Bonnet (Cover and Cap) Assembly
FIGURE 2 - Bonnet Assembly:
Removal:
1. Cover front and rear of vehicle to protect paint.
2. Mask off windshield and back window to avoid scratching glass.
3. Mask off side roof rail rear vertical scalp moldings to avoid scratching.
4. Remove feature strip, retainer and end caps as previously described.
5. Using a putty knife or other flat-bladed tool, carefully pry quarter belt moldings from retainers (9 and 10, Figure 2).
6. Using a putty knife, carefully loosen adhesive bond securing fabric cover (3, Figure 2) to fiberglass cap (4) along edge of right and left quarter panel to expose rivets that secure fiberglass cap to body.
7. Starting at rear end of side roof rail, use a hook tool (approximately 90 degree bend), and insert tool between fabric cover material and roof panel. Carefully pull material flap out from under the fiberglass cap along entire length of side roof rail.
8. Repeat step 6 and 7 on opposite side of car.
9. Using a putty knife, carefully loosen adhesive bond securing fabric cover to fiberglass cap along side roof rail to expose rivets that secure bonnet assembly to body (1, Figure 2).
10. Using a 1/8" (3.2 mm) drill bit equipped with an adjustable stop set at a maximum drilling depth of 1/2" (12 mm), drill and remove all exposed rivets around perimeter of bonnet assembly.
11. Using a flat-bladed tool, carefully break any remaining sealer bond between fiberglass cap and body.
FIGURE 4 - Roof Panel Assembly:
12. Using a flat-bladed tool, carefully break sealer bond between windshield header welt and roof panel assembly (3 and 10, Figure 4).
13. With the aid of a helper, carefully slide bonnet assembly forward to disengage fiberglass cap retainer from front bonnet retainer. Lift bonnet assembly from body.
Installation:
FIGURE 3 - ELDORADO (SEVILLE SIMILAR)-MEDIUM BODIED SEALER STRIPS:
FIGURE 4 - Roof Panel Assembly:
1. Prior to installing new bonnet assembly, be sure strips of medium-bodied sealer (1, 2 and 3, Figure 3) are complete. Where necessary, add additional sealer to roof panel to act as an anti-flutter (2, Figure 3). Use same pattern as shown in illustration. Apply 3/8" (10 mm) diameter bead of silicone across entire length of front bonnet retainer (8 and 9, Figure 4).
2. Where required, install new double sided tape in rear quarter rail and side roof rail areas (4, Figure 3).
3. With the aid of a helper, carefully position bonnet assembly on roof panel approximately 2" (50 mm) ahead of front bonnet retainer.
4. Pull bonnet assembly rearward until fiberglass cap retainer (11, Figure 4) on underside of bonnet assembly fully engages front bonnet retainer on roof panel.
5. When cap is in its installed position, use hand pressure as necessary to firmly seat fiberglass cap to roof panel.
NOTICE: Excessive pressure may cause cap to set too low and develop a flat spot in surface of cover. Once adhered in the wrong position, cap must be removed and rebonded to roof to establish proper adhesion and contour of the assembly.
6. The new bonnet should attach to the same rivet holes originally used. In the event new rivet attaching holes are needed, seal all old attaching holes with medium-bodied sealer to prevent water entry into body. Drill new holes as required using a 1/8" (3.2 mm) drill bit with an adjustable stop set at a maximum drilling depth of 1/2" (12 mm).
NOTICE: All rivets must be of an aluminum, closed-end type to prevent water entry into body.
7. Starting at front of car and working rearward, rivet cap to roof panel assembly. Repeat procedure on opposite side of car.
NOTICE: All rivet heads must be flush with fiberglass cap and free of burrs to prevent highlighting of rivet beads through the vinyl cover material. Carefully file or grind rivet heads as required.
8. Apply adhesive around perimeter of cover and fiberglass cap.
9. Firmly "slick" top material to fiberglass cap. Material must be free of all wrinkles and draws.
10. Using a headlining inserting tool, tuck top material flap under fiberglass cap along right and left side roof rail.
FIGURE 2 - Bonnet Assembly:
11. Trim excess top material at right and left quarter belt beneath belt reveal moldings (9, Figure 2).
CAUTION: Care must be exercised when trimming top material to prevent damage to painted surfaces.
12. Check quarter panel belt molding nuts and retainers. Replace nuts or retainers as required.
13. Install body caulking compound over all molding attaching nuts to prevent water entry into body.
14. Install all previously removed moldings.
15. Clean top assembly as required.
16. Remove all previously installed protective covers and tape from vehicle.