull gently to ensure proper connection.

4. Heat splice with heat gun until tubing shrinks and adhesive flows from each end of seal splice.

I TSB Revision

BODY - Configuration Diagrams

42-23

OVERALL CONFIGURATION DIAGRAM

Cl C .;::

.- en

s ~ oE

Oeo a:..c

Cl C

Cl C 'L: *

.- en

~en

.... Q) OC 0 ....

O~

.~

.... (J) Q)en "OQ) eoE Q)eo I..c

Cl C

.~

_ en oen .... Q) +-'c C ....

Oeo U..c

I ~T_S __ B_R_e_v_i_si_o_n J

(/) (/) Q.) C

....

co ..c

C> c

. .:::: as

.~~

.... (/)

.2..1:

COc> E·.::::

Q.) Q.) ..c..c

+-,+-'

>(0 C-o o Q.) (/)0.

~ .9-

o :::J ..cO" (/) Q.)

C 0 o (/) . .;::; co

~ (/) t)~

:::J co =u

.;;; :0

.- C LU ..c .-

f- f- *

0--

ZS~

Cl C .;::

.~ ~

+-,Q) CC

2~

u....c

42-24

BODY - Diagnostics and Testing

INTERIOR

E-112 E-113

E-127

E-111

E

E-117_

Connector symbol

E-116

C-110

E-115

E-114

E-34 -:
C-91
E-31 E-30 E-47
C-91 Data Link Connector (DLC) Retractable E-20 MMC (refer to Volume 2)*
hardtop E-21 MMC (refer to Volume 2)*
C-10 Battery supply to hardtop ECU. E-22 MMC (refer to Volume 2)*
E-01 MMC (refer to Volume 2)* E-23 MMC (refer to Volume 2)*
E-02 E-24 MMC (refer to Volume 2)*
E-03 MMC (refer to Volume 2)* E-25 Door light (LH)
E-04 MMC (refer to Volume 2)* E-26 MMC (refer to Volume 2)*
E-05 MMC (refer to Volume 2)* E-27 MMC (refer to Volume 2)*
E-06 MMC (refer to Volume 2)* E-28 MMC (refer to Volume 2)*
E-07 E-29 MMC (refer to Volume 2)*
E-08 MMC (refer to Volume 2)* E-30 Turn signal and hazard flasher unit
E-09 MMC (refer to Volume 2)* E-31 Diode (for MFI circuit)
E-10 MMC (refer to Volume 2)* E-32 MMC (refer to Volume 2)*
E-11 MMC (refer to Volume 2)* E-33 MMC (refer to Volume 2)*
E-12 MMC (refer to Volume 2)* E-34 Power window main switch
E-13 MMC (refer to Volume 2)* E-35 Power window motor
E-14 MMC (refer to Volume 2)* E-36 MMC (refer to Volume 2)*
E-15 MMC (refer to Volume 2)* E-37 MMC (refer to Volume 2)*
E-16 MMC (refer to Volume 2)* E-38 MMC (refer to Volume 2)*
E-17 MMC (refer to Volume 2)* E-39 MMC (refer to Volume 2)*
E-18 MMC (refer to Volume 2)* E-40 MMC (refer to Volume 2)*
E-19 MMC (refer to Volume 2)* E-41 MMC (refer to Volume 2)*
I TSB Revision BODY - Diagnostics and Testing

42-25

E-35

E-125

E-42 MMC (refer to Volume 2)*

E-43 MMC (refer to Volume 2)*

E-44 MMC (refer to Volume 2)*

E-45 Body to Header harness (LH)(6 way)

E-46 Body to Header harness (LH)(9 way)

E-47 Chime Module (retractable hardtop)

E-11 0** Not used

E-111 Header position switch (RH)

E-112 HomeLink™ Universal transmitter E-113 Header unlatch switch

E-114 Header position switch (LH)

E-115 Header latch switch

E-116 Rearview mirror (self dimming and lighted)

Header latch motor Defogger (neg)

Retractable quarter window retract switch

E-120 Defogger (pos)

E-121 Roof harness to rear harness (four way connector)

E-117 E-118 E-119

E-122

E-123

E-124 E-125

E-126 E-127

F-01

E-120

E-121

E-122

Roof harness to rear harness (eight way connector)

Retractable quarter window extend switch

Retractable quarter window motor Drivers window relay to power window motor

Drivers window relay to power window main switch

Jumper to mirror (from E-116)(P.I.A. mirror)

Interior temperature sensor

* Connectors (not shown) are in Mitsubishi wiring harness and are used on retractable hardtop.

** Connectors numbered 110 and higher are new connectors in ASC Inc. wiring harnesses for retractable hardtop.

I ~T_S_B __ R_e_v_is_io_n ]

42-26

BODY - Diagnostics and Testing

LUGGAGE COMPARTMENT

Connector symbol

F

F-06

F-111 F-112 F-113

F-110

.i->:

»->

F-40~

»->

F - 50 ---------

E-121** Roof harness to rear harness (four way connector)

E-122 Roof harness to rear harness (eight way connector)

F-01 Refer to Configuration Diagram E

F-02 Changed to E-120 (refer to Configuration Diagram E)

F-03

F-04 High mounted stop light

F-05 Changed to E-118 (refer to Configuration

Diagram E)

F-06 Rear speaker (RH)

F-07 ECS rear shock absorber (RH)

F-08 Luggage compartment lamp

F-09

F-10 Rear combination light (RH)

F-11 Back up light (RH)

F-12 MMC (refer to Volume 2)*

F-13 MMC (refer to Volume 2)*

F-14 Rear wiring harness (RH) and fuel tank wiring harness combination

F-15

F-16 Fuel tank

F-17 License plate light (RH)

F-18

F-19 F-20 F-21 F-22 F-23 F-24 F-25 F-26 F-27 F-28 F-29 F-30 F-31

F-32 F-33 F-34 F-35 F-36 F-37 F-38 F-39

F-46 F-33

F-48

F-49

Rear wiring harness (RH) and rear bumper wiring harness combination

License plate light (LH) Changed to F-116

Back up light (LH)

Rear combination light (LH)

Changed to A-79, MMC (refer to Volume 2)*

ECS rear shock absorber (LH) Rear speaker (LH)

I TSB Revision

BODY - Diagnostics and Testing

42-27

F-40 F-41 F-42 F-43 F-44

F-47

F-48 F-49 F-50

F-51

F-110 F-111 F-112 F-113

F- 4

F-32

F-120

F-119

F-118

CD changer

Body wiring harness (RH) and rear wiring harness combination (22 way)

F-45 F-46

Body wiring harness (LH) and rear wiring harness combination (17 way)

Body wiring harness (LH) and rear wiring harness combination (4 way)

Body wiring harness (LH) and rear wiring harness combination (19 way)

Body wiring harness (LH) and rear wiring harness combination (8 way)

Body wiring harness (LH) and rear wiring harness combination (2 way)

Body wiring harness (LH) and rear wiring harness combination (13 way)

Hardtop potentiometer

Hard tonneau latch switch (RH) Hard tonneau latch motor (RH) Hard tonneau drive motor

F-114 F-115

Hard tonneau potentiometer

Object in trunk sensor to rear harness (jumper)

Luggage compartment lamp switch High mounted stop light to rear harness Hard tonneau latch motor (LH)

Hard tonneau latch switch (LH)

Hardtop drive motor

Not used

Not used

ECU window motors and tonneau control ECU low current (control)

ECU high current

Object in trunk sensor

F-116 F-117 F-118 F-119 F-120 F-121 F-122 F-123 F-124 F-125 F-126

* Connectors (not shown) are in Mitsubishi wiring harness and are used on retractable hardtop.

** Connectors numbered 110 and higher are new connectors in ASC Inc. wiring harnesses for retractable hardtop.

~IT_S_B __ R_e_V_is_io_n ]

42-28

BODY - Diagnostics and Testing

WIRE COLOR CODES

Wire colors are identified by the following color codes.

Code Wire color Code Wire color
B Black PL Purple
BR Brown R Red
G Green SB Sky blue
GR Gray T Tan
L Blue V Violet
LG Light green W White
0 Orange Y Yellow
P Pink - - NOTE

If a cable has two colors, the first of the two color code characters indicates the basic color (color of the cable coating) and the second indicates the marking color.

Example: <F> 1.25G - B

---,
~J II. I

Marking COI~


Basic COlor]



Wire size (mm')
(1) No code indicates 0.5 mm' (.0008 in.').
(2) Cable color code in parentheses indicates
0.3 mm' (.0005 in.').

<F>: Flexible wire I <T>: TWisted wire

I TSB Revision

BODY - Diagnostics and Testing

42-29

RETRACTABLE HARDTOP OPERATION OPENING THE HARDTOP

The Electronic Control Unit (ECU) for the Mitsubishi 3000GT Spyder retractable hardtop is a self-contained computer. All electrical functions of the hardtop system are controlled by the ECU.

Power is supplied to the ECU through a 60-amp fuse in the junction box in the engine compartment. The ECU has a sleep mode. When no power is supplied to the ECU from the ignition circuit, or at the completion of its full cycle (either close or open) the ECU goes to sleep. This allows the ECU to draw minimal power from the battery.

The high-current grounds and the electronic logic ground are supplied through the vehicle chassis. The following is the sequence of events for the retractable hardtop to move from the fully closed position, to the fully open position, under normal conditions:

• The hardtop is in the fully closed position;

• Header latches are latched;

• Quarter windows are closed;

• Door windows are in any position;

• Tonneau is latched;

• Hardtop stowage area is empty;

• Vehicle in Park (AfT) or Neutral (MfT);

• Hand brake is applied.

To open the hardtop, start the vehicle. Power is then supplied to the ECU from the ignition circuit. At this time the ECU will go through internal diagnostics that will check iits internal memory and circuits and will monitor all hardtop and tonneau switches and sensors. If the internal circuitry is found fully operational and the hardtop or tonneau control switch is not pressed, then the ECU will go to sleep waiting for movement of the hardtop, tonneau or passenger side door window switch.

