Pavement Ends 51139 User Manual

Page 1
Replay
Fabric Replacement Top
Installation Instructions
For: Isuzu Amigo 1989 - 1994 with Part Number: 51139 Patented Belt Rail Tailgate Enhancement
The metal Belt Rail Tailgate Retainer included in this product is an original design and is protected by U.S. Patent #4,757,854.
WARNING
This product is designed to enhance the appearance of the vehicle and to shield the occupants from ordinary weather con­ditions. Do not rely in any way on the components of this product to contain occupants within the vehicle, or to protect against injury or death in the event of an accident. This top will not protect the occupants from falling objects. Never operate vehicle in excess of manufacturer’s specifications.
WEAR SEAT BELTS AT ALL TIMES
Read and follow, precisely, all installation instructions provided when installing top. Failure to do so may result in a poor fitting top and could place occupants of the vehicle in a potentially dangerous situation. After installing or reinstalling the top, check to make sure it has been properly installed.
Installation Tips
After completing the installation, keep these instructions for future reference. Before you begin installing this Replay Top assembly, read all instructions thoroughly. Below are a few tips to make this installation easier.
For a smooth fit:
It is normal for the fabric to contract and wrinkle when stored in the shipping carton. Within a few days after the installation, the fabric will relax and the wrinkles will disappear.
51139 pg 1
Rev. D 0903
Page 2
Parts List and Hardware Identification
Top Fabric Assembly Qty - 1 Rear Curtain (Window) Qty - 1 Adhesive Hook Strip, 5/8" x 2" Qty - 4 3-3/4" Plastic Strip Qty - 1
Tools Needed
Phillips Screwdriver
Flat Screwdriver
7/16" Wrench
10mm Wrench
50/50 Alcohol/Water Solution
Clean Cloth
Safety Glasses
Step One
Remove the old top.
1/4 - 20 Locknut, Qty - 9, Part Number 198.26
1/4 - 20 Phillips Head Bolt, Qty - 9, Part Number 257.92
Parts Shown in Actual Size
Tailgate Retainer, Qty - 1, Part Number 286.50
The appliation of the above part is protected under U.S. Patent #4,757,854.
#6-32 Locknut, Qty - 2, Part Number 298.25
#6-32 x 3/4 Pan Head Screw, Qty - 2, Part Number 298.23
#6 Washer, Qty - 4, Part Number 298.24
Body Stud, Qty - 2, Part Number 9.68
Lift up slightly on the rubber seal along the top of the tailgate to access the nuts securing the seven “Lift-a-Dot” Posts to the tailgate. Remove the “Lift-a-Dot” Posts.
Remove the corner screws, next to the tailgate on each side. Relocate the snaps on each end of the tailgate to the screw holes on either side of the tailgate.
FOR 1989 MODELS ONLY: On 1989 models, there is a turnbuckle on each end of the tailgate. Remove it. Use the Body Studs, #6-32 x 3/4 Pan Head Screws, #6-32 Washers and #6-32 Locknuts from the Parts Kit. Install the Body Studs with a washer behind the stud and one in front of the nut.
Rubber Seal Detail
Pull up gently on rubber seal
Remove Turnbuckles
View from Inside of Vehicle
FOR 1989 MODELS ONLY
Remove Turnbuckle and Install Body Stud
Body Stud
Remove Turnbuckles on Tailgate
#6-32 Locknut
Tailgate
Relocate Snap from Tailgate to Screw Hole
Remove Corner Screw
#6-32 x 3/4 Pan Head Screw
#6-32 Washers
51139 pg 2
Rev. D 0903
Page 3
Step Two
Install Tailgate Retainer on top of tailgate. Place the retainer over the holes from the turnbuckles and install it with the 9 Bolts and Locknuts provided. Check the rubber seal to make certain it returns to the proper position.
Tailgate Retainer Detail Cross Section
Tailgate Retainer
Bolt
Locknut
Tailgate
Rubber Seal Detail
Bolts and Locknuts
View from Inside of Vehicle
Tailgate Retainer
Make sure rubber seal returns to position over bolts
Snap
Step Three
Orient the top fabric on the vehicle with the weatherstripping and the Lift-a-Dots toward the front. With the bow folded forward, start in the center along the front of the vehicle and seat the rubber seal into the channel on the roof. Make sure the rubber seal is seated in the channel and not folded over. Push the Lift-a-Dot in the fabric over the stud on the vehicle. Alternate between seating the rubber seal into the channel and fastening the Lift-a-Dots across the top of the roof. Do not continue down the sides at this time.
Rubber Seal Detail Cross Section
3 3/4" Plastic Strip - Use to lever Rubber Seal into position
Front
Vehicle Body
Rubber Seal
Fabric
Channel
Front
Lift-a-Dots
Rubber Seal
Top Fabric
Note:
Make sure the rubber seal is seated in the channel (not folded over) before fastening the Lift­a-Dots. Alternate between seating the rubber seal and fastening the Lift-a-Dots.
51139 pg 3
Rev. D 0903
Page 4
Step Four
Drape the fabric over the bow and gently pull the bow back into position. Snap the five snaps inside the rear seam to the rear bow. Then wrap the hook and loop strips around the front bow.
