Overhaul
DISASSEMBLY1. REMOVE TARPAULIN LOCKS
a. Remove the 3 screws and tarpaulin lock.
b. Remove the RH and LH locks.
2. REMOVE CENTER TARPAULIN BOW STAY CATCH HANDLE
Remove the 2 screws and center tarpaulin bow stay catch handle.
3. REMOVE SET PLATE
Remove the 6 screws and set plate.
4. REMOVE FRONT ROOF SIDE RAIL WEATHERSTRIPS
a. Remove the screw, 2 clips and roof side rail weatherstrip.
b. Remove the RH and LH weatherstrips.
5. REMOVE CENTER ROOF DRIP SIDE FINISH MOULDINGS
a. Remove the 4 screws and roof side finish moulding.
b. Employ the same manner described above to the other side.
NOTE: Before removing the moulding, mark the positioning with a colored pencil on the installation holes.
6. REMOVE REAR ROOF SIDE RAIL WEATHERSTRIPS
a. Using a clip remover, remove the 2 clips and roof side rail weatherstrip.
HINT: Tape the screwdriver tip before use.
b. Employ the same manner described above to the other side.
7. REMOVE REAR ROOF SIDE FINISH MOULDINGS
a. Remove the 4 screws and rear roof side finish moulding.
b. Employ the same manner described above to the other side.
CAUTION: Before removing the moulding, mark the positioning with a colored pencil on the installation holes.
8. REMOVE TARPAULIN COVER
a. Close the tarpaulin lightly and cut out the tie lap band.
b. Remove the clip.
c. Pull up the spring cover and remove the spring B.
d. By making the tarpaulin assembly in a half-open condition, remove the upper cloth from the No.2 bow.
e. Remove the cloth affixed on the No.2 bow.
f. Remove the upper band.
g. Remove the inside cloth of the tarpaulin from the band assembly.
h. By making the tarpaulin assembly in a full-open condition, remove the nut and end plate.
NOTE: Remove the plate pinched in the end plate beforehand.
i. Remove the 6 right and left screws of the tarpaulin cover at the link side.
j. Remove the tarpaulin belt wrapping around the link side.
k. Remove the velcro holding both ends of the No.2 bow.
l. Pull up the cover at the link side and remove the caulking of the wire by using a screwdriver.
m. Remove the screw and spring.
n. Remove the front of the tarpaulin cover.
o. Using a rivet cutter and a drill, drill the rivets and remove the band.
HINT: Even if the fringes are taken out, continue drilling and push out remaining flangments with the drill.
p. Remove the tarpaulin cover from the rear of the link toward the front then take it out.
NOTE: Take out the cover so as not to damage the glass.
REASSEMBLY
1. INSTALL TARPAULIN COVER
a. Set the tarpaulin cover on the link assembly.
b. Rivet the band on the link using a pneumatic riveter or hand riveter.
NOTE:
- Do not prize a riveter, as riveter is damaged, it is not tightened and the mandrel is bent.
- Do not tilt the riveter and disconnect the rivet from the material while operating a riveter, otherwise the materials could not be tightened firmly.
- Install the rivet while attaching materials, as they are not be tightened firmly.
c. Apply the front part of the tarpaulin cover over the link header part.
d. Put the front part of the tarpaulin cover over the link.
NOTE: Pull the both edges of the cover in order to prevent wrinkles.
e. Tighten the wire at the link side.
f. After caulking the wire, affix a butyl tape to that position.
NOTE: Failing to tighten the caulking part securely may cause a break of the cover on the side.
g. install the spring with the screw.
NOTE: If the spring or the wire is leant toward either right or left, this may cause wind noise.
h. Retain the tarpaulin belt winding around the link side with a button.
i. Wind the velcro onto the tarpaulin.
NOTE: Secure the space for winding the cloth.
j. Install the tarpaulin cover to the link side part with the 6 screws.
NOTE: Pay attention to the screws on the vehicle back end, because they are short.
k. Install the set plate with the 6 screws.
NOTE: When installing, tighten the center screw first.
l. Apply adhesive to 2 or 3 threads of the mounting nut.
m. Install the end plate.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent.
NOTE: Do not let the head of the bolt sticking up over the nut upper surface. Pinch the plate, taking care of the plate facing direction.
HINT: Over-tightening of the nut causes wind noise.
n. Put the cloth for the inside tarpaulin cover into the inside.
o. Install the stud bolt to the rear of the tarpaulin cover on the body side.
NOTE: Take care not to damage the glass.
p. Tighten the upper tarpaulin cover retainer with the 7 nuts.
q. Affix the tailgate lower seal with velcro.
NOTE: Be careful that the inside cover or the tarpaulin is not caught.
r. By making the tarpaulin assembly in a close condition, lock it.
s. Pull the No.4 bow as shown in the illustration.
t. Install the center roof drip side finish mouldings.
1. Using a scraper, remove the adhesive sticking to the finish moulding.
2. Clean the roof side rail finish moulding.
3. Apply a butyl tape to the groove on the back of the moulding.
4. Install the roof side rail finish moulding with the screws by matching them with marking.
u. Employ the same manner described above to the other side.
v. Install the rear roof side finish mouldings.
w. Install the rear roof side rail weatherstrip with the 2 clips.
x. Employ the same manner described above to the other side.
y. Install the front roof side rail weatherstrip with the screw and 2 clips.
z. Employ the same manner described above to the other side.
aa. Affix the inside cover with velcro.
ab. As shown in the illustration, put a cloth and a band through the No.3 bow guide, and fix with a tie lap band.
- Fix with a band, checking the tension at the tarpaulin cover side.
- After installing the band, cut it by 5 mm (0.20 in.) or less.
ac. Install the spring B.
- Be sure to install the spring B securely to the groove.
- Check the tension of the link upper part of the tarpaulin cover.
- Check that the side of the cover is not caught in the link when opening or closing the tarpaulin assembly.
ad. Peel off the parting paper of a double adhesive tape, apply a new double adhesive tape, install the cloth of the main body side to the No.2 bow.
CAUTION: Install the cloth of the main body side, checking that it is not stretched too much.
ae. By making the tarpaulin assembly in a half-open condition, install the upper cloth by hanging it on the hook.
2. INSTALL CENTER TARPAULIN BOW STAY CATCH HANDLE
Install the center tarpaulin bow stay handle with the 2 screws.
Torque: 62 N.m (630 kgf.cm, 45 ft.lbf)
3. INSTALL TARPAULIN LOCKS
a. Apply adhesive to 2 or 3 threads of the mounting screw end.
Adhesive: Part No. 08833-00070, THREE BOND or equivalent
b. Install the tarpaulin lock with the 3 screws.
Torque: 62 N.m (630 kgf.cm, 45 ft.lbf)
c. Employ the same manner described above to the other side.