With the engine running and hardtop control switch pressed to the OI=»EN position, power is supplied to the ECU from the hardtop control switch, and this awakens the ECU. During normal hardtop operation the Light Emitting Diodes (LEOs) flash. The chime will sound at the same rate as the LED flash. The hardtop LEOs and chime will continue to operate as long as the tonneau is not latched and the ignition is turned to the ON position.

The ECU supplies power to the driver and passenger's side door window motors, and quarter window motor to drive them to the open position.

Once the quarter windows have been retracted the quarter window limit switch sends a signal to the ECU and power is supplied to drive the header latch motor to the fully unlatched position. The header latch motor will continue to move until the header latch limit switch indicates a fully unlatched position. Power is also supplied to the tonneau latch solenoids to pull the release cables, which releases the tonneau latches. Power is then supplied to the tonneau pump motor. This raises the tonneau allowing the hardtop to retract into the hardtop stowage area.

Once the potentiometer located on the tonneau lift mechanism senses a position where there is enough clearance for the hardtop, the hardtop pump motor will begin to move the hardtop to the open position.

If sufficient pressure from an object is detected in the hardtop stowage! area by the object-in-trunk sensor, the hardtop operation is restricted and can only open halfway, and the chime and LEOs will respond at twice the normal rate. In the event that an object does not apply sufficient pressure to activate the object-in-trunk sensor, the hardtop will continue to move to the open position until the hardtop applies pressure against the object in the hardtop stowage area and activates the object-in-trunk sensor. The hardtop will automatically reverse direction to the halfway position. Normal operation can start once the object in the hardtop stowage area has been removed.

I~T_S_B __ R_e_Vi_S_io_n J

42-30

BODY - Diagnostics and Testing

The potentiometer located on the hardtop main pivot then indicates the hardtop is stowed in the hardtop stowage area and the hardtop pump motor will shut off.

The tonneau continues to the closed position and is mechanically pulled to the latched position by cables attached to the tonneau lift mechanisms. The tonneau latch position switches confirm a latched position to the ECU and the tonneau pump motor is shut off. The chime sounds for one second and the chime and LEDs turn off, and the ECU will go to sleep.

I TSB Revision

BODY - Diagnostics and Testing

42-31

CLOSING THE HARDTOP

Under normal conditions:

• The hardtop in the fully open position (in stowage area);

• Tonneau is latched;

• Vehicle in Park (AfT) or Neutral (M[T);

• Hand brake applied.

Start the engine, press hardtop control switch to the CLOSED position. Power is supplied to the tonneau latch solenoids, which pull on the tonneau latch release cables, releasing the tonneau latches. Power is supplied to the chime and LED's, and the chime will sound and the LED's will flash.

Power is then supplied to the tonneau pump motor, which starts to raise the tonneau. The tonneau potentiometer sends a signal to the ECU indicating that the tonneau is fully opened.

This signal causes power to be supplied to the hardtop pump motor, raising the hardtop out of the stowage area.

As the hardtop moves forward the hardtop potentiometer sends a signal to the ECU to indicate that the tonneau can start closing.

The hardtop continues closing until coming to a safety stop position, which allows for checking for obstructions between hardtop and header. The hardtop control switch must be pressed again to continue movement.

When the header latch striker enters the header latch, the header latch position switches sends a signal to the ECU indicating that the hardtop is in a position to be latched, then power will be provided to the header latch motor to engage the latches. The header unlatch limit switch sends a signal to the ECU and then the hardtop pump motor is turned off.

The tonneau continues to the closed position and is mechanically pulled to the latched position by cables attached to the tonneau lift mechanisms. The tonneau latch position switches confirm a latched position to the ECU and the tonneau pump motor is shut off.

Only after tonneau is closed and latched, power is provided to the quarter window motor and side door window motors. When the quarter windows have fully extended and the door windows have fully raised, the chime will sound for one second to indicate the completion of the hardtop up cycle. The chime and LEOs turn off, and the ECU will go to sleep.

I TSB Revision

42-32

BODY - Diagnostics and Testing

INSPECTION AND VERIFICATION

1. Verify the customer's original concern by operating the system to duplicate the concern.

2. Inspect to determine if any of the following mechanical or electrical concerns apply:

MECHANICAL ELECTRICAL.
• Damaged linkage. (Linkage • Blown fuse.
binding or bent). • Circuitry open or shorted.
• Damaged or misaligned • Damaged control or window
latches. switches.
• Damaged or misaligned • Damaged motors.
strikers.
• Damaged or misaligned
cables.
• Damaged hydraulic cylinders.
• Damaged hydraulic lines.
• Damaged hydraulic
pump/motor.
• Damaged header latch limit
switch pins. 3. If the inspection reveals obvious concern(s) that can be readily identified, service as required.

4. If the concern(s) remain after inspection, determine the symptom and !lO to the Symptom Chart.

NOTE: A PC MUST BE CONNECTED AT THIS TIME TO CHECK AND RECOVER DTCs FROM THE ECU. REFER TO PC USER'S MANUAL.

I TSB Revision

BODY - Diagnostics and Testing

42-33

SYMPTOM CHART

NO DIAGNOSTIC TROUBLE CODES PRESENT

NOTE: AFTER DETERMINING THE PINPOINT TEST, REFER TO TROUB,LESHOOTING HINTS FOLLOWING SYMPTOM CHART.

CONDITION POSSIBLE CAUSE ACTION
• Chime does not operate with • Circuitry open/shorted. • Go to Pinpoint Test A.
hardtop or hard tonneau open. • Damaged chime module.
• Damaged ECU.
• Chime stays on continuously with • Circuitry shorted. • Go to Pinpoint Test B.
hardtop and hard tonneau • Damaged chime module.
closed/no DTCs present. • Damaged ECU.
• Driver window inoperative with • Circuitry open/shorted. • Go to Pinpoint Test C.
driver window switch. • Damaged window motor.
• Damaged window switches.
• Damaged ECU.
• Driver window inoperative with • Circuitry open/shorted. • Go to Pinpoint Test DTC 52.
hardtop operation. • Damaged window motor.
• Damaged window relays.
• Damaged ECU.
• Hard tonneau hydraulic system • Low fluid level. • Go to Pinpoint Test D.
inoperative. (Possible DTC 54) • Excessive air in system.
• Internal or external leaks.
• Damaged pump/motor.
• Damaged hydraulic cylinders.
• Damaged bypass valve.
• Valve in bypass.
• Damaged manifold.
• Hard tonneau inoperative with • Circuitry open/shorted. • Go to Pinpoint Test E.
control switch. • Damaged control switch.
• Damaged ECU.
• Hard tonneau will not unlatch with • Circuitry open/shorted. • Go to Pinpoint Test F.
control switch. • Damaged hard tonneau latch
solenoids.
• Damaged ECU.
• Hardtop Hydraulic system • Low fluid level. • Go to Pinpoint Test G.
inoperative. (Possible DTC 55) • Excessive air in system.
• Internal or External leaks.
• Damaged pump/motor.
• Damaged hydraulic cylinders.
• Damaged bypass valve.
• Valve in bypass.
• Damaged manifold.
• Hardtop inoperative with control • Circuitry open/shorted. • Go to Pinpoint Test H.
switch. • Damaged control switch.
• Damaged ECU.
• Hardtop operates when automatic • Circuitry shorted. • Go to Pinpoint Test J.
transmission is out of park • Damaged ECU.
position.
• Hardtop operates when vehicle is • Circuitry open/shorted. • Go to Pinpoint Test J for automatic
moving. • Damaged ECU. transaxle and Pinpoint Test L for
Note: Two different conditions manual transaxle, then proceed to
must exist for this to occur. Pinpoint Test K.
Proceed as indicated.
• Hardtop operates without parking • Circuitry shorted. • Go to Pinpoint Test L.
brake applied, (manual • Damaged ECU.
transmission). I TSB Revision

42-34

BODY - Diagnostics and Testing

SYMPTOM CHART

NO DIAGNOSTIC TROUBLE CODES PRESENT (CONTINUED)

NOTE: AFTER DETERMINING THE PINPOINT TEST, REFER TO TROUBLESHOOTING HINTS FOLLOWING SYMPTOM CHART.

CONDITION POSSIBLE CAUSE ACTION
• LEDs inoperative or on all the time. • Circuitry open/shorted. • Go to Pinpoint Test M.
• Damaged control switch.
• Damaged ECU.
• Passenger window inoperative • Circuitry open/shorted. • Go to Pinpoint Test DTC 53.
with hardtop. • Damaged passenger window
motor.
• Damaged ECU.
• Passenger window inoperative • Circuitry open/shorted. • Go to Pinpoint Test N.
with window switch. • Damaged switch.
• Damaged passenger window
motor.
• Damaged ECU.
• Passenger window will not work • Circuitry open/shorted. • Refer to Vol. 1 and 2 of Service
from drivers window switch. • Damaged switches. Manual for window service.
• PC will not communicate with • Circuitry open/shorted. • Go to Pinpoint Test P.
ECU. • Damaged PC.
• Damaged converter.
• Damaged cables.
• Damaged ECU.
• Retractable quarter window (one • Damaged cable. • Inspect and service mechanical
side) inoperative. • Damaged guide. problems. I TSB Revision

BODY - Diagnostics and Testing

42-35

SYMPTOM CHART

DIAGNOSTIC TROUBLE CODES

NOTE: AFTER DETERMINING THE DTC REFER TO TROUBLESHOOTING HINTS FOLLOWING SYMPTOM CHART.

