Frame, Folding Top - Installation

INSTALLATION






WARNING: Always use Urethane to bond Folding Top Fame to the vehicle. Never use products such as Silicone or other types of adhesives, as this will jeopardize the integrity of the roof system

WARNING: Failure to follow these instructions may result in serious or fatal injury

CAUTION: Protect all exposed painted and trimmed surfaces from coming in contact with urethane and primers

1. If re-using the original body side apertures, headers or the folding top frame, it will be necessary to remove the remaining urethane bead (1) down to a maximum height of 1mm. Use a gasket scraper (2) or equivalent to trim as close as possible to the part without cutting into the part or damaging the paint.





2. Place replacement weatherstrip (1) face down on a clean and dry surface.
3. Alcohol wipe (2) entire weatherstrip mating surface (bottom) and allow to dry for one minute.
4. Clean top surface of folding top frame with wax and grease remover, per manufacture recommendations.
5. Alcohol wipe the entire folding top frame area that the weatherstrip will make contact. Allow to dry for one minute.






NOTE: It is crucial that there are no skips or voids in the butyl bead.

6. Apply 4 mm of butyl (3) to the entire perimeter of the weatherstrip (2) mating surface. Butyl is to be placed between guide lines (1).










NOTE: Right side shown, left side typical.

7. Apply a 3-4 mm bead of weatherstrip adhesive to the outboard edge next to the butyl. From the front corners, the adhesive is to extend inward 300 mm (12 in) and 500 mm (20 in) rearward.






NOTE: Right side shown, left side typical.

NOTE: Care should be taken to avoid any contact with the adhesive and butyl areas of the weatherstrip.

8. With the aid of an assistant, place the folding top frame positioned with the top down over the weatherstrip.
9. Insert the weatherstrip alignment square tab (2) located on the right and left side of the weatherstrip (1) into the alignment square holes (3) located on the left and right rear corners of the folding top frame (4).





10. Tuck the front corners (1) of the weatherstrip onto the folding top frame (3).





11. Working toward the center, tuck the outer lip of the weatherstrip (2) onto the outer edge of folding top frame (1).
12. Repeat until the right, left and front areas have been completed.
13. Inspect the entire perimeter of the folding top frame to be certain the lip of the weatherstrip is properly seated.
14. Gently remove the protective tape from the butyl.






NOTE: A small wooden roller (2), or equivalent, should be used to aid in evenly compressing the butyl.

CAUTION: THIS STEP IS CRITICAL, if not done correctly leaking may occur

15. Firmly compress the weatherstrip, starting at the ends and working towards the center.

NOTE: Weatherstrip installation is complete, continue with prepping of vehicle and folding top frame.

NOTE: Any areas with an existing urethane bead should be trimmed down to no more than 1 mm, as explained in the folding top frame removal procedure.

16. Allow the weatherstrip adhesive to cure per manufacturer recommendations.





17. Use alcohol wipes (2) to clean the roof opening perimeter mating surfaces.
18. Alcohol wipe (2) the folding top frame (1) mating surface where urethane bead is to be applied.
19. Alcohol wipe the body side aperture, front header and rear header.
20. Allow areas that have been treated with alcohol wipes to dry for 1 minute.

NOTE: Follow the urethane primer manufacturer recommendations for application and dry time.

21. Apply urethane primer to any paint that may have been damaged on the roof flanges and headers during removal, ONLY within any area that the weatherstrip and frame will cover.
22. If the body side apertures or headers have been refinished, apply urethane primer to the mating surfaces.
23. If installing a new folding top frame, prime the mating surface area.






Urethane bead placement is as follows:
- Front (2) - 6 mm from edge of curve to edge of urethane
- Sides (3) - 4 mm from edge of weatherstrip to edge of urethane
- Rear Center (1) - 10 mm from bevel to edge of urethane
- Rear Sides (4) - 10 mm from bevel to edge of urethane





NOTE: Use Mopar Part # 04864015AB urethane to install the folding top frame. Follow the recommendations for work and handling the urethane.

24. Cut a 6 X 11mm. notch in the urethane tube nozzle (1) as shown.
25. Apply a 8 X 13 mm bead of urethane to the pre-primed area of the frame, using a power caulk gun or equivalent. Start and finish at the rear center of the frame.
26. With one person on each corner, carefully place folding top straight and evenly down upon the roof, allow the mounting fastener holes to aid in proper alignment.
27. Visually verify that the urethane has made complete touch-down to the roof around the entire perimeter.

NOTE: Proceed to frame fastening procedures before urethane is totally cured.






28. Accessing from the vehicle interior, loosely install the front fastener (1) securing the frame to the vehicle. Repeat on the opposite side.





