WOC & WOC Top & Back Installation Instructions

Transcription

1 Shown with optional Sun Roof WOC & WOC Top & Back Installation Instructions

2 Install Order! Heater Door System Wiper on to Windshield Windshield Rear Panel Top Panel Tools needed: 5/16 Allen wrench, socket (Windshield only) 6mm Allen wrench, socket (Windshield only) 3/16 Allen wrench, socket 5/32 Allen wrench, socket 10mm, 5/8, 1/2 and 7/16 Wrench of Socket Flat Screwdriver Utility Knife Tin snips or cable cutter for cutting trim Cap Screw #10 Washer Black Screw Cap Important notes: *Use Black screw caps with a #10 washer under the 1/4 button head bolts when assembling the body parts. *Use zinc washers and 1/4 nylock nuts to secure all 1/4 bolts. *Use zinc washers and nylock nuts (where applicable) with all 5/16 bolt used to secure the windshield. *To remove the plastic rivets use a flat screwdriver to first remove the center core and then the rivet body. Reverse the order when reinstalling the rivets. *Leave all fasteners loose until instructed to tighten. *Use caution when installing fiberglass body parts. Tighten fasteners just until the part surface starts to distort. *Examine all photos (Especially wiring) for general overview of the installation before beginning.

3 Step 1: Wiring Photo 1 (For Economy model skip to step 2. A: The 1131 harness runs power from under the passenger seat to the lights located in the back of the top panel. Loosely fasten (wire ties) the multiple plug accessory end of the harness to the center of the top of the rear cross brace. Route the harness to the passenger side and down the rear of the roll cage. B: Remove the 2 bolts securing the top of the passenger restraint D loop. Remove the plastic rivet securing the side panel to the rear panel. Gently pull the plastic side panel out and route the harness down the roll cage inside of the side panel under the D loop and under the seat. Replace the side panel and fasten securely. (See Photo 2 also). C: The power harness is located under the passenger set and has multiple legs. Install as follows. 1) (Photo 2) Secure the 2 relays to the front seat support. 2) (Photo 3) Route the single orange wire thru the drain hole in the center under seat compartment to the fuse block. Install the fuse clip on the brake light fuse and connect the orange wire to the clip. 3) (Photo 4) Route the long (Red & White) leg back to the throttle body. Locate the short pigtails coming out of the factory harness and connect the spade connectors Red to Red, White to White. 4) (Photo 2) Connect the Red and Black wires to the battery. 5) Plug the 1131 harness into the power harness. 6) Secure wires away from moving parts and pinch points. Photo 1A 1131 Harness Photo Harness Rivet Photo 2 Secure Relays here 1131 Harness This line to under box D Loop Bolts To Brake light fuse

4 Photo 3 Fuse Block Clip Wire from power harness Photo 5 Top Panel rests here Remove rivets and use bolts here Photo 4 Harness from under seat Brake light fuse Driver side view Connectors Step 2: Rear Panel (Photo 5) A: Raise the vehicle box and locate the row of 7 fasteners securing the plastic panel to the seat back support. Remove the (2) outside and the (1) center fasteners. B: Position the rear panel on the vehicle so the panel corners rest on the rear plastic roll cage covers. Align the panel with the holes in the plastic and secure loosely using 1/4 x 1 bolts, caps, washers and nuts. Use tape or other means to temporarily secure the top of the rear panel to the roll cage. NOTE: On 2014 models use a 1/4 x 2 bolt in the center hole with a 1/4 x 1 fender washer and nut on the inside. Panel rests here Step 3: Top Panel A: Position the top panel on top of vehicle so the rear edge rests on the indent at the top of the rear panel. Align the holes in the top and rear panel and secure loosely using 1/4 x 1 bolts, caps, washers and nuts. Allow the rear panel and top to slide back 2 inches from the roll cage to provide better access to the fasteners behind the top roll cage cross brace. (Refer to Photo5) B: Slide the top and rear panel forward and align the holes in the front of top with the holes in the windshield top. Loosely secure using 1/4 x 1 bolts, caps, washers and nuts. C: (Photo 6) Align the outer edges of the top and windshield as close as possible and tighten the (4) front bolts securing the top and windshield. D: Position the rear panel to rest on the top of the plastic roll cage covers and tighten the (3) fasteners across the bottom of the rear panel. E: Align the top and rear panel and tighten the (6) fasteners across the bottom of the top. Photo 6 Align before securing Top & Windshield

5 Step 3F: (Photos 7, 8 & 9) F: Install a continuous piece of bulb seal on the top and windshield. Square the end of the trim if necessary and start in the rear corner of the top. Butt the end of the bulb seal against the rear panel seal and press the trim on to the top edge. Make sure the trim is seated all the way in and does not bridge the corners. Use a mallet or handle to tap the trim on if necessary. Continue on across the top/windshield seam to the bottom of the windshield. Cut the trim to length (even with the bottom of windshield). Trim Hints: Trim may be taken off and slightly stretched or compressed to adjust length. Try to compress the trim during installation by working the trim towards your starting point. (Stretched trim can shrink). Trim may be cut with tin snips, cable, wire cutters or heavy duty scissors. Remove the exposed wire clips after cutting by using needle nose pliers Cut Long-Cut Twice! Photo 7 Photo 9 Step 4: (Standard model only) (Photos 10 & 11) A: Plug in the rear lights and brake light. B: Hold the interior panel upside down (to access the back side) and plug in the light switch and dome light. NOTE: The blue, double black and T plugs are not used in this application. C: Turn key on and check all lights. D: Secure the excess wiring on top or behind the cross brace. E: Position the interior panel and fasten in place. Install plastic rivets in the top holes first then use the 1/4 x 1-1/2 bolts, black caps, washers and nuts in the bottom holes and tighten. Continuous Trim Photo 10 Light Plugs Photo 8 Dome light Black & Pink Switch Red & Green

6 Photo 11 Rivets Bolts