FOR DTC DESCRIPTION REFER TO PAGES 42-47 AND 42-48

CONDITION POSSIBLE CAUSE ACTION
o DTC 00 o No fault. o Check for possible mechanical or
hydraulic concerns.
o Go to Symptom Chart-No
Diagnostic Trouble Codes present.
o DTC 01 o Reserved o Reserved.
o DTC 02 o Damaged ECU. o Go to Pinpoint Test DTC 02-06.
o Circuitry open/shorted.
o Damaged limit switch.
o DTC 03 o Damaged ECU. o Go to Pinpoint Test DTC 02-06.
o Circuitry open/shorted.
o Damaged limit switch.
o DTC 04 o Damaged ECU. o Go to Pinpoint Test DTC 02-06.
o Circuitry open/shorted.
o Damaged limit switch.
o DTC 05 o Damaged ECU. o Go to Pinpoint Test DTC 02-06.
o Circuitry open/shorted.
o Damaged limit switch.
o DTC 06 o Damaged ECU. o Go to Pinpoint Test DTC 02-06.
o Circuitry open/shorted.
o Damaged limit switch.
o DTC 07 o Blown fuse. o Go to Pinpoint Test DTC 07.
o Circuitry open/shorted.
o Damaged ECU.
o DTC 08 o Damaged battery. o Go to Pinpoint Test DTC 08.
o Charging system malfunction.
o Damaged ECU.
o DTC 09 o Damaged hardtop potentiometer. o Go to Pinpoint Test DTC 09-11.
o Circuitry open/shorted.
o Damaged ECU.
o DTC 10 o Damaged hardtop potentiometer. o Go to Pinpoint Test DTC 09-11.
o Circuitry open/shorted.
o Damaged ECU.
o DTC 11 o Damaged hardtop potentiometer. o Go to Pinpoint Test DTC 09-11.
o Circuitry open/shorted.
o Damaged ECU.
o DTC 12 o Damaged hard tonneau o Go to Pinpoint Test DTC 12-14.
potentiometer.
o Circuitry open/shorted.
o Damaged ECU.
o DTC 13 o Damaged hard tonneau o Go to Pinpoint Test DTC 12-14.
potentiometer.
o Circuitry open/shorted.
o Damaged ECU. I TSB Revision

42-36

BODY - Diagnostics and Testing

SYMPTOM CHART

DIAGNOSTIC TROUBLE CODES

NOTE: AFTER DETERMINING THE DTC REFER TO TROUBLESHOOTING HINTS FOLLOWING SYMPTOM CHART.

FOR DTC DESCRIPTION REFER TO PAGES 42-47 AND 42-48

CONDITION POSSIBLE CAUSE ACTION
• DTC 14 • Damaged hard tonneau
potentiometer. • Go to Pinpoint Test DTC 12-14.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 15 • Damaged hardtop and/or hard • Go to Pinpoint Test DTC 15.
tonneau potentiometer.
• DTC 16 • Circuitry open/shorted. • Go to Pinpoint Test DTC 16.
• Damaged ECU.
• DTC 17 • Damaged hardtop and/or hard • Go to Pinpoint Test DTC 17.
tonneau potentiometer.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 18 • Damaged header latch limit switch. • Go to Pinpoint Test DTC 18.
• Circuitry open/shorted.
• Damaged header latch motor.
• Damaged ECU.
• Damaged and/or binding linkage.
• DTC 19 • Damaged header latch limit switch. • Go to Pinpoint Test DTC 19.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 20 • Damaged header latch limit switch. • Go to Pinpoint Test DTC 20.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 21 • Damaged header latch limit switch. • Go to Pinpoint Test DTC 21.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 22 • Damaged header unlatch limit • Go to Pinpoint Test DTC 22.
switch.
• Circuitry open/shorted.
• Damaged header latch motor.
• Damaged ECU.
• Damaged and/or binding linkage.
• DTC 23 • Damaged header unlatch limit • Go to Pinpoint Test DTC 23.
switch.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 24 • Damaged header unlatch limit • Go to Pinpoint Test DTC 24.
switch.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 25 • Damaged header unlatch limit • Go to Pinpoint Test DTC 25.
switch.
• Circuitry open/shorted.
• Damaged ECU. I TSB Revision

BODY - Diagnostics and Testing

42-37

SYMPTOM CHART

DIAGNOSTIC TROUBLE CODES (CONTINUED)

NOTE: AFTER DETERMINING THE DTC REFER TO TROUBLESHOOTING HINTS FOLLOWING SYMPTOM CHART.

FOR DTC DESCRIPTION REFER TO PAGES 42-47 AND 42-48

CONDITION POSSIBLE CAUSE ACTION
• DTC 26 • Damaged LH retractable quarter • Go to Pinpoint Test DTC 26.
window extend limit switch.
• Circuitry open/shorted.
• Damaged retractable quarter
window motor.
• Damaged ECU.
• Damaged and/or binding linkage.
• DTC 27 • Damaged LH retractable quarter • Go to Pinpoint Test DTC 27.
window extend limit switch.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 28 • Damaged LH retractable quarter • Go to Pinpoint Test DTC 28.
window extend limit switch.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 29 • Damaged LH retractable quarter • Go to Pinpoint Test DTC 29.
window extend limit switch.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 30 • Damaged RH retractable quarter • Go to Pinpoint Test DTC 30.
window retract limit switch.
• Circuitry open/shorted.
• Damaged retractable quarter
window motor.
• Damaged ECU.
• Damaged and/or binding linkage.
• DTC 31 • Damaged RH retractable quarter • Go to Pinpoint Test DTC 31.
window retract limit switch.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 32 • Damaged RH retractable quarter • Go to Pinpoint Test DTC 32.
window retract limit switch.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 33 • Damaged RH retractable quarter • Go to Pinpoint Test DTC 33.
window retract limit switch.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 34 • Damaged LH header position limit • Go to Pinpoint Test DTC 34.
switch.
• Circuitry open/shorted.
• Damaged header latch motor.
• Damaged ECU.
• DTC 35 • Damaged LH header position limit • Go to Pinpoint Test DTC 35.
switch.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 36 • Damaged LH header position limit • Go to Pinpoint Test DTC 36.
switch.
• Circuitry open/shorted.
• Damaged ECU. I TSB Revision

42-38

BODY - Diagnostics and Testing

SYMPTOM CHART

DIAGNOSTIC TROUBLE CODES (CONTINUED)

NOTE: AFTER DETERMINING THE DTC REFER TO TROUBLESHOOTING HINTS FOLLOWING SYMPTOM CHART.

FOR DTC DESCRIPTION REFER TO PAGES 42-47 AND 42-48

CONDITION POSSIBLE CAUSE ACTION
• DTC 37 • Damaged LH header position limit • Go to Pinpoint Test DTC 37.
switch.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 38 • Damaged RH header position limit • Go to Pinpoint Test DTC 38.
switch.
• Circuitry open/shorted.
• Damaged ECU
• DTC 39 • Damaged RH header position limit • Go to Pinpoint Test DTC 39.
switch.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 40 • Damaged RH header position limit • Go to Pinpoint Test DTC 40.
switch.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 41 • Damaged RH header position limit • Go to Pinpoint Test DTC 41.
switch.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 42 • Damaged LH tonneau latch limit • Go to Pinpoint Test DTC 42.
switch.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 43 • Damaged LH tonneau latch limit • Go to Pinpoint Test DTC 43.
switch.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 44 • Damaged LH tonneau latch limit • Go to Pinpoint Test DTC 44.
switch.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 45 • Damaged LH tonneau latch limit • Go to Pinpoint Test DTC 45.
switch.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 46 • Damaged RH tonneau latch limit • Go to Pinpoint Test DTC 46.
switch.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 47 • Damaged RH tonneau latch limit • Go to Pinpoint Test DTC 47.
switch.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 48 • Damaged RH tonneau latch limit • Go to Pinpoint Test DTC 48.
switch.
• Circuitry open/shorted.
• Damaged ECU. I TSB Revision

BODY - Diagnostics and Testing

42-39

SYMPTOM CHART

DIAGNOSTIC TROUBLE CODES (CONTINUED)

NOTE: AFTER DETERMINING THE DTC REFER TO TROUBLESHOOTING HINTS FOLLOWING SYMPTOM CHART.

FOR DTC DESCRIPTION REFER TO PAGES 42-47 AND '~2-48

CONDITION POSSIBLE CAUSE ACTION
• DTC 49 • Damaged RH tonneau latch limit • Go to Pinpoint Test DTC 49.
switch.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 50 • Circuitry shorted. • Go to Pinpoint Test DTC 50.
• Damaged hardtop pump/motor.
• Damaged ECU.
• Damaged and/or binding linkage.
• DTC 51 • Circuitry shorted. • Go to Pinpoint Test DTC 51.
• Damaged hard tonneau
pump/motor.
• Damaged ECU.
• Damaged and/or binding linkage.
• DTC 52 • Circuitry open/shorted. • Go to Pinpoint Test DTC 52.
• Damaged driver window relay
assembly.
• Damaged driver window motor.
• Damaged ECU.
• Damaged and/or binding linkage.
• DTC 53 • Circuitry open/shorted. • Go to Pinpoint Test DTC 53.
• Damaged passenger window
motor.
• Damaged ECU.
• Damaged and/or binding linkage.
• DTC 54 • Circuitry open/shorted. • Refer to Pinpoint Test for any other
• Damaged hard tonneau DTC that occurred.
pump/motor. • Go to Pinpoint Test D, E, and F.
• Damaged ECU.
• Damaged and/or binding linkage or
latches.
• Operating off poor battery or poor
power supply.
• Obstruction of hard tonneau (other
than linkage).
• DTC 55 • Circuitry open/shorted. • Refer to Pinpoint Test for any other
• Damaged hardtop pump/motor. DTC that occurred.
• Damaged ECU. • Go to Pinpoint Test G, and H.
• Damaged and/or binding linkage or
latches.
• Operating off poor battery or poor
power supply.
• Obstruction of hard tonneau (other
than linkage).
• DTC 56 • Circuitry open/shorted. • Go to Pinpoint Test DTC 56.
• Damaged object-in-trunk sensor.
• Damaged ECU.
• Object-in-trunk sensor
disconnected.
• DTC 57 • Damaged and/or binding LH • Check and service mechanical
tonneau latches or cables. concerns.
• Damaged LH tonneau latch release • Go to Pinpoint Test F.
motor.
• Circuitry open.
• DTC 58 • Damaged and/or binding RH • Check and service mechanical
tonneau latches or cables. concerns.
• Damaged RH tonneau latch release • Go to Pinpoint Test F.
motor.
• Circuitry open. I TSB Revision

42-40

BODY - Diagnostics and Testing

SYMPTOM CHART

DIAGNOSTIC TROUBLE CODES (CONTINUED)

NOTE: AFTER DETERMINING THE DTC REFER TO TROUBLESHOOTING HINTS FOLLOWING SYMPTOM CHART.

