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Boot and roof won't open anymore

Discussion in 'Problems, Fixes, Tips...' started by Runners, Aug 28, 2013.

  1. Runners

    Runners Copenworld Member

    Joined:
    Aug 16, 2013
    Location:
    Essex
    Car(s):
    Daihatsu Copen, Series 1 Mazda RX7
    Well it didn't take long for me to get my first malfunction! Here's what happened:

    Got in the car and the roof flatly fused to open. The roof indicator light was flashing so something wasn't in place.,checked the boot and sure enough, the boot partition cover was retracted. So I put that back in place, and the roof worked a treat.

    I got home and the roof didn't want to go up. Red flashing light again, so popped boot open, fiddled with the partition and checked what I could see but still the red flashy light. With stress levels rising and profanities starting to be murmured, I dig out the manual and decide that this would be the perfect opportunity to test the manual operation of closing the roof.

    So boot open, slide the hooks, pull and keep out the blue rings etc etc and with my able assistant, I get the roof up. Still following the instructions, I reseat the hinge mechanism and slide the hooks forward, reset the blue pull loops and successfully close the boot. I'm pretty sure that it then auto closed, but I may have gone insane with stress at the point and completely imagined it.

    Anyway, feeling rather happy with self for sorting it, I then saw that the red flashing light had now gone to the solid red light. It thinks that the roof hasn't closed. I check the latches and it all looks good. So I thought that maybe it's something in the boot. That's when I found that the boot mechanism won't work.

    More profanities later, I removed the bottom panel in the console box, and pull on the manual release handle. A satisfying pop is heard and I sigh with relief. I walk round to the boot and it has opened about half an inch, I went to lift the boot up and the thing is stuck solid. It will not open. I push the boot down and release it manually again and the same. So I now have a car that thinks the roof is open, so it won't automatically open the boot, but even after using the manual boot release, it's still jammed. There was nothing in the boot to get caught up in the hinge either. I guess it's very secure now, but has anyone got any helpful ideas on possible ways to get in the boot?

    Cheers, Stressed of Chelmsford!
     
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  2. Adam K

    Adam K Copenworld Guru

    Joined:
    Oct 27, 2010
    Location:
    Worcester, UK
    Car(s):
    Nissan Cube Kaizen
    Well you have got yourself into a pickle.
    Sounds like your missing a step when trying to open the boot.
    Pulling the cord under the panel in the centre console releases the main boot lock in the centre. However the two latches at the corners of the boot are still locked down.
    You need to take the parcel shelf out to get to those two blue rings again. Have fun contorting into the space! That should fully release the boot.

    I think your roof system is confused. Like you said it still thinks it's down.
    I'd try to lower the roof manually again . Close the boot again. See if it starts to work again.
    From the directory section of the site (tabs at the top of the forum) you can download the service manuals. Might be worth having a look through. You need a error code reader to find out what's causing the issue though.
    Personally, I'd print out the roof diagnostic section, take the car back to the garage with the print out & get them to sort it.
     
  3. Runners

    Runners Copenworld Member

    Joined:
    Aug 16, 2013
    Location:
    Essex
    Car(s):
    Daihatsu Copen, Series 1 Mazda RX7
    You Sir are a genius!

    You were quite right, I had missed out the vital step of crushing my hand and arm under the parcel shelf, whilst hitting my head on the roof!

    With both blue loops pulled the boot released. It had caught on the seal at the front corner. Once inside the boot, I found that one of the hook latches had slipped back. So with this pushed forward, the boot closed and automatically shut. Then with a huge fanfare and much relief, the roof opened and closed without any problems!

    I am very mechanically minded, if not that observant at reading manuals, but that was quite some process to do manually! I might actually have to make a little document with photos for next time, as I'm bound to have forgotten the awkward bits by then!

    So a huge thank you, I would have been whirring that one round in my head all night otherwise.

    Sarah
     
  4. Adam K

    Adam K Copenworld Guru

    Joined:
    Oct 27, 2010
    Location:
    Worcester, UK
    Car(s):
    Nissan Cube Kaizen
    No problem, glad it's sorted. Have a nice nights sleep, dreaming of more top down motoring.
     
  5. Runners

    Runners Copenworld Member

    Joined:
    Aug 16, 2013
    Location:
    Essex
    Car(s):
    Daihatsu Copen, Series 1 Mazda RX7
    Well guess who spoke too soon!

    Car was fine this morning, then after work it was sunny so I had the roof down and ran a few errands. Get back home and guess what the red light flashes and the roof won't go up! I'm starting to feel rather well versed at manual closing and the number of bruises, scratches, scrapes and profanities have risen significantly!

