Sunroof Assembly
Sunroof Assembly
NOTE: This procedure includes roof panel, sliding mechanism, wind deflector, motor mounting bracket and guide tubes.
NOTE: Lower vehicle headlining ONLY if removing motor mounting bracket and guide tubes. Note that the headlining is secured around the roof opening using an adhesive tape. Remove edge trim and eight edge clips, carefully peel back headlining to remove.
Remove
1. Partially open sunroof rearwards and carefully unclip sunroof headliner from roof panel front. Slide the sunroof headliner back fully.
2. Position sunroof in the TILT position and disconnect battery negative terminal.
3. Remove three roof panel screws from each side and remove panel.
4. Remove motor securing screws and withdraw motor.
5. Remove the guide rail screws, seven each side.
6. Remove the pivot bracket and remove front guide rail.
Guide Rail Screws:
7. Remove the slide and tilt mechanism complete with flexible drive cable from both sides. Do not strip these assemblies unless replacement parts are required.
Drive Cable:
8. Unclip both wind deflector operating arms from rear mounting brackets. Remove arms from deflector, if required.
Wind Deflector:
9. Remove seven screws, and withdraw wind deflector.
10. Remove lower guide rails and rear edge finisher, seven screws, if required.
11. Remove screws from guide tubes, two each side. Remove five screws and withdraw motor mounting bracket.
12. Pull sunroof headliner assembly forward and remove.
Refit
NOTE: During assembly lightly lubricate all sliding parts using a silicon spray.
1. Position motor bracket and guide tube assembly. Fit and tighten the securing screws.
2. Position right hand guide rail in rear retaining bracket, push rearwards fully and locate leading edge under drive cable opening. Repeat operation for left hand guide rail.
3. Align holes, and loosely fit screw in seventh hole from the front.
4. Position finisher to rear edge of sun roof opening and secure using seven screws.
5. Position sunroof headliner assembly into outer guide runners, and push fully rearwards.
6. Lightly lubricate drive cables. Ensure that the slide and tilt mechanism is fully assembled.
7. Push the cable fully into the right hand side guide tube. Loop remaining cable and enter the rear end into the right hand inner side runner.
8. Repeat operation 19. for left hand side. Push both assemblies rearwards to take up slack in the cables, and push a further 75 mm (3 in) to the rear.
9. Position both front guide rails, aligning with the four forward holes. Secure with screws, do not tighten.
10. Position both pivot brackets, fit but do not tighten screws.
11. Fit the wind deflector and fully tighten fasteners.
12. Position right hand operating arm in locating slot in deflector. Secure opposite end in frame bracket. Repeat for left hand side.
13. Pull right hand slide and tilt mechanism forward, align with pivot bracket and secure in position using setting key (25). Repeat operation for left hand side.
Tilt Mechanism:
14. Tighten screws to guide rails, seven each side.
15. Fit and secure relay.
16. Ensure operating motor is in the PARK position i.e. hole on driven gear aligned with drive spindle. Fit and secure to mounting bracket.
17. Remove setting keys. Temporarily connect operating switch and reconned wiring including battery.
18. Operate switch sequence to TILT position.
19. Position roof panel into roof opening and secure with six screws, do not tighten.
20. Put roof into CLOSED position and adjust roof profile. The panel profile should be 0.5 mm low at forward edge, 1 mm high at rear edge.
21. Tighten roof panel screws.
22. Tilt sunroof, pull sunroof headliner forward and locate rear brackets in tilt mechanism. Align front six clips and push to secure.
23. Check operation of sunroof in all operating modes.
Edge Clips:
24. Refit vehicle headlining. The headlining is secured around the sunroof opening with 3M adhesive tape.
25. Refit the eight edge clips (37) as shown.
26. Finally fit the edging finisher (38).