FOR DTC DESCRIPTION REFER TO PAGES 42-47 AND 42-48

CONDITION POSSIBLE CAUSE ACTION
• OTC 59 • Damaged and/or binding hardtop • Check and service mechanical
linkage. concerns.
• Damaged header latch strikers. • Go to Pinpoint Test OTC 44 and
• Damaged header latch position DTC 48.
switches.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 60 • Damaged and/or binding hard • Check and service mechanical
tonneau linkage. concerns.
• Damaged tonneau latch strikers. • Go to Pinpoint Test OTC 42 and
• Damaged tonneau latch position DTC 46.
switches.
• Circuitry open/shorted.
• Damaged ECU.
• DTC 61 • Damaged and/or binding hardtop • Check and service mechanical
linkage. concerns.
• Obstruction in path of normal • Remove obstruction.
travel. • Refer to other DTCs that may have
occurred.
• DTC 62 • Damaged and/or binding hard • Check and service mechanical
tonneau linkage. concerns.
• Obstruction in path of normal • Remove obstruction.
travel. • Refer to other DTCs that may have
occurred. I TSB Revision

BODY - Diagnostics and Testing

42-41

TROUBLESHOOTING HINTS FOR NO OTCs PRESENT

Pinpoint Test A:

Indicates that the chime module is not operating when it should. This may occur if ignition voltage is not supplied to pins 1 and 2 of the chime module, ground is not provided to pin 7 of the chime module, ground is not provided to pin 10 of the chime module throuqh circuit AC 3, or the ECU or chime module are not responding to proper inputs.

Pinpoint Test B:

Indicates that the chime module is on at all times. This may occur if circuit AC 3 is grounded, or if the ECU or chime module is grounding this circuit.

Pinpoint Test C:

Indicates that the drivers window does not operate with the drivers window switch. This may occur if there is an open/short in circuits up to the drivers window relay assembly, or damaged drivers window relay assembly.

Driver window inoperative with hardtop operation:

Indicates that the drivers window does not operate with the hardtop operation. This may occur if circuits GW 51 or GW 52 are open/shorted, drivers window relay assembly is not functioning properly, ECU is not applying voltage and ground to circuits GW 51 and GW 52, or the drivers window motor is damaged.

Pinpoint Test D:

Indicates that the hard tonneau hydraulic system is not operating properly. This may occur with damaged pump/motor, not producing proper pressure to move hard tonneau, external leaks in cylinders and/or lines, internal leaks in cylinders or excessive air in the system.

Pinpoint Test E:

Indicates that the hard tonneau did not respond to control switch operation. This may occur if ignition voltage is not supplied to the hard tonneau control switch, darnaqed switch, circuits GC 5 and GC 6 open/shorted, or ECU does not respond to proper inputs.

Pinpoint Test F:

Indicates that the tonneau latches did not unlatch electrically. This may occur if circuit GC 32 or the ground wire to the tonneau latch solenoids are open/shorted, or the ECU did not send power to the solenoids.

Pinpoint Test G:

Indicates that the hardtop hydraulic system is not operating properly. This may occur with damaged pump/motor, not producing proper pressure to move hardtop, external leaks in cylinders and/or lines, internal leaks in cylinders or excessive air in the system.

Pinpoint Test H:

Indicates that the hardtop did not respond to control switch operation. This may occur if ignition voltage is not supplied to the hardtop control switch, damaged switch, circuits GC 28 and GC 4 open/shorted, or ECU does not respond to proper inputs.

II TSB Revision

42-42

BODY - Diagnostics and Testing

TROUBLESHOOTING HINTS (CONTINUED)

Pinpoint Test J:

Indicates that the ECU is seeing voltage still supplied to circuit GC 7. This may occur with an internal ECU short to voltage, circuit GC 7 shorted to voltage, or parking switch damaged or out of adjustment.

Pinpoint Test K:

Indicates that the hardtop and/or hard tonneau may be operated while driving vehicle over 3 mph. Two conditions must be present for this to occur, circuit GC 7 must have voltage present, or circuit GC 28 must be grounded, and GC 12 (HE 3 at the ETAC) must have approximately 9 volts or greater present. These conditions may occur in the circuits, ECU, or both.

Pinpoint Test L:

Indicates that the ECU is seeing a ground supplied to circuit GC 28. This may occur with an internal ECU short to ground, circuit GC 28 shorted to ground, or the parkinq brake switch damaged or out of adjustment.

Pinpoint Test M:

Indicates that the LEOs either do not operate or are on all the time. If the LEOs are on all the time circuits GC 51 and/or GC 52 would be shorted to ground, depending on which LED was on. If the both LEOs do not work, this may occur if voltage is not present on circuit GC 53 from the ECU, or control switch, or ECU is damaged. If one LED does not work, this may occur if circuit GC 51 or GC 52 is open, or control switch, or ECU is damaged.

Passenger window inoperative with hardtop:

Indicates that the passengers window does not operate with the hardtop operation. This may occur if circuits GW 53 or GW 54 are open/shorted, ECU is not applying voltage and ground to circuits GW 53 and GW 54, or the passengers window motor is damaged.

Pinpoint Test N:

Indicates that the passenger window does not operate with the passenger window switch. This may occur if circuits GW 43, GW 44, are open/shorted, damaged passenqer window switch, or ignition voltage not supplied to switch, or if ECU does not respond to input voltage.

Passenger window will not work from drivers window switch:

Indicates that passenger window works with hardtop and passenger window switch operation, this may occur if circuits GW 9 and/or GW 10 from drivers window switch to passenger window is open/shorted or damaged switch.

Pinpoint Test P:

Indicates that the Personal Computer (PC) and the ECU cannot communicate with each other. This may occur if ignition and ground are not supplied to the Data Link Connector (OLC), circuit GC 9 is open/shorted, PC version software does not match ECU version software, convertor and/or cables damaged, or the PC is not functioning properly.

Retractable quarter window (one side) inoperative:

If one retractable quarter window operates properly then the electrical components must be operating properly and mechanical binding or breakage is the probable cause.

I TSB Revision

BODY - Diagnostics and Testing

42-43

TROUBLESHOOTING HINTS FOR DTCs

DTC 02-06:

Indicates an internal ECU fault. This may also occur if the ECU no longer sees its reference voltage (circuits GC 20 and GC 23), which could occur if reference voltage (circuit GC 20 or GC 23) are shorted to ground or to voltage above reference voltage. These circuits must be tested before replacing ECU.

DTC 07:

Indicates that battery voltage is missing from both circuits (GC1A AND GC 1) at the ECU. This may occur if there is an open in circuits or heavy current draw (such as a short circuit or shorted motor) causing the fuse to blow.

DTC 08:

Indicates that battery voltage is below 10 VDC or above 16 VDC. Normallv caused by a damaged battery or malfunctioning charging system.

DTC 09-11:

Indicates a fault with hardtop potentiometer and/or potentiometer feed circuit GC 18, potentiometer ground circuit GC 19, or potentiometer signal return circuit GC 16.

DTC 12-14:

Indicates a fault with hard tonneau potentiometer and/or potentiometer feed circuit GC 18, potentiometer ground circuit GC 19, or potentiometer signal return circuit GC 17.

DTC 15:

Indicates an internal diode fault in either the hardtop or hard tonneau potentiometer.

DTC 16:

Indicates that the ECU is seeing higher than reference voltage on the potentiometer feed circuit. This may occur if circuit GC 18 is shorted to voltage.

DTC 17:

Indicates that the ECU is seeing the potentiometer feed circuit being grounded. This may occur if circuit GC 18 is shorted to ground.

DTC 18,22,26,30:

Indicates that the ECU did not see a change in limit switch position within the specified time (timeout). This may occur if a switch or circuits are damaged, or the motor did not move the component to move the switch.

NOTE: If the concern is with the retractable quarter window switch the magnet on the end of the cable may need to be inspected.

~IT_S_B __ R_eV_i_Si_o_n J

42-44

BODY - Diagnostics and Testing

TROUBLESHOOTING HINTS FOR DTCs (CONTINUED)

DTC 19,23,27,31,35,39,43,47:

Indicates that the limit switch return circuit must be grounded on the ECU side and also open, this can occur in the limit switch return circuit to the ECU, through the limit switch, or in the reference circuits (GC 20 and GC 23) to the point where they would splice together to go to other limit switches. If the reference circuits (GC 20 and GC 23) are grounded beyond the splice point (qroundinq the circuit to more than one limit switch) the ECU will log an internal fault indicating the reference voltage is too low or missing.

DTC 20,24,28,32,36,40,44,48:

Indicates that the limit switch return circuit must be shorted to higher than reference voltage on the ECU side and also open, this can occur in the limit switch return circuit to the FCU, through the limit switch, or in the reference circuits (GC 20 and GC 23) to the point where they would splice together to go to other limit switches. If the reference circuits (GC 20 and GC 23) are shorted to voltage beyond the splice point (shorting the circuit to more than one limit switch) the ECU will log an internal fault indicating the reference voltage is to high. The short to higher voltage may occur from any circuit in or near the limit switch harness, therefore it is necessary to operate all accessories and hardtop system that may affect the harness, while locating the short.