    Then the boot won't open, so sort that and check the fuses, then the boot works, three tries later, it doesn't work. Roof light is solid red and by then it was dark, so I gave up. Ringing the dealer I brought it from in the morning and saying dirty words down the phone to him like 'warranty'! Hopefully it will be covered and get sorted. On the plus side, I have a nice collection of photos of the latches, levers, hinges, and hooks!
     
  6. Adam K

    Adam K Copenworld Guru

    Joined:
    Oct 27, 2010
    Location:
    Worcester, UK
    Car(s):
    Nissan Cube Kaizen
    Sorry I jinxed you. :)
     
  7. TooCopen

    TooCopen Copenworld Member

    Joined:
    Aug 8, 2013
    Location:
    France
    Car(s):
    Copen 0.7
    Hello Sarah,

    Just to be sure : can you confirm that each time you want to close or open the roof you engine is running (and handbrake is on, confirmed by lamp on the indicator) ?
    Sometimes Copen have battery problem, so that if the engine is not running, the roof system has not enough current to work properly :-((
    And sometimes the switch on handbreak is dirty, contact is not good, but the roof safety needs that handbrake is on :-((
    Let us know, and I hope you will go through soon :)
     
  8. Runners

    Runners Copenworld Member

    Joined:
    Aug 16, 2013
    Location:
    Essex
    Car(s):
    Daihatsu Copen, Series 1 Mazda RX7
    Hello, yep handbrake is fully on, out of gear and engine running each time.

    Had a good look at it yesterday and I think it's the hinges in the boot. The right hand side had no lubrication, so when the hook slides backwards is was rubbing against the metal. That side now works fine. The left hand side hook keeps sliding backwards a bit. It feels like the hydraulic ram rod is pushing it out, almost as if the is an air bubble in the ram rod.

    I found that if I make sure that hook is slid fully forward and I'm gentle when closing the boot, the boot will work. I have now managed to get the roof warning light to go out. However if I try to operate the roof, the light comes on to indicate its ajar (solid light).

    Good news, spoke to the dealer yesterday, and his first words were, "yep I need to get that sorted for you". So it's going to get sorted under warranty, phew! A good car dealer is worth their,weight in gold! So it will be up the A14 with the roof up today, but at least I can use the car.
     
  9. Runners

    Runners Copenworld Member

    Joined:
    Aug 16, 2013
    Location:
    Essex
    Car(s):
    Daihatsu Copen, Series 1 Mazda RX7
    Update

    Thought I'd gve an update on my boot and roof problems. The dealer has got the car at the moment (missing her terribly) to sort out the roof. However I fixed the boot not opening issues and the 'ajar' warning light for the roof.

    In the boot, on each hinge is the hook latch. These are pushed in and out by the hydraulic ram rods and lock in a pin which stops the boot from opening backwards (as it does when the roof is opening or closing). The metal runners that the hook latches slide in were showing signs that bare metal was rubbing it. I used a bit of grease in these sliders and manually pulled and pushed the hook latches until they moved a bit easier. The hook latches now fully return and lock the pin in place, so the car now thinks that the roof is fully closed. That means that the boot now works and the constant red light and the warning beeps to say the roof isnt fully closed have stopped.

    That has left me with the original fault of the roof not working, but that is being fixed this week courtesy of the dealer.
     
  10. Adam K

    Adam K Copenworld Guru

    Joined:
    Oct 27, 2010
    Location:
    Worcester, UK
    Car(s):
    Nissan Cube Kaizen
    Sounds we should all check to grease our runners then, as a bit of preventative maintenance
     
  11. Runners

    Runners Copenworld Member

    Joined:
    Aug 16, 2013
    Location:
    Essex
    Car(s):
    Daihatsu Copen, Series 1 Mazda RX7
    All fixed!

    Got my little baby back and she's all fixed! I went with the dealer to pick her up as it was quite local to me, and the guy that fixed it explained the fix to me, so I thought I'd share it in case anyone else gets the problem.

    I did have intermittent roof operation issues, but that was partly because of the boot issue which I detailed the fix for above. That left me with the light that says something isnt right so it can't operate the roof. Whilst I had the engine running, in neutral, and handbrake on, what I didn't notice is that the handbrake warning light didn't actually light up on the dash. If you take the centre console out, below the handbrake is a sensor. This sensor gets dirty over time, and stops registering that the handbrake is on. All you need to do is give it a good clean. The guy sprayed it with something similar to wd40 to help it to keep dirt free a bit, reset the ECU as it had got a bit confused, and that resolved it. He reckons it was probably the first time it needed doing as its not a common fault.

    Happy days again, just in time for all this rain!
     
  12. amalia

    amalia Copenworld Newbie

    Joined:
    Oct 20, 2015
    Location:
    athens
    Car(s):
    copen
    I'm facing the ame problem today.. Hope its because it might need a new battery..
     
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