SAFARI

BODY

21. PROCEDURE FORREMOVAL / ASSEMBLYOF

ROOF LINING

EX version / Roof AC version

1. Recover AC gas with recovery machine.

2. Remove front and rear door primary rubber

moulds.

3. Remove screw caps at roof AC cover trims'

remove all 10 screws of cover trim. (5 screws for

each cover trim). Remove cover trims.

4. Disconnect liquid & vapour lines from RH side of

roof AC. Take off drain tubes from LH, RH side &

tie them at 'B' pillar so that they will not fall inside

'B' pillar.

5. Disconnect wiring harness connectors of roof AC.

Also take off the screw used for clamping earth

wire on body.

6. Remove 4 nos. of M8 bolts that clamp roof AC to

roof. (2 LH side & 2 RH side each). Roof AC to be

held cautiously so as not to let roof AC load fall

on one side only.

7. Remove middle roof lamp (mind the wiring

connectors), tail gate primary rubber mould, rear

header trim, LH & RH roof header trims, LH & RH

side 'C' and 'D' pillar trims.

8. Remove LH & RH sun visors, front roof lamp

(mind the wiring connectors), LH & RH 'A' pillar

trims, and sun visor mould.

9. Remove rear roof lamp (mind the wiring

connectors) and near-roof grab handles.

10. Remove 6 nos. of roof fixing buttons cautiously

so as to prevent roof-liner bending.

11. Take out roof-liner from tailgate side, also keep

the foam spacer at the roof AC top carefully as it

is required while re-assembling roof-liner back in

vehicle.

PROCEDURE FOR ASSEMBLY OF ROOF LINING

EX version / Roof AC version

1. Check that all 8 nos. of roof insulation foampieces

are OK and not loosened while removing roof-

liner. Check if all 4 foam pieces at 'B' pillar top

are in place (2 each side).

2. Check that all 'J' spire clips are in place.

3. Take roof-liner in from tailgate side and put with 6

buttons.

4. Assemble sun visor moulding, rear roof lamp and

roof grab handles.

5. Insert roof AC top center foam assembly in the

roof ACmounting slot, such that trapezoidal foam

pieces are facing down and are adjacent to roof

AC slot lines of roof-liner.

6. Mount roof AC on roof with 4 nos. of M8 bolts.

7. Connect liquid & vapour line pipes, wiring harness,

wiring earth, and drain tubes.

8. Assemble cover trims using 10 screws.

9. Mount front roof lamp, LH & RH sun visors.

10. Put 'A' pillar trims, 'C' & 'D' pillar trims, roof header

trims and rear header trim.

11. Put primary rubber moulds at tailgate, at 'A' pillar

trims and 'B' pillar trims.