DTC 21,25,29,33,37,41,45,49:

Indicates that the limit switch return circuit is open on the ECU side, this can occur in the limit switch return circuit to the ECU, through the limit switch, or in the reference circuits (GC 20 and GC 23) to the point where they would splice together to go to other limit switches. If the reference circuits (GC 20 and GC 23) are open beyond the splice point (opening the circuit to more than one switch) then multiple limit switch DTCs will log indicating the reference voltage is missing.

DTC 34,38:

Indicates that the ECU did not see a change in limit switch position when the hardtop is in the closed position. This may occur if the hardtop did not enter the header properly, or with damaged switches or circuitry.

DTC 42,46:

Indicates that the ECU did not see a change in limit switch position when it has seen a change in hard tonneau potentiometer position. This can occur in either the latched or unlatched position. This may indicate that the hard tonneau did not latch or unlatch properly, or damaged switch and/or circuitry.

DTC 50:

Indicates that the ECU has seen an excessive current draw from the hardtop pump and motor circuit (GC 29 and GC 30). This may occur if hardtop linkage is binding, or motor or circuitry is shorted.

DTC 51:

Indicates that the ECU has seen an excessive current draw from the hard tonneau pump and motor circuit (GC 31 and GC 32). This may occur if hard tonneau is binding, or motor or circuitry is shorted.

DTC 52: Indicates that the ECU has not seen the driver side window motor stall current before a specified time (timeout). This may occur if there is mechanical failure allowing the window motor to run without a load, or if the motor or circuitry is open. (Window may operate from drivers window switch.)

I TSB Revision

BODY - Diagnostics and Testing

42-45

TROUBLESHOOTING HINTS FOR DTCs (CONTINUE[»)

DTC 53:

Indicates that the ECU has not seen the passenger window motor stall current before a specified time (timeout). This may occur if there is mechanical failure allowing the window motor to run without a load, or if the motor or circuitry is open.

DTC 54:

This DTC will normally occur with other DTC's, this indicates that the ECU has not seen movement from the hard tonneau when it should have seen movement, this DTC is recorded as the result of other concerns and not the cause. This may occur as a result of various components not allowing movement, latches not releasing, motors not operating, limit switches indicating wrong positions, etc.

DTC 55: This DTC will normally occur with other DTC's, this indicates that the ECU has not seen movement from the hardtop when it should have seen movement, this DTC is recorded as the result of other concerns and not the cause. This may occur as a result of various components not allowing movement, latches not releasing, motors not operating, limit switches indicating wrong positions, etc.

DTC 56:

Indicates that the ECU is no longer seeing a return voltage from the object-in-trunk sensor (OTS) on circuit GC 49. This may occur with damaged OTS, circuits GC 47 or GC 49 open or OTS is disconnected.

DTC 57:

Indicates that the LH tonneau latch has stayed latched for too long after the ECU has received input to release and open the tonneau. This may occur with damaged and/or binding, LH tonneau latch, release cable, and/or latch release motor, or if LH tonneau latch limit switch is sticking.

DTC 58:

Indicates that the RH tonneau latch has stayed latched for too long after the ECU has received input to release and open the tonneau. This may occur with damaged and/or binding, RH tonneau latch, release cable, and/or latch release motor, or if RH tonneau latch limit switch is sticking.

DTC 59:

Indicates that the ECU has not received input from either the RH or LH header position switch when the hardtop is in the CLOSED position. This may occur with binding, misaligned and/or damaged hardtop linkage, header latch strikers, header position switches.

DTC 60:

Indicates that the ECU has not received input from either the RH or LH tonneau position switch when the hard tonneau is in the CLOSED position. This may occur with binding, misaligned and/or damaged hard tonneau linkage, tonneau latch strikers, tonneau position switches.

I TSB Revision

42-46

BODY - Diagnostics and Testing

TROUBLESHOOTING HINTS FOR OTCs (CONTINUED)

DTC 61:

Indicates the ECU has seen the hardtop hydraulic pump stall current (high current), when the hardtop is not either fully open (against the down stop), or fully closed (against the header). This would normally occur if there is binding hardtop linkage, or an obstruction in the normal path of travel.

DTC 62:

Indicates the ECU has seen the hard tonneau hydraulic pump stall current (high current), when the hard tonneau is not either fully open, or fully closed. This would normally occur if there is binding hard tonneau linkage, or an obstruction in the normal path of travel.

I TSB Revision

BODV- Diagnostics and Testing

42-47

DTC* LOG IDENTIFICATION LIST

DTC* D.R.C.** When ALLOWS DESCRIPTION
ACTIVE MOTION
00 NO UP/DOWN No Fault
01 -- -- Reserved
02 NO NO MOTION EEPROM Failure
03 NO NO MOTION Abnormal Reset
04 NO NO MOTION AID Failure or Quarter Window Switches shorted to bat/ign (8-16 volts dc)
05 NO NO MOTION ROM Checksum Failure
06 NO NO MOTION RAM Checksum Failure
07 NO NO MOTION Battery missing when ignition is on
08 NO UP Supply voltage out of limits (10 to 16 volts)
09 NO UP/DOWN Hardtop potentiometer reading beyond limit
10 NO NO MOTION Hardtop potentiometer short/open
11 NO UP/DOWN Hardtop potentiometer reading unstable
12 NO UP/DOWN Tonneau potentiometer reading beyond limit
13 NO NO MOTION Tonneau potentiometer short/open
14 NO UP/DOWN Tonneau potentiometer reading unstable
15 NO NO MOTION Potentiometer diode fault
16 NO UP/DOWN Potentiometer feed overload
17 NO NO MOTION Potentiometer feed short
18 YES UP/DOWN Header latch limit switch does not indicate latched before timeout
19 YES NO MOTION Header latch limit switch grounded
20 YES NO MOTION Header latch limit switch voltage too high (3 - 5 volts de)
21 YES NO MOTION Header latch limit switch wiring open
22 YES UP/DOWN Header unlatch limit switch does not indicate unlatched before timeout
23 YES NO MOTION Header unlatch limit switch grounded
24 YES NO MOTION Header unlatch limit switch voltage too hiqh (3 - 5 volts de)
25 YES NO MOTION Header unlatch limit switch wiring open
26 YES UP/DOWN Retracted quarter window limit switch indicates not retracted after timeout
27 YES UP Retracted quarter window limit switch grounded
28 YES UP Retracted quarter window limit switch voltage too high (3 - 5 volts dc)
29 YES UP Retracted quarter window limit switch wiring open
30 YES UP/DOWN Extended quarter window limit switch indicates not retracted after timeout
31 YES UP/DOWN' Extended quarter window limit switch grounded
32 YES NO MOTION Extended quarter window limit switch voltage too high (3 - 5 volts de)
33 YES UP Extended quarter window limit switch wiriing open
34 YES UP/DOWN Left header position switch indicates not in position when top is up
35 YES NO MOTION Left header position switch grounded
36 YES NO MOTION Left header position switch voltage too hiqh (3 - 5 volts de)
37 YES NO MOTION Left header position switch wiring open
38 YES UP/DOWN Right header position switch indicates not in position when top is up
39 YES NO MOTION Right header position switch grounded
40 YES NO MOTION Right header position switch voltage too high (3 - 5 volts de)
41 YES NO MOTION Right header position switch wiring open
42 YES UP/DOWN Left tonneau latch limit switch indicates unlatched while in latched position or
Left tonneau latch limit switch indicates latched while in unlatched position
43 YES UP/DOWN Left tonneau latch limit switch grounded
44 YES NO MOTION Left tonneau latch limit switch voltage too high (3 - 5 volts de) I TSB Revision

42-48

BODY - Diagnostics and Testing

DTC* LOG IDENTIFICATION LIST

DTC* D.R.C.** When ALLOW DESCRIPTION
ACTIVE
45 YES UP Left tonneau latch limit switch wiring open
46 YES UP/DOWN Right tonneau latch limit switch indicates unlatched while in latched position or
Right tonneau latch limit switch indicates latched while in unlatched position
47 YES UP/DOWN Right tonneau latch limit switch grounded
48 YES NO MOTION Right tonneau latch limit switch voltage too high (3 - 5 volts de)
49 YES UP Right tonneau latch limit switch wiring open
50 NO UP/DOWN Hardtop motor short circuit/grounded
51 NO UP/DOWN Tonneau motor short circuit/grounded
52 NO UP/DOWN Driver window timeout without stall
53 NO UP/DOWN Passenger window timeout without stall
54 NO UP/DOWN Hardtop motion fault (dV/dt)
55 NO UP/DOWN Tonneau motion fault (dV/dt)
56 YES UP Object in trunk sensor not connected
57 YES UP/DOWN Left tonneau latch limit switch latched too long on tonneau up motion
58 YES UP/DOWN Right tonneau latch limit switch latched too long on tonneau up motion
59 YES UP/DOWN No header position switches when hardtop is full up
60 YES UP/DOWN No tonneau limit switches when tonneau is full down
61 NO UP/DOWN Hardtop motor detected stall while not in end position
62 NO UP/DOWN Tonneau motor detected stall while not in end position .. DTC - Diagnostic Trouble Code . ._.. Double Rate Chime.

I TSB Revision

BODY - Diagnostics and Testing

42-49

PINPOINT TESTS

REFER TO: PAGES 42-15 THROUGH 42-17 FOR PRE:CAUTIONS BEFORE SERVICE, NOTES AND DEFINITIONS OF TERMS.

PAGES 42-33 THROUGH 42-40 FOR SYMPTOM CHARTS.

PAGES 42-41 THROUGH 42-46 FOR TROUBLESHOOTING HINTS.

