B.Preparation For Installation:

Figure 10:

Note: Use adequate eye and skin protection when cutting or grinding metal parts. Take steps to cover and protect the vehicle interior and glass surfaces.

1. Bracket removal: In order to install the new type lifting element in an older vehicle, the old roof element mounting brackets (Figure 10) must be removed. These brackets are spot welded to the roof panel and also bead welded on the rear edge. It is very important not to distort the lifting roof opening when removing these brackets. Therefore, use a carbide cut-off wheel to cut through the bead weld and a spot weld removal bit to drill out the spot welds. After the brackets are removed, grind away all remaining spot and bead weld material leaving a smooth, flat surface. Coat all exposed metal surfaces with corrosion proof paint.

Figure 11:

2. Enlarge the right side drain tube hole approximately three times its original size (Figure 11). This permits the installation of the cable housing extension of the right side lifting element. With adequate eye protection, use a carbide grinding bit to open the hole toward the front and down. Use care not to damage the lifting roof drain tube.

Figure 12:

3. Reinstall the mounting screws (Figure 12) from the center gear box using at least 2.0 mm of spacers to prevent possible roof panel damage from the bolt ends.

Figure 13:

4. Determine the exact center of the lifting roof opening and mark the rear inside panel accordingly (Figure 13). Measure from the left of center (driving direction) 12.0 mm and draw another line parallel to the first. From the edge of the roof opening, measure to the rear 60.0 mm along the line drawn 12.0 mm from the left of vehicle center. Center punch this location and drill a 7.3 mm hole and install the cable tie supplied with the lifting roof set.

Caution: Use a distance piece to limit the penetration of the drill bit into the roof panel. Otherwise the outer roof panel will be damaged.

Figure 14:

5. Determine the center of the new mounting brackets and scribe a line on the bracket. Note that the speed nut tabs on the brackets go to the inside. Measure from the exact center line of the roof opening to the left side 317.5 mm and draw a line. Measure from the center line to the right side 311.5 mm and draw another line (Figure 14). Align the center of the new mounting brackets with their respective distance marks. Install the brackets to the rear as far as possible. The front part of the bracket will rest in approximately the same place as the original bracket.

With the brackets centered on their marks and rearward as far as possible, mark the location of the rivet holes in the top panel using the bracket as a template. Select the appropriate size drill bit using the supplied pop rivets as a guide.

Caution: Use a distance piece to limit the penetration of the drill bit, otherwise damage to the roof panel will occur.

Install mounting brackets using supplied pop rivets.