Classification: Reference: Date: BT03-046a NTB03-116a January 29, 2004 2004 350Z ROADSTER; SOFT TOP ASSEMBLY REMOVAL AND INSTALLATION This bulletin amends NTB03-116. This version updates the Parts Information. Please discard all paper copies of the earlier version. APPLIED VEHICLE: 2004 350Z Roadster (Z33) SERVICE INFORMATION The Service Procedure in this bulletin contains step-by-step instructions for removal and installation of the 350Z Roadster soft-top assembly. IMPORTANT: Make sure to order new seat bar finishers (clam shells) when ordering a new soft-top assembly (see Parts Information). PARTS INFORMATION When replacing the soft-top assembly, the finishers (clam shells) that cover the seat bars (guard frames) will need to be removed (see page 4, Figures 6 and 7). They are likely to break during removal and will not be reusable. They will need to be replaced. The part numbers for these finishers are listed below. DESCRIPTION PART # QUANTITY Folding Roof-complete (Black) 97003-CE446 1 Folding Roof-complete (Blue) 97003-CE447 Seat Bar/Guard Frame Finishers (clam shells) Listed in the parts system as: Front Half Cover-Strut Bar Upper, Center (Black) 93130-CE400 Right Side Cover-Strut Bar Upper, Center (Gray) 93130-CE401 Front Half Protector-Guard Frame, LH (Black) 93131-CE400 Left Side Protector-Guard Frame, LH (Gray) 93131-CE401 Rear Half Plate-Guard Frame, RH (Black) 93154-CE400 Right Side Plate-Guard Frame, RH (Gray) 93154-CE401 Rear Half Plate-Guard Frame, LH (Black) 93155-CE400 Left side Plate-Guard Frame, LH (Gray) 93155-CE401 1 1 1 1 1/16
SERVICE PROCEDURE NOTE: The illustrations in this procedure are for the left side (driver s side). Each operation must also be done for the right side (passenger s side). Soft Top Assembly Removal 1. Fully open the soft-top using the power switch. 2. Leave the storage lid in the open position (straight up). Figure 1 3. Move both seats as far forward as possible. 4. Tilt both seat backs as far forward as possible. 5. Remove the inner rocker panel (inner kicking plate). Inner Kicking Plate Figure 2 2/16
6. Remove the rubber trim pad from the rear of the door frames. Rubber Trim Pad Figure 3 7. Remove the rear portion of the door weather strips. Figure 4 8. Remove the rear side finishers. Figure 5 3/16
9. Remove finishers (clam shells) from the seat bars. a. First, pull off the front halves. NOTE: When the front half of the finisher is pulled off, the plastic attaching clips are likely to break. You should order new seat bar finishers before starting this procedure (see Parts Information). Figure 6 Clam Shells b. Then remove the rear halves. The rear halves are held on with six screws (three on each side). Figure 7 10.Remove the back panel finisher. a. Remove the 6 clips on the top (3 on each side). The 3 left side clip locations are shown with white circles. There are three duplicate locations on the right side. b. After removing the 6 top clips, pull up on the panel to snap loose the 4 additional clips along the underside of the panel. Figure 8 Back Panel Finisher 4/16
11.Remove the Back Panel Finisher Support Brackets. Support Bracket Figure 9 12.Close the soft-top to the position shown in Figure 10 using the power switch. However, keep the storage lid in the open position as shown. Figure 10 5/16
13.Locate the rear mounting brackets in the soft-top storage area. Rear Mounting Bracket 14.Remove only the nuts (1 on each side) from the rear mounting brackets. See CAUTION below. Remove this nut. Figure 11 Do not disturb (loosen or remove) these bolts. CAUTION: Do not disturb (loosen or remove) the bolts shown above with white circles around them. These bolts secure the mounting brackets to the vehicle body. The mounting brackets are very precisely (accurately) adjusted at the factory to ensure proper soft-top fit and function. Any change to this adjustment may cause poor fit, resulting in possible water leaks and wind noise. If loosened or removed, they will require the services of a body shop to accurately re-adjust them. 15.Fully open the soft-top using the power switch. Leave the storage lid in the open position as shown. Figure 12 6/16
16.Remove the seat belt guides from the seat belts (see Figure 13). The seat belt guides will be reused. 17.Remove bolts (2 on each side) securing the soft-top to the front mounting brackets. See CAUTION below. Seat Belt Guide Remove these bolts. Front Mounting Bracket Do not disturb (loosen or remove) these bolts. Figure 13 CAUTION: Do not disturb (loosen or remove) the bolts shown above with white circles around them. These bolts secure the mounting brackets to the vehicle body. The mounting brackets are very precisely (accurately) adjusted at the factory to ensure proper soft-top fit and function. Any change to this adjustment may cause poor fit, resulting in possible water leaks and wind noise. If loosened or removed, they will require the services of a body shop to accurately re-adjust them. 7/16
