23 - 6 BODY |
Ä |
||||
POWER SUNROOF |
|||||
INDEX |
|||||
page |
page |
||||
Adjustment Bracket . . . . . . . . . . . . . . . . . |
. . . . . . . 7 |
Glass Vertical Height Adjustment . . . . . . . . . . . . |
. 6. |
||
Drain Channel . . . . . . . . . . . . . . . . . . . . . |
. . . . . . . 7 |
Guide Assembly . . . . . . . . . . . . . . . . . . . . . . . . . |
. 8. |
||
Drive Cable Locators . . . . . . . . . . . . . . . . |
. . . . . . . 7 |
Motor and Drive Gears . . . . . . . . . . . . . . . . . . . . |
. 7. |
||
Drive Cables . . . . . . . . . . . . . . . . . . . . . . |
. . . . . . . 8 |
Sunshade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. 8. |
||
General Information . . . . . . . . . . . . . . . . . |
. . . . . . . 6 |
Wind Deflector . . . . . . . . . . . . . . . . . . . . . . . . . . |
. 6. |
||
Glass Panel . . . . . . . . . . . . . . . . . . . . . . . |
. . . . . . . 7 |
||||
All sunroofs are equipped with drain tubes that are located in the A, B or C-pillars. The drain tubes must be kept open to prevent water from entering the passenger compartment.
(1)Lubricate cables with Lubriplate or equivalent when cables are replaced.
(2)Periodically clean dirt from guide rail covers.
²Inspect the drain holes, located in the trough around the sunroof opening to verify they are clear. Inspection should be performed at least once a year or when problems are suspected. If drain hose or tubes are plugged, use compressed air or blunt flexible wire to clear them. If tubes cannot be cleared, they must be repaired.
²The lower ends of the rear drain tubes are located in the rear quarter panel drop wells. To clear rear drain tubes, use compressed air or blunt flexible wire from the lower ends of the tubes.
(1)Open glass to vent position.
(2)Slide upper half of mechanism covers rearward until clips disengage and separate covers from vehicle.
(3)Close glass panel, separately loosen adjusting bolts and individually adjust the corners of glass.
(4)Adjust front of glass panel to 1.0 mm (0.040 in.) below top surface of roof panel.
(5)Adjust rear of glass to 1.0 mm (0.040 in.) above top surface of roof panel.
(6)Secure adjustment bolts and install cover.
(1)Open sun roof glass panel.
(2)Remove screws holding wind deflector to sun roof unit side rail.
(3)Separate wind deflector from vehicle.
Fig. 1 Glass Adjustment
Reverse the preceding operation.
Fig. 2 Deflector Assembly
(1) Open sunroof.
Ä |
BODY 23 - 7 |
|
(2)position wind deflector so 19 mm (0.75 in.) above top surface of roof panel and 1 mm (0.040 in.) rearward of roof panel forward edge.
(3)Secure wind deflector to sunroof unit.
(1)Remove wind deflector mechanism covers (Fig.
1).
(2)Position glass to vent position.
(3)Position sunshade full rearward.
(4)Loosen nuts holding glass panel to side adjustment brackets.
(5)Slide glass panel rearward 12 mm (0.5 in.) and separate glass from sunroof unit.
(1)Position glass panel in opening with logo rearward and slide panel forward 12 mm (0.5 in.).
(2)Verify that attaching nuts are below top surface of glass adjustment brackets.
(3)Close sunroof to center glass panel in roof open-
ing.
(4)Tighten center screws to hold adjustment.
(5)Open glass to vent position and tighten nuts to 8 NIm (70.8 in-lbs.).
(6)Close glass and check alignment.
(7)Install the mechanism covers.
(8)Adjust wind deflector, if necessary.
(1)Remove wind deflector, mechanism covers and glass panel.
(2)Move glass carriage to vent position and remove rearward adjustment bolt from adjustment bracket.
(3)Lift rear of adjustment bracket to highest vertical position and disengage front of bracket from unit.
Reverse the preceding operation. Adjust glass, and wind deflector as necessary.
(1)Remove wind deflector mechanism covers and glass panel.
(2)Locate glass carriage to vent position and drain channel in full forward position.