Fasten Hook and Loop Strips to each other
Front Bow
Rear Bow
Inside of Top
Rear Window
Snap to Rear Bow
Step Five
Install the remaining rubber seal and the Lift-a-Dots down the front and around the corner on the side panel. As before, make sure that the rubber seal is seated in the channel and not folded over before fastening the Lift-a-Dots. Alternate between seating the rubber seal and fastening the Lift-a-Dots.
Lift-a-Dots (Hidden)
Rubber Seal
Note: The Lift-a-Dot studs may be adjusted from side to side on the vehicle, if necessary to match the Lift-a-Dots in the top. Use a wrench to loosen the studs from inside the vehicle, underneath the rubber seal and slide the stud in the direction required.
Channel
Rubber Seal Detail Cross Section
Fabric
Front
Rubber Seal
3 3/4" Plastic Strip ­Use to lever Rubber Seal into position
Vehicle Body
Note: Make sure the rubber seal is seated in the channel (not folded over) before fastening the Lift-a­Dots. Alternate between seating the rubber seal and fastening the Lift-a-Dots.
51139 pg 4
Rev. D 0903
Page 5
Step Six
Locate the two 3" loop strips sewn to the inside of the top in the corner of the side panels, between the Lift-a-Dots. Use the loop strips as guides to install the 5/8" x 2" Adhesive Hook Strips between the Lift-a-Dot Studs. Peel the backing off the Adhesive Hook Strips and press them firmly into place. After installing the Adhesive Hook Strips, fasten the loop strips on the side panel to the hook strips.
Hook and Loop Installation
The Adhesive Hook Strip in the parts kit fastens to the loop strip sewn into the cover.
Use a 50/50 solution of alcohol and water to clean the locations for the adhesive Hook Strip. Be sure to remove all dirt, silicone sealants, wax, and any other substances which might prevent the adhesive from sticking to the paint.
Note: Do not attempt to apply the adhesive hook in temperatures of less than 60˚ F. The adhesive backing will fully set within 72 hours of application. You may install the Top after about 12 hours, but you should avoid unnecessary fastening and unfastening of the cover for 72 hours.
Step Seven
Locate the hook and loop strips sewn to the inside of the top between the side windows. Wrap the strips around the bow and fasten them to each other.
Hook and Loop Strips
Adhesive Hook Strip ­Inside Side Panel
Inside of Vehicle
Rear Window
Zip Rear Window into Top
Step Eight
Open the tailgate. Start on the passenger side and zip the Rear Window to the top.
51139 pg 5
Rev. D 0903
Page 6
Fasten Hook and Loop Strips
Step Nine
Lift up the bottom of the Rear Window and close the tailgate. Slip the plastic strip sewn to the bottom of the Rear Window into the Tailgate Retainer. Snap the snaps on each side of the tailgate. Tuck the loops on the inside of the top and along the bottom of the Rear Window up out of the way and fasten the hook and loop strips to each other.
Fasten Snap
Left Rear Corner of Vehicle
Fold Loop Up
Tailgate
Tailgate Retainer Detail Cross Section
Fabric
Tailgate Retainer
Plastic Strip into Tailgate Retainer
Plastic Strip
Note: The loops sewn to the rear curtain to assist in working the plastic strip into and out of the Tailgate Retainer may be tucked between the rear curtain and the side fabric when fastening the hook and loop strips.
Tailgate
To remove the Lift-a-Dots along the top of the vehicle, pull the fabric toward the near side of the vehicle (from the center) and
Please Note:
straight out to release the Lift-a-Dots.
When removing the top, the Lift-a-Dots must be removed carefully in order to avoid damage to the top or to the Lift-a-Dots.
To remove the Lift-a-Dots along the bottom and front sides, pull the fabric straight down and straight out to release the Lift-a-Dots.
51139 pg 6
Rev. D 0903
Page 7
LIMITED WARRANTY
We warrant our product to be free from defects in material and workmanship, for the terms specified below, provided there has been normal use and proper maintenance. This warranty applies to the original purchaser only. All remedies under this warranty are limited to the repair or replacement of any item or items found by the factory to be defective within the time period specified.
If you have a warranty claim, first you must call our factory at the number below for instructions. You must retain proof of purchase and submit a copy with any items returned for warranty work. Upon completion of warranty work, if any, we will return the repaired or replaced item or items to you freight prepaid. Damage to our products caused by accidents, fire, vandalism, negligence, misinstallation, misuse, Acts of God, or by defective parts not manufactured by us, is not covered under this warranty.
THE WARRANTY TIME PERIOD IS AS FOLLOWS: ALL “SOFT GOODS” MANUFACTURED BY OUR COMPANY (USING PRIMARILY VINYLS, PLASTICS, AND/OR FOAM): ONE YEAR FROM DATE OF PURCHASE.
ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND/OR FITNESS FOR A PARTICULAR PURPOSE CREATED HEREBY ARE LIMITED IN DURATION TO THE SAME DURATION AND SCOPE AS THE EXPRESS WRITTEN WARRANTY. OUR COMPANY SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGE.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the above limitations or exclusions may not apply to you.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. For further information or request for warranty work, please contact: Customer Service
877 638-9509
51139 pg 7
Rev. D 0903
Loading...