18.Remove the bolts (both sides) from the soft-top mounting plates as follows: a. Hold the adjusting shims with one hand so they will not fall out. b. Loosen both bolts. c. Remove the adjusting shims (see Figure 15). Adjusting Shims d. Completely remove both bolts. Figure 14 19.Mark the adjusting shims so you can put them back in the same place. Adjusting Shims VERY IMPORTANT: All shims that are removed MUST be put back (reinstalled) on the same side they were removed from. These adjusting shims match the vehicle and not the soft-top. Figure 15 20.Disconnect the soft-top electrical connectors. There are 3 connectors on the driver s side as shown. There are only 2 connectors on the passenger s side (not shown). Figure 16 8/16
NOTES: At this point you are ready to remove the soft-top from the vehicle. Make sure both seats are moved as far forward as possible and the seat backs are tilted as far forward as possible. To remove the soft-top, you will be walking through the vehicle. Be careful not to get the carpet dirty. The soft-top is very heavy and will require 2 people to remove it from the vehicle. While removing the soft-top, be very careful. The edges of the soft-top assembly can easily scratch the paint. 21.Remove the soft-top assembly from the vehicle. Lift it out of the storage area by first raising the rear of the top and then pulling upward. Then, walk though the vehicle with one side as shown in Figure 17. Figure 17 9/16
Install the Soft-Top into the Vehicle 1. Make sure the electrical connectors (both sides) are secured in place as shown so they will not get caught under the assembly. 2. Put the soft-top in the vehicle in reverse of step 21 on page 9. 3. Connect the soft-top electrical connectors. Figure 18 4. Loosely install the bolts on the front mounting brackets (see Figure 19). 5. Make sure the soft-top mounting bracket is flush against the aligning pegs (see Figure 19). Loosely install these bolts. Aligning Peg. Do not disturb (loosen or remove) these bolts. Figure 19 10/16
6. Loosely install the mounting plate bolts. Figure 20 7. Move the soft-top to the position shown in Figure 22 using the power switch. The soft-top should be straight up (90 ). NOTE: If the top is too far back, it will slowly move toward the storage area by its own weight. Figure 21 8. Make sure the soft-top bracket is completely seated on the rear mounting bracket stud. Rear Mounting Bracket 9. Install and tighten the nuts on the rear mounting brackets. Install and tighten this nut. Do not disturb (loosen or remove) these bolts. Figure 22 11/16
10.Tighten the soft-top to front mounting bracket bolts (see Figure 23). Make sure front brackets are flush against the aligning pegs. Tighten these bolts. Aligning Peg Front Mounting Bracket Do not disturb (loosen or remove) these bolts. Figure 23 11.Install the mounting plate shims. It may be necessary to push (shift) the soft-top from side-to-side to make room for the shims. Make sure the shims do not fall out during installation, hold them in place until the bolts are tightened. VERY IMPORTANT: Make sure you install all shims in the same side they were removed from. Figure 24 12/16
12.Tighten the mounting plate bolts. Figure 25 NOTE: It s important that all soft-top mounting bolts are tightened in the order given in steps 7 12. 13.Reinstall all remaining parts in reverse order. NOTE: Make sure to use new seat bar finishers clam shells (see Parts Information). Check Soft-Top Forward Movement 1. Apply masking tape to the soft-top Latch Sockets. Tape Applied Apply tape to the left and right side sockets. Tape is not needed on the center Latch Socket. The masking tape will help you determine if the soft-top Forward Adjustment is correct. Figure 26 Latch Socket 13/16
2. Use a colored marker to color ( paint ) the left and right Latch Hooks. Colored Marker 3. Close the soft-top but do not latch it. Latch Hook Figure 27 4. Open the soft-top and check the tape on the Latch Sockets, left and right side (see Figure 28). There should be 2.5 mm between the color mark and the front of the latch socket. If color transferred to the tape within the 2.5-mm area, the soft-top is moving too far forward and will need to be adjusted. See Adjust soft-top forward movement on the next page. 2.5 mm area (no color should be in this area) Front of Vehicle OK for color to transfer to this area. Figure 28 NOTE: Do Not adjust the Latch Sockets. The soft-top Latch/Locating Sockets are very precisely (accurately) adjusted at the factory to ensure proper soft-top fit and function. Any change to this adjustment may cause poor fit, resulting in possible water leaks and wind noise. If loosened or removed, they will require the services of a body shop to accurately re-adjust them. 14/16
Adjust Soft-Top Forward Movement 1. Open the soft-top to about ½ open. Top should be straight up (90 ) as shown in Figure 29. Figure 29 2. Locate the adjustment point as shown in Figures 30 and 31. NOTE: There is an adjustment point below this one that looks similar. Make sure you only adjust the upper one (shown in Figure 30). Adjustment Point Figure 30 15/16
3. Loosen the adjustment lock nut. Reach in from the soft-top storage area. 12-mm Wrench Use a 12-mm open-end wrench to loosen the adjustment lock nut. Figure 31 Allen 4. Use a 5-mm Allen wrench to adjust. Turning the adjustment screw left (counterclockwise) will move the soft-top (Latch Hook) backward, towards the rear of the vehicle. 5-mm Allen Wrench Adjust ½ turn at a time. Tighten the lock nut and recheck between each adjustment as per steps 3 4 on page 14. Figure 32 Perform this adjustment for the left and right side as needed. 16/16