TESTA

CHIME DOES NOT OPERATE WITH HARDTOP OR HARD TON"IEAU OPEN

TEST STEP RESULT ~ ACTION TO TAKE
A-1 I CHECK IGNITION TO PIN 2 AT CHIME MODULE
• Access and disconnect connector E-47 at chime module. Yes ~ Go to A-2.
• Using a Digital Volt/Ohm Meter (DVOM) set to DC volt,
connect negative lead to known good ground. No ~ Repair circuit AC 2.
• Connect positive lead to pin 2 at chime module Restore vehicle.
connector E-47. Retest system.
• Turn ignition to ON position.
• Read voltmeter.
• Is system voltage present?
A-2 I CHECK IGNITION TO PIN 1 AT CHIME MODULE
• Connector E-47 at chime module disconnected. Yes ~ Go to A-3.
• Using a DVOM set to DC volt, connect negative lead to
known good ground. No ~ Repair ignition circuit
• Connect positive lead to pin 1 at chime module between pin 2 and pin
connector E-47. 1.
• Turn ignition to ON position. Restore vehicle.
• Read voltmeter. Retest system.
• Is system voltage present?
A-3 I CHECK GROUND CIRCUIT TO CHIME MODULE
• Connector E-47 at chime module disconnected. Yes ~ Go to A-4.
• Using a DVOM set to ohm scale" connect negative lead
to known good ground. No ~ Repair circuit AC 4.
• Connect positive lead to pin 7 at chime module Restore vehicle.
connector E-47. Retest system.
• Read ohmmeter.
• Is there 3 ohms or less?
A-4 I CHECK CHIME MODULE OPERATION
• Connect connector E-47 at chime module. Yes ~ Replace ECU.
• Access connector F-124 at ECU. Restore vehicle.
• Using a jumper wire, connect one end to a known good Retest system.
ground.
• Back probe and connect the second end to pin 9 at ECU No ~ Go to A-5.
connector F-124.
• Turn ignition to ON position.
• Does chime sound?
A-5 I CHECK CIRCUIT GC 39 FOR OPEN
• Disconnect connector F-124 at ECU. Yes ~ Replace chime module.
• Disconnect connector E-47 at chime module. Restore vehicle.
• Using a DVOM set to ohm scale connect positive lead Retest system.
to pin 9 at ECU connector F-124.
• Connect the negative lead to pin 10 at chime module No ~ Repair circuit AC 3.
connector E-47. Restore vehicle.
• Read ohmmeter. Retest system.
• Is there 3 ohms or less? I TSB Revision

42-50

BODY - Diagnostics and Testing

PINPOINT TESTS

REFER TO: PAGES 42-15 THROUGH 42-17 FOR PRECAUTIONS BEFORE SERVICE, NOTES AND DEFINITIONS OF TERMS.

PAGES 42-33 THROUGH 42-40 FOR SYMPTOM CHARTS.

PAGES 42-41 THROUGH 42-46 FOR TROUBLESHOOTING HINTS.

TEST 8

CHIME STAYS ON CONTINUOUSLY WITH NO DTCs PRESI:NT

TEST STEP RESULT ~ ACTION TO TAKE
8-1 I CHECK ECU GROUND CIRCUIT
o Access and disconnect connector F-124 at ECU. Yes ~ Go to 8-2.
o Turn ignition to ON position.
No ~ Replace ECU.
o Does chime still sound? Restore vehicle.
Retest system.
8-2 I CHECK CIRCUIT GC 39 FOR SHORT TO GROUND
o Connector F-124 at ECU disconnected. Yes ~ Repair circuit AC 3.
o Access and disconnect connector E-47 at chime module. Restore vehicle.
o Using a Digital Volt/Ohm Meter (DVOM) set to ohm Retest system.
scale, connect negative lead to known good ground. No Replace chime module.
o Connect positive lead to pin 9 at ECU connector F-124. ~
o Read ohmmeter. Restore vehicle.
Retest system.
o Is there continuity? I TSB Revision

BODY - Diagnostics and Testing

42-51

PINPOINT TeSTS

REFER TO: PAGES 42-15 THROUGH 42-17 FOR PRI:CAUTIONS BEFORE SERVICE, NOTES AND DEFINITIONS OF TERMS.

PAGES 42-33 THROUGH 42-40 FOR SYMPTOM CHARTS.

PAGES 42-41 THROUGH 42-46 FOR TROUBLESHOOTING HINTS.

TESTC

DRIVER WINDOW INOPERATIVE WITH DRIVER WINDOW SWITCH

TEST STEP RESULT ~ ACTION TO TAKE
C-' I CHECK DRIVER WINDOW OPERATION
• Access and disconnect driver window relay assembly. Yes ~ Refer to PINPOINT
• Connect driver window switch connector E-126 to TEST DTC 52.
driver window motor connector E-35.
• Turn ignition to ON position. No ~ Refer to Vol. 2 of
• Operate driver window. Service Manual, for
• Observe driver window operation. window repair.
• Does driver window operate properly? I TSB Revision

42-52

BODY - Diagnostics and Testing

PINPOINT TESTS

REFER TO: PAGES 42-15 THROUGH 42-17 FOR PREGAUTIONS BEFORE SERVICE, NOTES AND DEFINITIONS OF TERMS.

PAGES 42-33 THROUGH 42-40 FOR SYMPTOM CHARTS.

PAGES 42-41 THROUGH 42-46 FOR TROUBLESHOOTING HINTS.

TEST 0

HARD TONNEAU HYDRAULIC SYSTEM

TEST STEP RESULT ~ ACTION TO TAKE
0-1 CHECK HARD TONNEAU HYDRAULIC PUMP
MOTOR OPERATION
• Place automatic transaxle in Park W) manual transaxle Yes ~ Go to 0-2.
in neutral.
• Apply parking brake. No ~ Go to Pinpoint Test E.
• Turn ignition switch to ON position.
• Operate hard tonneau control switch to OPEN position.
• Does hard tonneau pump motor run?
0-2 CHECK HARD TONNEAU BYPASS VALVE POSITION
• Access and check hard tonneau bypass valve position. Yes ~ Go to 0-3.
• Is hard tonneau bypass valve in POWER position? No ~ Rotate hard tonneau
bypass valve to the
POWER position.
Restore vehicle.
Retest system.
0-3 CHECK HARD TONNEAU HYDRAULIC FLUID LEVEL
• Access hard tonneau hydraulic fluid reservoir. Yes ~ Go to 0-4.
• Is hard tonneau hydraulic fluid at proper level? No ~ Add fluid, bleed system
if necessary.
Restore vehicle.
Retest system.
0-4 CHECK HARD TONNEAU HYDRAULIC LINES
• Access lines from hard tonneau pump to hydraulic Yes ~ Service as required.
cylinders. Restore vehicle.
Retest system.
• Are lines bent or kinked?
No ~ Go to 0-5.
0-5 CHECK HARD TONNEAU MANUAL OPERATION
• Turn hard tonneau bypass valve to MANUAL position. Yes ~ Go to 0-6.
• Operate hard tonneau manually. Check for binding
No ~
• Does hard tonneau operate manually? linkage or hinges.
Service as required.
Restore vehicle.
Retest system. I TSB Revision

BODY - Diagnostics and Testing

42-53

REFER TO: PAGES 42-15 THROUGH 42-17 FOR PRIECAUTIONS BEFORE SERVICE, NOTES AND DEFINITIONS OF TERMS.

PAGES 42-33 THROUGH 42-40 FOR SYMPTOM CHARTS.

PAGES 42-41 THROUGH 42-46 FOR TROUBLESHOOTING HINTS.

PINPOINT TESTS

TEST 0 (CONTINUED)

HARD TONNEAU HYDRAULIC SYSTEM

TEST STEP

ACTION TO TAKE

0·6 CHECK HARD TONNEAU HYDRAULIC PUMP OPEN (EXTEND) PRESSURE

NOTE: BE CAREFUL CONNECTING PRESSURE GAUGE IF HARD TONNEAU IS OPEN. MOVEMENT OF THE HARD TONNEAU MAY OCCUR.

• Route pressure gauge and hose through rear seat, in order to stay clear of moving components.

• Place transaxle in park (P) automatic, neutral for manual.

• Parking brake applied.

• Open and manually move and support hard tonneau to half open position.

• Turn hard tonneau bypass valve to MANUAL position.

• Connect pressure gauge to hard tonneau hydraulic pump open (extend) side.

• Cap open fitting on manifold.

RESULT

Yes

~ Go to 0-7.

~ Replace hard tonneau hydraulic pump. Restore vehicle. Retest system.

~I

~ .~

• Turn ignition to ON position.

• Operate hard tonneau control switch to OPEN position.

• Read pressure gauge.

• Is pressure 250 psi ~ 20 psi?

No

I TSB Revision

42-54

BODY - Diagnostics and Testing

REFER TO: PAGES 42-15 THROUGH 42-17 FOR PRECAUTIONS BEFORE SERVICE, NOTES AND DEFINITIONS OF TERMS.

PAGES 42-33 THROUGH 42-40 FOR SYMPTOM CHARTS.

PAGES 42-41 THROUGH 42-46 FOR TROUBLESHOOTING HINTS.

TEST D (CONTINUED)

HARD TONNEAU HYDRAULIC SYSTEM

PINPOINT TESTS

TEST STEP

RESULT

ACTION TO TAKE

D-7 CHECK HARD TONNEAU HYDRAULIC PUMP CLOSE (RETRACT) PRESSURE

NOTE: BE CAREFUL CONNECTING PRESSURE GAUGE IF HARD TONNEAU IS OPEN. MOVEMENT OF THE HARD TONNEAU MAY OCCUR.

• Place transaxle in park (PI automatic, neutral for manual.

• Parking brake applied.

• Open and manually move and support hard tonneau to half open position.

• Connect pressure gauge to hard tonneau hydraulic pump close (retract) side.

• Cap open fitting on manifold.

• Turn ignition to ON position.

• Operate hard tonneau control switch to CLOSE position.

• Read pressure gauge.

• Is pressure 350 psi or greater?

Yes

~ Go to D-8.

No

~ Replace hard tonneau hydraulic pump. Restore vehicle. Retest system.

I TSB Revision

BODY - Diagnostics and Testing

42-55

REFER TO: PAGES 42-15 THROUGH 42-17 FOR PRECAUTIONS BEFORE SERVICE, NOTES AND DEFINITIONS OF TERMS.