(3)Remove screws holding drain channel to support frame.
Reverse the preceding operation.
Fig. 3 Glass Height Vertical Adjustment
(1)Position glass 19 mm (0.75 in.) until rearward until cable locator is visible.
(2)Remove screws holding drive cable locator to
unit.
(3)Remove travel limiting micro switch grommet and disconnect wire connector.
(4)Insert a small screwdriver under rear edge of locator and pry locator from track.
Reverse the preceding operation. The small outboard lip underneath cable locator slips under bottom slot on guide track. After locator is seated install screws.
Fig. 4 Removing Cable Drive Locator
(1)Open sunroof to vent position.
(2)Remove head lining.
23 - 8 BODY |
Ä |
|
(3)Remove bolts holding sunroof motor to motor bracket.
(4)Disconnect wire connector.
(5)Separate motor and drive gear from drive cables.
(1)Verify that sunroof is in vent position. Push mechanism forward on both sides to align drive cables.
(2)Engage drive gears onto drive cables.
(3)Install motor and drive gear screws and tighten to 5 NIm (44 in-lbs.).
(4)Install head lining.
Fig. 5 Sunroof Motor and Drive Gear
(1)Open sunroof to vent position.
(2)Remove head lining, wind deflector, mechanism covers, glass panel, side glass adjustment brackets, motor and drive cable locators.
(3)Lift cable out of cable retainer and pull forward. Separate cable from assembly.
Verify sunroof is in vent position. Push mechanism forward on both sides to align drive cables. Reverse the preceding operation.
(1)Remove wind deflector, mechanism covers and glass panel.
(2)Position system to full rearward position.
(3)Slide sunshade panel full forward and release the front tabs from track assembly.
(4)Pull rear retaining clip inboard and lift sun shade out.
Fig. 6 Drive Cables
Reverse the preceding operation.
Fig. 7 Sunshade Assembly
(1)Remove wind deflector, mechanism covers, glass panel, drain channel, sunshade and drive cable locator as necessary.
(2)Move glass carriage to vent position.
(3)Remove front slide from guide assembly.
(4)Remove screws holding front and center guide track to unit.
(5)Pull cable out of groove for cable end.
(6)Pull guide outward to release from housing. Separate rear end of guide from clips. Slide guide out of unit.
(1)Install guide cable into rear of guide assembly.
(2)Install guide assembly at an angle so the rear portion slips under finger clips at rear of module housing.
Ä |
BODY 23 - 9 |
|
(3)Place cable in groove of cable holder.
(4)Install screws in track assembly.
(5)Install locators.
(6)Reverse removal operation.
Fig. 8 Guide Assembly
WARNING: DO NOT USE URETHANE ADHESIVE OR PRIMER IN CLOSED WORK AREA, PERSONAL INJURY CAN RESULT.
PROTECT SKIN FROM COMING IN CONTACT WITH URETHANE, PERSONAL INJURY CAN RESULT.
WEAR EYE AND HAND PROTECTION WHEN WORKING WITH GLASS, PERSONAL INJURY CAN RESULT.
CAUTION: Protect all painted or trimmed surfaces from coming in contact with urethane or primers, damage will result.
Do not damage painted surfaces when removing mouldings or cutting urethane around windshield.
It is difficult to salvage a windshield during the removal operation. The windshield is part of the structural support for the roof. The urethane bonding used to secure the windshield to the fence is difficult to cut or clean from any surface. If the mouldings are set in urethane, it would also be unlikely they could be salvaged. Before removing the windshield, check the availability of the windshield and mouldings from the parts supplier.
(1)Remove inside rear view mirror.
(2)Remove cowl cover.
(3)Remove windshield mouldings using a suitable hook tool and trim stick (Fig. 1).
(4)Cut urethane bonding from around windshield using a suitable sharp cold knife. A pneumatic cutting device can be used if available (Fig. 2).
(5)Separate windshield from vehicle.
CAUTION: Open the left front door glass before installing windshield to avoid pressurizing the pas-
Fig. 1 Windshield Mouldings
Fig. 2 Cut Urethane Around Windshield
senger compartment if a door or the trunk lid is slammed before urethane bonding is cured. Water leaks can result.