29. Loosely install the two fasteners (1) located under the package tray securing the package tray/frame to the vehicle.





30. Accessing from the vehicle interior, loosely install the fastener (1) located in the lower C-pillar area just above the package tray that secures the frame to the vehicle. Repeat on the opposite side.





31. Accessing from the vehicle interior, loosely install the fastener (1) located in the upper C-pillar area securing the frame to the vehicle. Repeat on the opposite side.





32. Install the three fasteners (1) securing the lower rear portion of the frame to the body.
33. Tighten all frame fasteners to 8 N-m (71 in. lbs.).
34. Allow the urethane to cure per manufacturer recommendations.





35. Using appropriate tools, carefully install the windshield (1) to the vehicle.

WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment.

WARNING: To avoid serious or fatal injury when removing a deployed airbag, rubber gloves, eye protection, and a long-sleeved shirt should be worn. There may be deposits on the airbag unit and other interior surfaces. In large doses, these deposits may cause irritation to the skin and eyes.

WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the side curtain airbag, or becoming entrapped between the side curtain airbag cushion and the headliner. Failure to observe this warning could result in occupant injuries upon airbag deployment.

NOTE: At no time should any source of electricity be permitted near the inflator on the back of a non-deployed airbag or seat belt tensioner. When carrying a non-deployed airbag, the trim cover or airbag cushion side of the unit should be pointed away from the body to minimize injury in the event of an accidental deployment. If the airbag unit is placed on a bench or any other surface, the trim cover or airbag cushion side of the unit should be face up to minimize movement in the event of an accidental deployment.

NOTE: The Side AirBag Inflatable Curtain (SABIC) is color-coded for the side of the vehicle onto which it will be installed. The left side SABIC will have blue tape at the rear end of the cushion and a blue label beneath the inflator. The right side SABIC will have red tape at the rear end of the cushion and a red label beneath the inflator.

NOTE: Be certain that the airbag cushion is not twisted during installation. A black stripe extends along the entire inboard length of the cushion. If this stripe is visible anywhere along the outboard length of the cushion, the SABIC is twisted and must be untwisted before it is secured to the roof side rail.





36. Position and insert the T-tab at the front of the SABIC inflator (5) into the slotted hole in the inner roof side rail (1).
37. Engage the hook of the bracket at the back of the SABIC inflator into the slotted hole in the inner roof side rail.
38. Align and insert the locating hooks of the metal mounting tabs on the SABIC into the locating holes in the inner roof side rail. Check that the black stripe along the inboard length of the cushion faces inboard to confirm the cushion is not twisted.





39. Align and insert the plastic push-in fastener through the mounting tab on the SABIC front tether (2) and into the inner A-pillar (3) until it is fully seated.





40. Loosely install three screws. One goes through the bracket at the back of the inflator into the inner roof side rail and two (1) go through the metal mounting tabs forward of the inflator into the inner roof side rail.
41. Align and insert the anti-rotation tab at the end of the front tether into the hole in the inner A-pillar and loosely install the screw that secures it.
42. Tighten the four screws in the following sequence to 9 Nm (80 in. lbs.).
1. Bracket at the back of the inflator.
2. Mounting tab at the front of the B-pillar.
3. Mounting tab over the door window opening.
4. Tab at the end of the front tether.

43. Align and insert the locating hook of the metal mounting tab on the SABIC behind the inflator into the locating hole in the inner C-pillar. Check that the black stripe along the inboard length of the cushion faces inboard to confirm the cushion is not twisted.
44. Loosely install the screw that secures the metal mounting tab to the inner roof side rail.
45. Align and position the mounting tab at the end of the rear tether over the stud on the inner C-pillar.
46. Install and tighten the nut that secures the rear tether mounting tab to the inner C-pillar. Tighten the nut to 9 Nm (80 in. lbs.).
47. Tighten the screw that secures the metal mounting tab on the SABIC behind the inflator to the inner roof side rail. Tighten the screw to 9 Nm (80 in. lbs.).
48. Reconnect the body wire harness connector for the SABIC to the connector receptacle at the back of the inflator. Be certain the connector is fully engaged and locked.
49. Reinstall the headliner into the vehicle. Headliner - Installation.
50. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) Verification Test procedure should be performed following service of any SRS component. Service and Repair.





51. Position the headliner side rail (2).
52. Install the fastener (1) securing the tether to the airbag.
53. Hand tap the headliner side rail to engage the retaining clips.





54. Position the coat hook (1) in the "9 o'clock" position, push in and twist clockwise to the "12 o'clock" position.





55. Position the front header cover (1).
56. Hand tap the front header cover (1) to engage the retaining tabs.
57. Install the rivet (2) located in the dome lamp cavity securing the front header cover (1) to the roof header.