PAGES 42-33 THROUGH 42-40 FOR SYMPTOM CHARTS.

PAGES 42-41 THROUGH 42-46 FOR TROUBLESHOOTING HINTS.

PINPOINT TESTS

TEST D (CONTINUED)

HARD TONNEAU HYDRAULIC SYSTEM

TEST STEP

RESULT

ACTION TO TAKE

D-8 CHECK HARD TONNEAU HYDRAULIC SYSTEM FLOW PRESSURE

• Operate hard tonneau and support in OPEN position.

• Turn hard tonneau bypass valve to MANUAL position.

• Connect pressure gauge to LH cylinder retract side.

• Turn hard tonneau bypass valve to POWER position, remove support.

• Turn ignition to ON position.

• Press hard tonneau control switch and operate hard tonneau to CLOSE position.

• Press hard tonneau control switch and operate hard

tonneau to OPEN position.

• Read and record highest pressure indicated.

• Restore LH cylinder retract side.

• Support hard tonneau in open position.

• Turn hard tonneau bypass valve to MANUAL position.

• Connect pressure gauge to RH cylinder retract side.

• Turn hard tonneau bypass valve to POWER position, remove support.

• Turn ignition to ON position.

• Press hard tonneau control switch and operate hard tonneau to CLOSE position.

• Press hard tonneau control switch and operate hard tonneau to OPEN position.

• Read and record highest pressure indicated.

• Are pressures less than 250 psi s 20 psi and within 100 psi of each other?

Yes

No

~ Hydraulic system Okay.

Restore vehicle. Retest system.

~ Pressure over 250 psi :!: 20 psi check for hard tonneau binding. Under 250 psi e 20 psi replace hydraulic cylinder on side with the lowest pressure.

Restore vehicle.

Retest system.

I TSB Revision

42-56

BODY - Diagnostics and Testing

PINPOINT TESTS

REFER TO: PAGES 42-15 THROUGH 42-17 FOR PRECAUTIONS BEFORE SERVICE, NOTES AND DEFINITIONS OF TERMS.

PAGES 42-33 THROUGH 42-40 FOR SYMPTOM CHARTS.

PAGES 42-41 THROUGH 42-46 FOR TROUBLESHOOTING HINTS.

TESTE

HARD TONNEAU INOPERATIVE WITH CONTROL SWITCH

TEST STEP RESULT ~ ACTION TO TAKE
E-' CHECK CIRCUIT GC 2 FOR VOLTAGE AT HARD
TONNEAU CONTROL SWITCH
o Access connector D48 at hardtop and hard tonneau Yes ~ Go to E-2.
control switch.
o Using a Digital Volt/Ohm Meter (DVOM) set to DC volt, No ~ Repair circuit GC 2.
connect negative lead to a known good ground. Restore vehicle.
o Back probe and connect the positive lead to pin 8 at Retest system.
hardtop and hard tonneau control switch connector D48.
o Turn ignition to ON position.
o Read voltmeter.
o Is system voltage present?
E-2 CHECK CIRCUIT GC 5 AT HARDTOP AND HARD
TONNEAU CONTROL SWITCH
o Access connector D48 at hardtop and hard tonneau Yes ~ Go to E-3.
control switch.
o Using a DVOM set to DC volt, connect negative lead to No ~ Replace hardtop and
a known good ground. hard tonneau control
o Back probe and connect the positive lead to pin 10 at switch.
hardtop and hard tonneau control switch connector D48. Restore vehicle.
o Turn ignition to ON position. Retest system.
o Press hard tonneau control switch to OPEN position.
o Read voltmeter.
o Is system voltage present?
E-3 CHECK CIRCUIT GC 5 FOR VOLTAGE AT ECU
o Access connector F-123 at ECU. Yes ~ Go to E-4.
o Using a DVOM set to DC volt, connect negative lead to
a known good ground. No ~ Repair circuit GC 5.
o Back probe and connect the positive lead to pin 3 at Restore vehicle.
ECU connector F-123. Retest system.
o Turn ignition to ON position.
o Press hard tonneau control switch to the OPEN
position.
o Read voltmeter.
o Is system voltage present?
E-4 CHECK CIRCUIT GC 6 AT HARDTOP AND HARD
TONNEAU CONTROL SWITCH
o Access connector D48 at hardtop and hard tonneau Yes ~ Go to E-5.
control switch.
o Using a DVOM set to DC volt, connect negative lead to No ~ Replace hardtop and
a known good ground. hard tonneau control
o Back probe and connect the positive lead to pin 9 at switch.
hardtop and hard tonneau control switch connector D48. Restore vehicle.
o Turn ignition to ON position. Retest system.
o Press hard tonneau control switch to CLOSE position.
o Read voltmeter.
o Is system voltage present? I TSB Revision

BODY - Diagnostics and Testing

42-57

PINPOINT TESTS

REFER TO: PAGES 42-15 THROUGH 42-17 FOR PRIECAUTIONS BEFORE SERVICE, NOTES AND DEFINITIONS OF TERMS.

PAGES 42-33 THROUGH 42-40 FOR SYMPTOM CHARTS.

PAGES 42-41 THROUGH 42-46 FOR TROUBLESHOOTING HINTS.

TEST E (CONTINUED)

HARD TONNEAU INOPERATIVE WITH CONTROL SWIITCH

TEST STEP RESULT ~ ACTION TO TAKE
E-5 I CHECK CIRCUIT GC 6 FOR VOLTAGE AT ECU
• Access connector F-123 at ECU. Yes ~ Replace ECU.
• Using a Digital Volt/Ohm Meter (DVOM) set to DC volt, Restore vehicle.
connect negative lead to a known good ground. Retest system.
• Back probe and connect the positive lead to pin 4 at ~ Repair circuit GC 6.
ECU connector F-123. No
• Turn ignition to ON position Restore vehicle.
• Press hard tonneau control switch to the CLOSE Retest system.
position.
• Read voltmeter
• Is system voltage present? ~BReviSion

42-58

BODY - Diagnostics and Testing

PINPOINT TESTS

REFER TO: PAGES 42-15 THROUGH 42-17 FOR PRECAUTIONS BEFORE SERVICE, NOTES AND DEFINITIONS OF TERMS.

PAGES 42-33 THROUGH 42-40 FOR SYMPTOM CHARTS.

PAGES 42-41 THROUGH 42-46 FOR TROUBLESHOOTING HINTS.

TEST F

HARD TONNEAU WILL NOT UNLATCH WITH CONTROL SWITCH

TEST STEP RESULT ~ ACTION TO TAKE
F-1 CHECK TONNEAU LATCH OPERATION
• Position tonneau to latched position. Yes ~ Go to F-2.
• Access and turn tonneau by-pass valve to MANUAL
position. No ~ Go to F-4.
• Turn ignition to ON position.
• Operate tonneau to OPEN position
• Observe tonneau operation.
• Did either tonneau latch release?
F-2 CHECK CIRCUIT GC 35 BETWEEN TONNEAU
LATCH SOLENOIDS
• Access and disconnect connector F-125 at ECU. Yes ~ Go to F-3.
• Disconnect RH and LH tonneau latch solenoid
connectors F-112 and F-118. No ~ Repair circuit GC 35.
• Using a Digital Volt/Ohm Meter (DVOM) set to ohm Restore vehicle.
scale, connect one lead to pin A at RH tonneau latch Retest system.
solenoid connector F-112.
• Connect the second lead to pin A at LH tonneau latch
solenoid connector F-118.
• Read ohmmeter.
• Is there 3 ohms or less?
F-3 CHECK CIRCUIT GC 50 AT SUSPECT TONNEAU
LATCH SOLENOID
• Connectors F-112 and F-118 at RH and LH tonneau latch Yes ~ Replace suspect
solenoids disconnected. solenoid.
• Connector F-125 at ECU disconnected. Restore vehicle.
• Using a DVOM set to ohm scale, connect negative lead Retest system.
to known good ground.
• Connect the positive lead to pin B at suspect tonneau No ~ Repair circuit GC 50.
latch solenoid, connector (F-112 or F-118). Restore vehicle.
• Read ohmmeter. Retest system.
• Is there 3 ohms or less?
F-4 CHECK CIRCUIT GC 35 FOR OPEN
• Access and disconnect RH and LH tonneau latch Yes ~ Go to F-S.
solenoids.
• Access and disconnect connector F-125 at ECU.
• Using a Digital Volt/Ohm Meter (DVOM) set to ohm No ~ Repair circuit GC 35.
scale, connect one lead to pin A at either solenoid Restore vehicle.
connector F-112 or F-118. Retest system.
• Connect the second lead to pin 12 at ECU connector
F-125.
• Read ohmmeter.
• Is there 3 ohms or less? I TSB Revision

BODY - Diagnostics and Testing

42-59

PINPOINT TESTS

REFER TO: PAGES 42-15 THROUGH 42-17 FOR PRECAUTIONS BEFORE SERVICE, NOTES AND DEFINITIONS OF TERMS.

PAGES 42-33 THROUGH 42-40 FOR SYMPTOM CHARTS.

PAGES 42-41 THROUGH 42-46 FOR TROUBLESHOOTING HINTS.

TEST F (CONTINUED)

HARD TONNEAU Will NOT UNLATCH WITH CONTROL SWITCH

F-5 I CHECK CIRCUIT GC 50 FOR OPEN
• Connectors F-112 and F-118 at RH and LH tonneau latch Yes ~ Replace ECU.
solenoids disconnected. Restore vehicle.
• Connector F-125 at ECU disconnected. Retest system.
• Using a DVOM set to ohm scale, connect one lead to a
known good ground. No ~ Repair circuit GC 50.
• Connect the second lead to pin B at each tonneau latch Restore vehicle.
solenoid connector F-112 or F-118. Retest system.
• Read ohmmeter.
• Is there 3 ohms or less? I TSB Revision

42-60

BODY - Diagnostics and Testing

PINPOINT TESTS

REFER TO: PAGES 42-15 THROUGH 42-17 FOR PRECAUTIONS BEFORE SERVICE, NOTES AND DEFINITIONS OF TERMS.