Allow the urethane at least 4 hours to cure before returning the vehicle to use.
The windshield fence should be cleaned of old urethane bonding material. Support spacers should be cleaned and properly installed on weld studs or repair screws at bottom of windshield opening.
23 - 10 BODY |
Ä |
|
Fig. 3 Center Windshield and Mark at Support
Spacers
Fig. 4 Work Surface Set-up and Mouldings
Installation
(1)Place replacement windshield into windshield opening and position glass in the center of the opening against the support spacers. Mark the glass at the support spacers with a grease pencil or pieces of masking tape and ink pen to use as a reference for installation. Remove replacement windshield from windshield opening (Fig. 3).
(2)Position the windshield inside up on a suitable work surface with two padded, wood 10 cm by 10 cm by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed parallel 75 cm (2.5 ft.) apart (Fig. 4).
(3)Clean inside of windshield with Mopart Glass Cleaner and lint-free cloth.
(4)Apply clear glass primer 25 mm (1 in.) wide around perimeter of windshield and wipe with clean/dry lint-free cloth.
(5)Install mouldings on windshield (Fig. 4).
(6)Apply black-out primer 15 mm (.75 in.) wide on top and sides of windshield and 25 mm (1 in.) on bottom of windshield. Allow at least three minutes drying time.
Fig. 5 Position Urethane Compression Spacers
Fig. 6 Lower Windshield Into Position
(7)Position windshield bonding compression spacers on lower fence above the support spacers at the edge of the windshield opening (Fig. 5).
(8)Apply a 10 mm (0.4 in.) bead of urethane around perimeter of windshield along the inside of the mouldings.
(9)With the aid of a helper, position the windshield over the windshield opening. Align the reference marks at the bottom of the windshield to the support spacers.
(10)Slowly lower windshield glass to windshield opening fence. Guide the top moulding into proper position if necessary. Push windshield inward to fence spacers at bottom and until top moulding is flush to roof line (Fig. 6).
(11)Clean access urethane from exterior with Mopart, Super Clean or equivalent.
(12)Install cowl cover and wipers.
(13)Install inside rear view mirror.
(14)After urethane has cured, water test windshield to verify repair.
Ä |
AA-BODY |
23 - 11 |
|||
AA-VEHICLE BODY COMPONENT SERVICE |
|||||
INDEX |
|||||
page |
page |
||||
A-Pillar and Roof Rail Mouldings . . . . . . . . . . . . |
. 25 |
Overhead Console . . . . . . . . . . . . . . . . . . . . |
. . . . 30 |
||
B-Pillar Trim Panel . . . . . . . . . . . . . . . . . . . . . . . |
. 25 |
Quarter Extension Trim Panel . . . . . . . . . . . . |
. . . . 27 |
||
Body Side Moulding and Applique . . . . . . . . . . . . |
. 24 |
Quarter Trim Panel . . . . . . . . . . . . . . . . . . . . . |
. . . 27 |
||
Cowl Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. 13 |
Rear Deck Filler Panel . . . . . . . . . . . . . . . . . . |
. . . 31 |
||
Cowl Panel Trim and Scuff Plates . . . . . . . . . . . . |
. 25 |
Rear Door and Hinge . . . . . . . . . . . . . . . . . . . |
. . . 20 |
||
Door Opening Weatherstrips . . . . . . . . . . . . . . . . |
. 24 |
Rear Door Belt Moulding and Weatherstrip . . . |
. . . 22 |
||
Floor Carpet . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. 30 |
Rear Door Glass . . . . . . . . . . . . . . . . . . . . . . |
. . . 22 |
||
Front Center Console . . . . . . . . . . . . . . . . . . . . . |
. 29 |
Rear Door Glass Run Weatherstrip . . . . . . . . . |
. . . 22 |
||
Front Door and Hinge . . . . . . . . . . . . . . . . . . . . |
. 15 |
Rear Door Glass Stationary Glass Module . . . |
. . . 23 |
||
Front Door Belt Moulding and Weatherstrip . . . . . |
. 17 |
Rear Door Latch . . . . . . . . . . . . . . . . . . . . . . |
. . . 21 |
||
