For 1990-2009 cars

#### Removal Procedure (On-Vehicle Service)

Important: If servicing an outer arm on only one side of the vehicle, follow the procedure titled On-Vehicle Service. If servicing an outer arm on both sides of the vehicle, follow the procedure titled Off-Vehicle Service.

1. Lower the folding top approximately halfway down. Prop the top with a suitable support.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

2. Disconnect the negative battery cable.
3. Remove the outer arm weatherstrip. Refer to Weatherstrip Replacement - Folding Top.
4. Remove the outer arm weatherstrip retainer. Refer to Front Side Door Window Upper Rear Weatherstrip Retainer Replacement .
5. Remove the quarter window filler bolts (4).
6. Remove the quarter window fillers (2).
7. Remove the cover from the outer arm (1) by removing the bolts.
8. Peel the cover away from the adhesive in order to remove the cover from the outer arm (1).
9. Remove the cover retainer cable.
10. Remove the staples connecting the number 1, 2, 3, and 4 bow position pad (10) to the number three bow (9).

Mark the location of the pad and staples.

11. Remove the bolts (1) from the number 3 bow (2).

Slide the plastic tackstrip along the channel in the number 3 bow in order to reveal the bolts.

12. Remove the front side rail link rear bolt (13) and washer (4).
13. Remove the front side rail link (2) and bushing (14) from the outer arm (12).
14. Remove the side rail link pivot bolt (10) and washer (4).
15. Remove the side rail link (11) from the outer arm (12).
16. Remove the pivot bracket locking pin (8) and the cylinder pivot pin (9).
17. Remove the cylinder (6) from the outer arm (1).
18. Remove the bolt (7).
19. Remove the outer arm pivot pin retainer (1).
20. Remove the outer arm (9) with the inner arm link cam (12) attached.
21. Clean the adhesive from the outer arm (9).

#### Installation Procedure (On-Vehicle Service)

1. Use Hughes P/N HC-4183, 3M P/N 8046, or equivalent adhesive on the headliner or top cover attaching surfaces.
2. Install the outer arm (9) with the inner arm link cam (12) attached.
3. Install the outer arm pivot pin retainer (1).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Install the cylinder bolt (7).

Tighten
Tighten the bolt (7) to 5 N·m (44 lb in).

5. Install the cylinder (6) to the outer arm (1).
6. Install the cylinder pivot pin (9) and pivot bracket locking pin (8).
7. Install the side rail link (11) to the outer arm (12).
8. Install the front side rail link (2) and bushing (14) to the outer arm (12).
9. Install the side rail link pivot bolt (10) and washer (4).

Tighten
Tighten the bolt (10) to 17 N·m (13 lb ft).

10. Install the bolt (13)

Tighten
Tighten the bolt (13) to 17 N·m (13 lb ft).

11. Install the bolt (1) attaching the number 3 bow (2) to the outer arm (7).

Tighten
Tighten the bolts (1) to 10 N·m (89 lb in).

12. Return the plastic tackstrip to the original position.
13. Install the number 1, 2, 3, and 4 bow position pad (10) to the original position on the number 3 bow (9).

Install the staples to their original location.

14. Install the cover retainer cable.
15. Install the cover to the outer arm (1).

15.1. | Apply adhesive to the outer arm and to a portion of the cover being attached.

15.2. | Press the cover into place.

15.3. | Install the bolts.

16. Install the quarter window filler (2).
17. Install the quarter window filler bolts (4).

Tighten
Tighten the bolt (4) to 10 N·m (89 lb in).

18. Install the outer arm weatherstrip retainer. Refer to Front Side Door Window Upper Rear Weatherstrip Retainer Replacement .

Important: The outer arm service part is not pre-drilled for the weatherstrip retainer screws. Use the weatherstrip retainer as a template in order to drill holes at the appropriate locations on the new outer arm.

19. Install the outer arm weatherstrip. Refer to Weatherstrip Replacement - Folding Top.
20. Reconnect the negative battery cable.
21. Remove the support prop and raise the folding top.