Active cables
2. Active cables should always be replaced in pairs, even if only one is damaged.
3. Once the roof hatch structure has been removed, unscrew the gutter mounting screws and remove the gutter. Also remove the crankshaft drive mechanism.
4. Remove the plugs from the rear ends of the roof rails.
5. Remove the cables from the roof guides. Separate them from the sliding blocks of the guides (see Figure 11.80).
Figure 11.80. Construction of the end of the operating cable.; 1. Sliding block guides; 2. Cable; 3. Bolt; 4. Retaining clamp
6. Install new cables into the roof guides. Install the sliding blocks and secure them with pins and clamps. Spring clamps are placed on the outer sides of the guides (see Figure 11.81).
Figure 11.81 Installing cables.
7. Slide the cable guides forward until their pins are aligned as shown in Figure 11.79. Adjust the crank mechanism as described above.
8. Install roof rail caps and gutter.
Gutter guide
9. Loosen the gutter mounting screws and remove the gutter. Also remove the crankshaft and roof rail end caps.
10. Partially pull out the cables until the gutter guide and tie rod can be removed from the sliding block (see Figure 11.82).
Figure 11.82 Construction of the gutter guide. 1. Sliding block guide; 2. Gutter guide; 3. Connecting rod
11. Install the new guide and tie rod. Push the sliding block and gutter guide forward until the lever fits into the recess in the roof guide.
12. Adjust the cable guides and crankshaft as described in Section 51 (see points 6 and 7) and in Section 49 (see items 22 to 25 inclusive).
13. Install roof rail caps and gutter.
Front guide
14. The process is similar to that described for removing the gutter guide. The front guide is attached to the sliding block guide (see Figure 11.83).
Figure 11.83. Front guide design. 1. Spring clamp; 2. Hairpin; 3. Spring clamp; 4. Front guide; X. Sliding Block
15. When installing, lightly lubricate the surfaces of the sliding block. Adjust the cable and crankshaft guides as described above.
Sliding block
16. Proceed as you did when replacing the cable until you gain access to the sliding block guide. Remove the spring clip and detach the sliding block from its guide (see Figure 11.84).
Figure 11.84. Sliding block design. 1. Retaining ring; 2. Connecting rod; 3. Sliding block
17. Install the new sliding block and secure it with the new spring clip. Lightly lubricate the sliding block surfaces.
18. Reassembly is carried out by performing the above steps in reverse order; adjust the cable guides and crankshaft as described above.
Sliding block guide
19. Again, the process is similar to that described for replacing the cable. For assembly details, refer to Figure 11.85.
Figure 11.85. Sliding block guide design 1. Front guide; 2. Cable guide; 3. Gutter guide
The source is on the online website: OPELBOOK
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