Front Door Glass . . . . . . . . . . . . . . . . . . . . . . . . |
. 17 |
Rear Door Silencer and Water Shield . . . . . . . |
. . . 20 |
||
Front Door Glass Channel and Run Weatherstrip |
. 18 |
Rear Door Trim Panel . . . . . . . . . . . . . . . . . . |
. . . 20 |
||
Front Door Glass Run Lower Channel . . . . . . . . |
. 18 |
Rear Door Window Regulator/Manual . . . . . . . |
. . . 23 |
||
Front Door Latch . . . . . . . . . . . . . . . . . . . . . . . . |
. 16 |
Rear Door Window Regulator/Power . . . . . . . . |
. . . 23 |
||
Front Door Side View Mirror . . . . . . . . . . . . . . . . |
. 17 |
Rear Power Door Lock Actuator . . . . . . . . . . . |
. . . 22 |
||
Front Door Silencer and Water Shield . . . . . . . . . |
. 15 |
Rear Seat Belts . . . . . . . . . . . . . . . . . . . . . . . |
. . . 28 |
||
Front Door Trim Panel . . . . . . . . . . . . . . . . . . . . |
. 14 |
Rear Seats . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . 28 |
||
Front Door Window Regulator/Manual . . . . . . . . . |
. 18 |
Rear Shelf Trim Panel . . . . . . . . . . . . . . . . . . |
. . . 27 |
||
Front Door Window Regulator/Power . . . . . . . . . |
. 19 |
Rear Window Glass . . . . . . . . . . . . . . . . . . . . |
. . . 32 |
||
Front End Splash Shields . . . . . . . . . . . . . . . . . . |
. 13 |
Sun Roof Air Deflector . . . . . . . . . . . . . . . . . . |
. . . 31 |
||
Front Fender . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. 14 |
Sun Roof Drain Tubes . . . . . . . . . . . . . . . . . . |
. . . 31 |
||
Front Power Door Lock Actuator . . . . . . . . . . . . . |
. 19 |
Sun Roof Weatherstrip . . . . . . . . . . . . . . . . . . |
. . . 31 |
||
Front Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . |
. 27 |
Trunk Lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . 33 |
||
Front Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. 28 |
Trunk Lid Hinge . . . . . . . . . . . . . . . . . . . . . . . |
. . . 34 |
||
Fuel Fill Door . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. 36 |
Trunk Lid Latch . . . . . . . . . . . . . . . . . . . . . . . |
. . . 34 |
||
Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. 11 |
Trunk Lid Lock . . . . . . . . . . . . . . . . . . . . . . . . |
. . . 34 |
||
Head Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. 30 |
Trunk Lid Luggage Rack . . . . . . . . . . . . . . . . |
. . . 35 |
||
Hood and Hinges . . . . . . . . . . . . . . . . . . . . . . . . |
. 11 |
Trunk Lid Torsion Bar . . . . . . . . . . . . . . . . . . . |
. . . 34 |
||
Hood Latch and Release Cable . . . . . . . . . . . . . |
. 12 |
Trunk Lining . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . 35 |
||
Outside Front Door Latch Release Handle . . . . . |
. 16 |
Trunk Opening Weatherstrip . . . . . . . . . . . . . . |
. . . 35 |
||
Outside Rear Door Latch Release Handle . . . . . . |
. 21 |
Vinyl Roof Bonnet . . . . . . . . . . . . . . . . . . . . . |
. . . 31 |
||
(1)Raise hood to full up position.
(2)Remove hood safety catch release rod retainer and separate rod from grille.
(3)Remove grille end reinforcement attaching
bolts.
(4)Remove nuts holding grille to hood.
(5)Separate grille from hood.
Reverse the preceding operation.
(1)Raise hood to full up position.
(2)Lift front edge of cowl cover on the right side of the windshield washer bottle and disconnect the under hood lamp wire connector.
(3)Mark all bolt and hinge attachment locations with a grease pencil or other suitable device to provide reference marks for installation. When installing hood,
Fig. 1 Grille Assembly
align all marks and secure bolts. The hood should be aligned to 4 mm (0.160 in.) gap to the front fenders and flush across the top surfaces along fenders.
(4) Remove the top hood to hinge attaching bolts and loosen the bottom bolts until they can be removed by hand.