58. Install the dome lamp and power top switch, Full Open Retractable Roof Switch - Installation.
59. Install the visor support and visor (2), Visor Support - Installation ,Visor - Installation.





60. Position and slide the rear view mirror (2) downward over the support bracket/button on the inside of the windshield glass until the tab is fully engaged.
61. Connect the harness (1) to the rear view mirror (2).





62. Install the harness cover (1).
63. Install the cover (2) located on the rear of the mirror.





64. Position the cover to the vehicle.
65. Engage the first set of roof bow blocks into the tracks, slide the cover forward and engage the remaining roof bow blocks.
66. Engage the top stow slider block (1) by turning the front screw (2) counter clockwise. Repeat on the opposite side.





67. Position the rear stop block to the rear of the track.
68. Install the fastener (2) securing the rear stop block (1). Tighten the fastener securely. Repeat on the opposite side.





69. Position and engage the rear track cover (1) by inserting the outboard edge of the cover and rolling the track cover outward and down. Hand tap to seat properly. Repeat on the opposite side
70. Attach the seal at the bottom of the rear track cover (1).





71. Install the cover to the second bow retainer (1). Repeat on the opposite side.





72. Position the front bow tension belt.
73. Install the rivet (1) securing the front tension belt to the front bow. Repeat on the opposite side.





74. Open the roof (1) fully until the front edge tilts back.
75. Install the front bow bolts (2). Tighten the bolts securely. Repeat on the opposite side.
76. Close the roof (1) to 3/4 open position.





77. Attach the four bow.
78. Install the fastener (1) securing the four bow cap (2). Tighten the fastener securely. Repeat on the opposite side.





79. Attach the headliner tension belt/tether (1) to the linkage. Repeat on the opposite side.
80. Engage the pin (3) to the fastener (2). Repeat on the opposite side.





81. Accessing from inside the vehicle, install three of the washers between the hinge and linkage (1). Then install the remaining washer and fastener (2) securing the backlite/glass linkage (1). Tighten the fastener securely. Repeat on the opposite side.





82. Position the backlite bracket. Repeat on the opposite side.
83. Install the clip (1) to the backlite bracket. Repeat on the opposite side.





84. Install the tension cable (2) to the bracket (1). Repeat on the opposite side.





85. Using Miller tool 10321 lanyard/adapter (2), loop the lanyard/adapter through the tension cable bracket (1).
86. Using Miller tool 8828A pull gauge (3), attach the pull gauge to the lanyard/adapter (2).
87. Set the pull gauge to 178 N (40 lbs.force) and pull back until the spec is achieved.
88. Install the fastener securing the bracket (1) to the roof frame. Tighten the fastener securely.
89. Repeat steps 84-87 for the opposite side.





90. Position the tension bar (1).





91. Install the four fasteners (1) securing the tension bar. Tighten the fasteners securely.





92. Attach the harness to the rear shelf.
93. Connect the electrical connector to the motor (1) and the module (2).





94. Align and position the motor cover plate (2).
95. Install the four rivets (1) securing the motor cover plate (2).
96. Install the headliner fabric from the rear shield and the entire backlite/glass areas.





97. Feed the CHMSL harness in the opening on the cover.
98. Engage the CHMSL harness grommet located on the cover.
99. With the help of an assistant, align and position the CHMSL (1) to the cover.





100. Install the four fasteners (2) securing the CHMSL to the cover.
101. Connect the CHMSL wiring harness.
102. Attach the CHMSL wiring harness (1) to the cover.





103. Position the C-pillar trim panel (1).
104. Hand tap to engage the C-pillar trim panel (1) retaining tabs/clips. Repeat on the opposite side.





105. Position the B-pillar trim panel (1).
106. Hand tap to engage the B-pillar trim panel (1) retaining tabs/clips. Repeat on the opposite side.





107. Position the rear shelf (2).
108. Install the push pin retainers (3) to the rear shelf.
109. Position the bracket (1).
110. Install the three fasteners securing the bracket (1) to the rear shelf (2). Tighten the fasteners securely.





111. Install the rear wind deflector/windscreen (1).





112. Install the decklid cut seal (1).





113. Install the decklid, Decklid - Installation.
114. Connect the negative battery cable.





115. With the help of an assistant(s), cycle the cover (1) to the closed position while applying pressure to the front of the cover. Make sure the cover (1) is fully seated. Repeat process if necessary.
116. The cover will need to stay in the closed position for at least 30 minutes to properly stretch.
117. Reconnect the negative battery cable.