Formal Roof, Carriage Roof, Bonnet Assembly - Replacement
1. Remove drip rail moulding and "C" pillar mouldings, right and left side.FIGURE 8:
FIGURE 9:
2. Remove belt mouldings, right, left, and rear, (1) screw and (1) nut each side. (Figure 8 and 9).
FIGURE 10:
3. Starting at the front of roof rail, using a hook tool, bend bonnet retaining tabs downward to release right and left sides. (Figure 10).
4. Carefully loosen cement bond securing fabric cover to fiberglass cap along belt line, sufficiently to expose pop rivets retaining bonnet assembly to vehicle.
5. Drill out all exposed pop rivets around perimeter of the fiberglass cap along belt line area. (Use 1/8" drill bit with an adjustable stop, set at max. drill depth of 3/8".)
FIGURE 9:
FIGURE 10:
FIGURE 11:
6. Carefully lift the bonnet assembly off vehicle by starting at the rear and lifting the bonnet assembly and breaking the adhesive bond between bonnet and roof of vehicle (two men). Caution must be excersized to avoid breaking the fiberglass cap when lifting bonnet assembly from vehicle roof. Slide the bonnet assembly forward to disengage from front retainer and remove bonnet assembly. (Figure 9, 10, and 11).
8. Clean off all excessive adhesive from vehicle top and underside of bonnet if bonnet is to be reused.
FIGURE 11:
9. Apply adhesive (deadener) to roof of vehicle (apply 1/2" bead of adhesive in front of the front retainer, the complete length of the retainer). (Figure 11).
FIGURE 11:
10. Carefully place the bonnet assembly onto roof of vehicle, position 2" forward of windshield header, pull the bonnet rearward until the retainer on the underside of bonnet leading edge is fully engaged with retainer on vehicle roof. Lower bonnet assembly and fit to vehicle top, use hand pressure to firmly seat bonnet to roof - two men. (Figure 11).
11. Seal all old bonnet attachment holes to prevent water entry into body.
12. Drill new bonnet to body attaching holes using 1/8" drill bit with an adjustable stop set at a maximum drilling depth of 1/2" (apply zinc-rich primer to all holes).
13. Starting at the "C" pillar and working rearward, pop rivet bonnet assembly to body at the belt line, right and left sides and the rear of the bonnet, using 1/8" x .328 pop rivets.
NOTE: All rivet heads must be flush with the fiberglass cap and free of burrs to prevent highlighting of rivet heads through the vinyl cover material. Carefully file or grind rivet heads as required.
14. Apply adhesive (D9AZ-19C525-A) around perimeter of cover and fiberglass; firmly "stick" top material to fiberglass cap (material must be free of wrinkles and draws).
15. Carefully trim off excess material around the belt line of vehicle.
CAUTION: Be careful not to damage painted surfaces when trimming excess material.
FIGURE 10:
16. Reposition tabs to roof rail to secure bonnet assembly along right and left roof rails. (Figure 10).
17. Install right, left and rear belt mouldings. (Replace any defective barrel nut retainers before installation of mouldings and apply sealer to all barrel nuts.)
FIGURE 8:
18. Install drip rail mouldings and "C" pillar mouldings. (Figure 8).
FIGURE 14:
BACKLITE REPLACEMENT
1. Remove the backlite interior garnish moulding (8) screws retaining. (Figure 14).
2. Follow steps under bonnet replacement, loosen bonnet assembly, and prop the bonnet assembly up approximately 6 inches above the backlite rather than lifting it off the vehicle.
FIGURE 12:
3. Remove the valance panel and position a side. (Figure 12).
4. Disconnect the heated backlite lead from backlite.
5. Replace the backlite glass as outlined in the Car Shop Manual in Section 43-11 - Glass, Stationary
- Butyl Type Seal.
6. Reposition valance panel to backlite and belt area (Figure 12).
7. Remove the bonnet assembly prop. following the steps under "Bonnet Assembly Replacement". Reinstall bonnet assembly to vehicle.
8. Reconnect heated backlite lead.
FIGURE 14:
9. Install backlite interior garnish moulding, (8) retaining (Figure 14).
FIGURE 8:
BELT MOULDING - REMOVE AND INSTALL
1. Remove "C" pillar moulding, right and/or left side, (3) screws each. Figure 8.
FIGURE 8:
FIGURE 9:
2. Remove belt moulding, right, left and/or rear. Remove (1) screw at "C" pillar, (1) nut inside luggage compartment, retaining side mouldings and remove mouldings. (Figures 8 and 9).
3. Replace all barrel nuts damaged during disassembly and apply sealer to all barrel nuts and attaching locations.
4. Install rear belt moulding, position right and left mouldings to body engaging ends in rear belt moulding and install (1) screw and (1) nut each side to retain mouldings. (Figures 8 and 9).
FIGURE 8:
5. Reposition "C" pillar mouldings and install 3 screws each side to retain (Figure 8).
FIGURE 8:
VALANCE - REMOVE AND INSTALL
1. Remove "C" pillar moulding right and left side. (Figure 8).
FIGURE 8:
FIGURE 9:
2. Remove belt moulding, right, left and rear. Remove
(2) screws at "C" pillar and (2) nuts inside luggage compartment and remove mouldings. (Figures 8 and 9).
FIGURE 12:
3. Remove valance panel. (2) tabs on ends of valance panel are positioned behind bonnet assembly above belt line. (Figure 12).
4. Position valance panel to bonnet, engaging tabs behind bonnet and align with belt line. (Figure 12).
5. Install belt mouldings, right, left, and rear (2 screws and 2 nuts each side). Replace any damaged barrel nuts and seal all moulding attaching points.
FIGURE 8:
6. Install "C" pillar mouldings, right and left sides. (Figure 8).
FIGURE 13:
BOW FEATURE STRIP - REMOVE AND INSTALL
1. Remove bow feature strip end caps, (1) screw each. (Figure 13).
2. Grasp the bow feature strip and pull toward you and slide off of feature strip retainer. (Figure 13).
3. Remove adhesive from retainer using a cloth or rag dampened with solvent (Ditzler No. 440 or equivalent - grease and wax remover).
NOTE: Do not leave damp rag or cloth laying on top fabric as solvent may discolor material.
4. To replace the feature strip retainer, drill out all (11) rivets retaining feature strip retainer to fiberglass cap (use a 1/8" drill bit (.125") with an adjustable stop set at a maximum drilling depth of 3/8"). (Figure 13).
5. Seal open rivet holes in fiberglass cap with sealant. Position feature strip retainer on top and attach retainer to bonnet assembly, (11) 1/8" x .328" flat head rivets.
6. Apply bead of adhesive (cyno/lote) across entire length of retainer, starting at the center of retainer, roll bow feature strip into retainer.
7. Trim ends of feature strip to correct length and install (2) end caps (1) screw each. (Figure 13.)