PAGES 42-33 THROUGH 42-40 FOR SYMPTOM CHARTS.

PAGES 42-41 THROUGH 42-46 FOR TROUBLESHOOTING HINTS.

TESTG

HARDTOP HYDRAULIC SYSTEM

TEST STEP RESULT ~ ACTION TO TAKE
G-1 CHECK HARDTOP HYDRAULIC PUMP
MOTOR OPERATION
• Place automatic transaxle in Park (P) manual transaxle Yes ~ Go to G-2.
in neutral.
• Apply parking brake. No ~ Go to Pinpoint Test H.
• Turn ignition switch to ON position.
• Operate hardtop control switch to OPEN position.
• After hard tonneau opens does hardtop pump motor
run?
G-2 CHECK HARDTOP BYPASS VALVE POSITION
• Access and check hardtop bypass valve position. Yes ~ Go to G-3.
• Is hardtop bypass valve in POWER position? No ~ Rotate hardtop bypass
valve to the POWER
position.
Restore vehicle.
Retest system.
G-3 CHECK HARDTOP HYDRAULIC FLUID LEVEL
• Access hardtop hydraulic fluid reservoir. Yes ~ Go to G-4.
• Is hardtop hydraulic fluid at proper level? No ~ Add fluid, bleed system
if necessary.
Restore vehicle.
Retest system.
G-4 CHECK HARDTOP HYDRAULIC LINES
• Access lines from hardtop pump to hydraulic cylinders. Yes ~ Serviced as required.
Restore vehicle.
• Are lines bent or kinked? Retest system.
No ~ Go to G-5.
G-5 CHECK HARDTOP MANUAL OPERATION
• Note: A second person will be needed for manual Yes ~ Go to G-S.
operation.
No ~ Check for binding
• Turn hardtop bypass valve to MANUAL position. linkage or hinges.
• Operate hardtop manually. Service as required.
Restore vehicle.
• Does hardtop operate manually? Retest system. I TSB Revision

BODY - Diagnostics and Testing

42-61

REFER TO: PAGES 42-15 THROUGH 42-17 FOR PRECAUTIONS BEFORE SERVICE, NOTES AND DEFINITIONS OF TERMS.

PAGES 42-33 THROUGH 42-40 FOR SYMPTOM CHARTS.

PAGES 42-41 THROUGH 42-46 FOR TROUBLESHOOTING HINTS.

TEST G (CONTINUED) HARDTOP HYDRAULIC SYSTEM

PINPOINT TESTS

TEST STEP

G-6 CHECK HARDTOP HYDRAULIC PUMP OPEN (EXTEND) PRESSURE

NOTE: BE CAREFUL CONNECTING PRESSURE GAUGE IF HARDTOP IS PARTIALLY OPEN. MOVEMENT OF THE HARDTOP MAY OCCUR.

• Route pressure gauge and hose through rear seat, in order to stay clear of moving components.

• Place transaxle in park (P) automatic, neutral for

manual.

• Parking brake applied.

• Hard tonneau open.

• Turn hardtop bypass valve to MANUAL position.

• Connect pressure gauge to hardtop hydraulic pump open (extend) side.

• Cap open fitting on manifold.

• Manually move hardtop to half open position.

• Turn ignition to ON position.

• Operate hardtop control switch to OPEN position.

• Read pressure gauge.

• Is pressure 400 psi or greater?

ACTION TO TAKE

RESULT

Yes

~ Go to G-7.

~ Replace hardtop hydraulic pump. Restore vehicle. Retest system.

No

I TSB Revision

42-62

BODY - Diagnostics and Testing

PINPOINT TESTS

REFER TO: PAGES 42-15 THROUGH 42-17 FOR PRECAUTIONS BEFORE SERVICE, NOTES AND DEFINITIONS OF TERMS.

PAGES 42-33 THROUGH 42-40 FOR SYMf'TOM CHARTS.

PAGES 42-41 THROUGH 42-46 FOR TROUBLESHOOTING HINTS.

TEST G (CONTINUED) HARDTOP HYDRAULIC SYSTEM

TEST STEP

G-7 CHECK HARDTOP HYDRAULIC PUMP CLOSE (RETRACT) PRESSURE

NOTE: BE CAREFUL CONNECTING PRESSURE GAUGE IF HARDTOP IS PARTIALLY OPEN. MOVEMENT OF THE HARDTOP MAY OCCUR.

• Place transaxle in park (P) automatic, neutral for

manual.

• Parking brake applied.

• Turn hardtop bypass valve to MANUAL position.

• Connect pressure gauge to hardtop hydraulic pump close (retract) side.

• Cap open fitting on manifold.

• Manually move hardtop to half open position.

• Turn ignition to ON position.

• Operate hardtop control switch to CLOSE position.

• Read pressure gauge.

• Is pressure 400 psi or greater?

RESULT

ACTION TO TAKE

Yes

~ Go to G-B.

~ Replace hardtop hydraulic pump. Restore vehicle. Retest system.

No

I TSB Revision

BODY - Diagnostics and Testing

42-63

REFER TO: PAGES 42-15 THROUGH 42-17 FOR PRECAUTIONS BEFORE SERVICE, NOTES AND DEFINITIONS OF TERMS.

PAGES 42-33 THROUGH 42-40 FOR SYMPTOM CHARTS.

PAGES 42-41 THROUGH 42-46 FOR TROUBLESHOOTING HINTS.

TEST G (CONTINUED) HARDTOP HYDRAULIC SYSTEM

PINPOINT TESTS

TEST STEP

RESULT

ACTION TO TAKE

G-B CHECK HARDTOP HYDRAULIC SYSTEM FLOW PRESSURE

• Operate hard tonneau to OPEN position.

• Operate hardtop to CLOSED position.

• Turn hardtop bypass valve to MANUAL position.

• Connect pressure gauge to LH cylinder retract side.

• Turn hardtop bypass valve to POWER position.

• Turn ignition to ON position.

• Press hardtop control switch and operate hardtop to OPEN position.

• Press hardtop control switch and operate hardtop to

CLOSE position.

• Read and record highest pressure indicated.

• Restore LH cylinder retract side.

• Turn hardtop bypass valve to MANUAL position.

• Connect pressure gauge to RH cylinder retract side.

• Turn hardtop bypass valve to POWER position.

• Turn ignition to ON position.

• Press hardtop control switch and operate hardtop to OPEN position.

• Pressure hardtop control switch and operate hardtop to CLOSE position.

• Read and record highest pressure indicated.

• Are pressure less than 400 psi and within 100 psi of each other?

Yes

No

~ Hydraulic system Okay.

Restore vehicle. Retest system.

~ Pressure over 400 psi check for hardtop binding.

Under 400 psi replace hydraulic cylinder on side with the lowest pressure.

Restore vehicle. Retest system.

I TSB Revision

42-64

BODY - Diagnostics and Testing

PINPOINT TESTS

REFER TO: PAGES 42-15 THROUGH 42-17 FOR PRECAUTIONS BEFORE SERVICE, NOTES AND DEFINITIONS OF TERMS.

PAGES 42-33 THROUGH 42-40 FOR SYMI'TOM CHARTS.

PAGES 42-41 THROUGH 42-46 FOR TROUBLESHOOTING HINTS.

TEST H

HARDTOP CONTROL SWITCH INOPERATIVE

TEST STEP RESULT ~ ACTION TO TAKE
H-1 CHECK CIRCUIT GC 2 FOR VOLTAGE AT HARDTOP
CONTROL SWITCH
• Access connector D48 at hardtop and hard tonneau Yes ~ Go to H-2.
control switch.
• Using a Digital Volt/Ohm Meter (DVOM) set to DC volt, No ~ Repair circuit GC 2.
connect negative lead to a known good ground. Restore vehicle.
• Back probe and connect the positive lead to pin 4 at Retest system.
hardtop and hard tonneau control switch connector D48.
• Turn ignition to ON position.
• Read voltmeter.
• Is system voltage present?
H-2 CHECK CIRCUIT GC 4 AT HARDTOP AND HARD
TONNEAU CONTROL SWITCH
• Access connector D48 at hardtop and hard tonneau Yes ~ Go to H-3.
control switch.
• Using a DVOM set to DC volt, connect negative lead to No ~ Replace hardtop and
a known good ground. hard tonneau control
• Back probe and connect the positive lead to pin 11 at switch.
hardtop and hard tonneau control switch connector D48. Restore vehicle.
• Turn ignition to ON position. Retest system.
• Press hardtop control switch to OPEN position.
• Read voltmeter.
• Is system voltage present?
H-3 CHECK CIRCUIT GC 4 FOR VOLTAGE AT ECU
• Access connector F-124 at ECU. Yes ~ Go to H-4.
• Using a DVOM set to DC volt, connect negative lead to
a known good ground. ~ Repair circuit GC 4.
• Back probe and connect the positive lead to pin 42 at No
ECU connector F-124. Restore vehicle.
• Turn ignition to ON position. Retest system.
• Press hardtop control switch to the OPEN position.
• Read voltmeter.
• Is system voltage present?
H-4 CHECK CIRCUIT GC 3 AT HARDTOP AND HARD
TONNEAU CONTROL SWITCH
• Access connector D48 at hardtop and hard tonneau Yes ~ Go to H-5.
control switch.
• Using a DVOM set to DC volt, connect negative lead to No ~ Replace hardtop and
a known good ground. hard tonneau control
• Back probe and connect the positive lead to pin 3 at switch.
hardtop and hard tonneau control switch connector D48. Restore vehicle.
• Turn ignition to ON position. Retest system.
• Press hard tonneau control switch to CLOSE position.
• Read voltmeter.
• Is system voltage present? I TSB Revision