INSTRUCTIONS Installation and Operating Instructions In these installation instructions is described the replacement of the elevating support with gas springs. This conversion kit applies to all California Coach with pop-top. Important remark: - We recommend to read these instructions carefully prior to installation and to perform the installation accordingly to the following assembly steps. Parts - list Pos. Name Quantity 1 2 3 sealing tape 10 x 2, 200 lg. 1 4 closing plugs (stoppers) 4 5 bearing blocks 2 6 blind rivets 6.4 x 12.7 4 7 ball pins 4 8 gas spring 400 N 1 9 gas spring 400 N, with safety lock 1 10 Left bracket 1 11 Right bracket (not in picture) 1 The anticorrosive agent is not included. Subject to errors and technical changes. Mounting Preparing the vehicle Put up the roof completely. Remove the front bed board and the two bed cushions from the vehicle. Pull out the profile (a) and the cord insert of the folding canvas (c) from the lower rail (b).
Removing the existing elevating support Relieve the elevating support, and put something under the pop-top in order to keep it up safely. Detach the elevating support from the roof shell (unscrew the hexagon bolts or loosen the hexagon nuts) and unscrew the cap screws from the roof frame. Afterwards, insert the stoppers in order to seal the holes now visible in the roof frame (4). Marking the position for the bearing block Mark the attachment point (X) for the bracket (5). Then starting from the lower screw points (Y) of the elevating support, align the bearing block (5) on the roof frame after measuring right and left. Mark the hole pattern for the bearing block (5) onto the roof frame, then drill (hole diameter 6.5 mm). Note: Align the bearing block (5) as outwards as possible, still leaving enough space for lowering the bed board. Refine the holes, carefully removing drill cuttings and treat cut edges with an anticorrosive agent. Bearing block on the roof frame Align the bearing block (5) and fasten it with blind rivets (6) onto the roof frame. Screw the ball pin (7) onto the bearing block (5). Note (only for vehicles with Trans Lift): Handles are already mounted in this area on the roof frame, so you need to dismantle them. After mounting the bearing blocks (5) these handles need to be positioned immediately behind the brackets still on the roof frame. The handles are necessary to provide additional support for the "Trans Lift System". Bracket on the roof shell Keep the upper bracket (10) onto the roof shell and tighten with the existing hexagon
bolts (d) or truss-head bolts (g) depending on the version of the roof shell you have. At this point, screw the ball pin (7) on the bracket (10). Here in the picture the left side assembly diagram on the roof shell. Arrow indicates the driving direction. Note: Before the insertion of the coach bolts (g) we recommend to carefully remove the old sealing tape and to wrap the heads of the coach bolts (g) with new sealing tape (3). Installation of gas springs Note: Make sure that the gas spring with built-in safety lock is installed on the right side. This gas spring has a red mark. First, press the gas springs (8/9) until it clicks on the ball pin located at the top of the roof shell (7). Then lift the front roof shell and remove any support. Keep the roof shell raised until the lower ends of the gas springs (8/9) can be pressed into the ball pin mounted on the roof frame (7). Attention! Before lowering the roof you need to unlock the right gas spring. To do this press against the gas spring (9) while pulling down the roof by the handle. Fastening the folding canvas (see Figure 113 -. 01) Lower the pop-top of about 100 mm and secure it (tie it with a strap, cable or other). Align the canvas, insert the cord of the canvas (c) into the lower rail (b) and press the profile (a) in the lower rail using the auxiliary tool V.A.G. 1474/5. Then fully open the roof. Operating instructions Afterwards put the front bed board back in position and verify whether the locking for the bed board still works. Thereafter, lay the double-bed pad on the bed board.
If corrections are needed in the setting of the roof, these are described in the "Setting up the elevating roof" chapter. Opening the roof - First unlock the roof, as described in the additional operating instructions. - Then push the roof until the lateral gas springs can keep themselves the roof open. At the same time secure the lock of the right gas spring (9). Closing the roof - Unlock the right gas spring, to do this press against the gas spring (9) (arrow) and at the same time pull down the roof from the front by the handle. - The next steps match with the description in your additional operating instructions. Setting up the elevating roof As a guideline for the roof top setup: 60mm is the distance to have from the seal of the elevating roof to the rear edge of the sheet metal roof, measured in the center rear of the vehicle on the vehicle roof. Setting up the roof hinge Open the pop-up roof. Mark the position of the hinges on the roof frame. Then loosen the three screws (h) on both sides so that the hinges can be moved. Move the pop-up in the right position, and tighten again the cap screws (h). Setting up the lock Loosen the two Allen screws (E) and then remove the lock until the locking pin (F) again engages in the lock. Tighten again the hexagon bolts (E). The centering pin (G), after loosening it with a key, can also be adjusted. After having changed the setting of the pop-up roof, it must be checked whether the bed board can still be mounted in the holder. The position of the holders can be adjusted by loosening the screws.
Setting up the locking pin If the pop-up roof doesn t rest correctly on the metal roof at the front, the issue can be corrected by re-positioning the lock bolts. Loosen the hex nut (K) and screw the locking bolt (F) further in or out a few turns. Close the pop-top and check how it seats on the metal roof. The locking bolt (F) is properly set when the pop-top in locked position is not drawn inward and the sealing frame rests close to the metal roof. Re-tighten the hexagon nut (K). Setting up the hinge If the pop-top and the sealing frame stay too tight or doesn t lie (leaks) on the roof surface near the hinges, the roof hinge adjustment must be changed. If the sealing frame is too tight Loosen the hex nut (A), let the bracket (B) slide about 2 mm ahead, then re-tighten the hexagon nut. Tightening torque: 20 Nm
If the sealing frame doesn t lie on the roof surface Loosen hex nut (A), move the bracket (B) by about 2 mm backwards, then re-tighten the hex nut. Tightening torque: 20 Nm Then close the pop-up roof - as described in the additional Operating instructions of the vehicle (closure must audibly engage) - and check for correct positioning. If the adjustment should not yet be correct, then repeat the last point until pop-up rests properly. SERIAL Kombi - 80 route de Chambéry - 38420 - Le Versoud Permanence téléphonique 04 76 77 59 18 du lundi au vendredi de 9h30 à 12h30 Mail : info@serial-kombi.com