3.Bonnet Assembly Replacement

Removal

1. Cover front and rear of vehicle to protect painted and glass surface.
2. Mask off windshield and back window to avoid scratching glass, using a paper blanket or masking tape.
3. Remove drip rail moulding and "C" pillar mouldings, left and right side.
4. Using a moulding pry tool, remove mouldings by pulling push-in type retainers out of the barrel nut retainers.
5. Clean out remaining sealer from retainers and replace any damaged retainers.

Figure 3:

6. Starting at front of roof rail, left and right side, use a hook tool (approximately 90~ bend), insert and bend tabs downward to release (Figure 3).
7. Using a putty knife, carefully loosen cement bond securing fabric cover to fiberglass cap along belt areas sufficiently to expose pop rivets that secure fiberglass cap to body.
8. Using a 1/8" drill bit, equipped with an adjustable stop set at a maximum drilling depth of 3/8", drill out all exposed pop rivets around perimeter of
fiberglass cap to quarter belt and back belt area (both sides).
9. Using a putty knife, carefully break sealer bond between windshield header welt and roof panel assembly.
10. With aid of helper, carefully slide fiberglass cap forward sufficiently to disengage fiberglass cap from front retainer and remove cap assembly from body.

Figure 4:

Installation

1. Prior to installing new bonnet assembly, apply deadener (Figure 4).
2. Apply 1/2" bead of sealer immediately in front of retainer the complete length of retainer (Figure 4).
3. With aid of helper, carefully place bonnet assembly on roof panel approximately two (2) inches ahead of bonnet retainer.
4. Pull bonnet assembly rearward until retainer on underside of bonnet assembly leading edge is fully engaged with 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.
6. Seal all old attaching holes with medium-bodied sealer to prevent water entry into body. Drill new holes using a 1/8" drill bit with an adjustable stop set at a maximum drilling depth of 1/2".
7. Starting at quarter belt area and working rearward, pop rivet cap to roof panel assembly. Repeat procedure on opposite side.
NOTE: All rivet heads must be flush with the fiberglass cap and free of burrs to prevent highlighting of rivet head through the vinyl cover material. Carefully file or grind rivet heads as required.

8. Apply cement around perimeter of cover and fiberglass.
9. Firmly "Stick" top material to fiberglass cap. Material must be free of all wrinkles and draws.
10. Trim excess top material at right and left quarter belt and back belt areas.

CAUTION: CARE MUST BE EXERCISED WHEN TRIMMING TOP MATERIAL TO PREVENT DAMAGE TO PAINTED SURFACES.
11. After replacing damaged retainers, apply a daub of sealer to each barrel nut retainer.
12. Select correct quarter moulding part #P-17D4-0788/9 and back belt moulding part #P-17D4-0587 and position the retainers to each barrel nut location and apply pressure to each retainer location to seal retainers snugly.
13. Clean up top assembly as required.
14. Remove all previously installed protection covers and tape from vehicle.