Perform Additional Operations When Replacing Manual Pop-Up Roof - AR77.70-S-0001-05E

Model 447.7/8 

With Code ZK9 (Lifting roof hatch) 

Remove 

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1. Lay old pop-up roof (1) with bottom upward on suitable assembly stands.

   Helper required.

2. Remove cover caps at nuts of screws of left and right roof bed grab strap (2).
3. Remove nuts, remove left and right roof bed grab strap (2) from old pop-up roof (1).

   Do not remove loosened bolts form mounting roof bed support strap (2), because they are replaced.

4. Remove left and right retaining clip (3) from old pop-up roof (1).
5. Remove front and rear safety net mount (4) from left and right side of old pop-up roof (1).

   Shown on removed pop-up roof (1) 

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6. Remove cover cap at nut of screw of closing strap (9).
7. Remove nuts and remove closing strap (9) from old pop-up roof (1).

   Do not removed loosened bolt for mounting pulling loop (9), because they are replaced.

   Shown on removed pop-up roof (1) 

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8. Remove cover caps from nuts of screws of left and right pneumatic spring ball pin bracket (11).
9. Remove nuts and remove left and right pneumatic spring ball pin bracket (11) from old pop-up roof (1).

   Shown on removed pop-up roof (1) 

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10. Remove all profile rails (5) and corner reinforcements (7) together with electrical wiring harness (6) from old pop-up roof (1).

    Side profile rails (5), front profile rails (5) and front corner reinforcements (7) are installed together with electrical wiring harness (6).

11. Remove all blind plugs from bottom of old pop-up roof (1).

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    Install 

12. At underside of screw head on screw for attaching closing strap (9), apply a butyl rope in a ring shaped and gap-free manner.

    The bolt must be clean and free of grease Otherwise leakage is not possible.

    Use new bolt.

13. Install pulling loop (9) on pop-up roof (1).
14. Install cap on nut for fastening pulling loop (9).

    Shown on removed pop-up roof (1) 

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15. Lay butyl cord ring-shaped and gap-free down on bottom side of bolt head on bolts for fastening roof bed support straps (2).

    The bolts must be clean and free of grease.

    Otherwise leakage is not possible.

    Use new bolts.

16. Install left and right roof bed support strap (2) on pop-up roof (1) .
17. Install caps on nuts for fastening roof bed support straps (2).
18. Install left and right retaining clip (3) on pop-up roof (1).

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19. Install front and rear safety net mount (4) on left and right side of pop-up roof (1).

    Shown on removed pop-up roof (1) 

20. Install all profile rails (5) together with electrical wiring harness (6) on pop-up roof (1).
21. Install all inner and outer corner reinforcements (7) on pop-up roof (1).
22. Close blind holes not required with blind plugs at bottom of pop-up roof (1)
23. Lay butyl cord ring-shaped and gap-free down on bottom side of bolt head on bolts which are required to close needless through holes on pop-up roof (1).

    The bolts must be clean and free of grease.

    Otherwise leakage is not possible.

    Use new bolts.

24. Plug all through holes on pop-up roof (1) not required with previously prepared bolts.
25. Install caps on nuts of previously installed bolts.

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26. Lay butyl cord ring-shaped and gap-free down on bottom side of bolt head on bolts for fastening gas-filled strut ball stud bracket (11).

    The bolt heads must be clean and free of grease.

    Otherwise leakage is not possible.

    Use new bolts.

27. Install left and right gas-filled strut ball stud bracket (11) on pop-up roof (1).
28. Install caps on nuts for fastening gas-filled strut ball stud bracket (11).
29. Remove excess butyl at screw heads at upper side of pop-up roof (1).

    Shown on removed pop-up roof (1) 

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30. Lay old pop-up roof (1) with top upward on suitable assembly stands.

    Use padded protective base for pop-up roof (1).

    Otherwise the painted surface of the pop-up roof (1) can be damaged.

    Aid of helper required.

31. Affix WESTFALIA sticker (10) to pop-up roof (1) taking into account the dimensions (A, B).

    Dimension (A): 55 mm

    Dimensions (B): 25 mm

    The reference point for the dimensions (B) is the bottom edge of pop-up roof (1) before installing rubber sealing frame.

    Shown on removed pop-up roof (1) 

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