Drain Tube Rerouting & Sunroof Frame Resealing Information

DRAIN TUBE REROUTING (Headliner removed)



NOTE: This procedure is included in the labor operation for Headliner, R/I.

Check drain tube routing to ensure that they are not kinked.

Insert a plastic hose or a cable (i.e. P-20 hood cable) in the drain tube. If it is difficult to insert, release drain tube clamps (front and rear) and pull down.
Remove foam rubber pads from roof (2x at rear).


CAUTION:

Clamp retaining screws must be positioned at side of clamp to prevent damage to headlining. Use new clips (P/N 1334115-1).

NOTE: Make sure that clips do not kink tubes. Tubes must be aligned properly, at correct angle so that air locks are prevented.

Carefully stretch front tube near ventilation inlet and rear tube in the trunk compartment.
SUNROOF FRAME, RESEALING; OP. # 836312



NOTE: If not already done, remove vehicle headliner; see previous work sequence.

Remove sunroof tray.

This operation requires two people. Remove bracket from front edge of backplate. Remove retaining screws from side mounts. Remove all retaining screws (10x). Lift sunroof tray over roof wiring and out through front right door.
Remove tube/rails from sunroof tray. Remove old sealing completely from rails and tray. If damaged, remove white foam on top of the tray with a heat gun.



Before reinstalling tube/rails, apply sealer (P/N 277253-1) to:
(A) underside 1200 mm (47.24 in), one on each side. Make sure that sealer is applied to top of rails at rear.
(B) next to crank housing, 550 mm (21.65 in).
(C) at corners, 200 mm (7.87 in).



Seal splash cover with butyl tape P/N 1342927-9 and body sealer.

NOTE: Make sure that junction between the rail, tray and splash cover is properly sealed.



If damaged, install new seal on top side of tray.

Rear white foam seal:
- P/N 1334381-9, sedan only

Center rear white foam seal:
- P/N 1355689-9, wagon only
Rear side seals (two) :
- P/N 1355688-1, wagon only

Stick on rear seals, edge to edge with front seal.
Check for leakage (bench test, before reinstalling tray)

Plug drain holes.

Pour soapy water onto cross gutter and side rails.

NOTE: Cross gutter should be noticeably higher in the center and arc smoothly to the side gutters. If necessary, correct rear cross gutter by grabbing with both hands toward the center of the cross gutter and pulling upwards to gently curve gutter.

Check that water does not leak under rails into tray area. Correct as necessary.

Remove drain hole plugs.



Install sunroof tray (two people)

Attach bracket at front of sunroof tray. Install side retaining clips. Remove protective paper from rear sealing strip. Lift the tray in through right front door and over dome light harnesses. Finger-tighten retaining screws.



NOTE: Align front corners of tray with appropriate section of roof. Tighten screws.


CAUTION:
Be careful not to tighten front retaining screws too tightly as this may cause damage to outer roof surface.


Install drain tubes. Tighten clamps.

NOTE: Retaining screws must be positioned at side of clamp to prevent damage to headlining. Use new clips (P/N 1334115-1), to support drain hose.



CHECK SUNROOF DRAINAGE

Pour soapy water onto cross gutters. Check that water drains properly from rear cross gutter into side gutters and through drain hoses. If necessary, correct.