Repair Procedure
REPAIR PROCEDURE
1. Remove the headliner (see the 3.5RL Service Manual).
2. Remove the moonroof glass bracket cover (one plug and one screw), then remove the four flange nuts from the glass bracket. Note the number and location of shims (if any). Repeat this step for the other side.
3. Carefully lift out the glass.
4. Disconnect the connectors, detach the harness clip, and remove the ground wire. Release the tube clips, and disconnect the four drain tubes from the frame.
5. Disconnect the connector, and remove the moonroof motor (three flange nuts and two bolts).
6. Remove the 12 frame mounting bolts. Be sure you remove the two front bolts last.
7. Move the frame slightly forward to detach the rear hooks, remove the frame from the vehicle, and place it upside down on a work bench.
8. Disconnect the connector to the moonroof control unit, detach the two harness clips, and peel back the blue adhesive tapes holding the wire harness to the underside of the frame.
9. Turn over the frame, and remove the drain channel (two screws) and the frame seal.
10. Remove the rail holder B cover, then remove rail holder B (one flange nut). Repeat this step for the other rail holder B.
11. Move the glass bracket to the position where the moonroof normally pivots down, then remove the glass bracket from the cable assembly slider (three screws). Repeat this step for the other glass bracket.
12. Remove rail holder A (one flange nut). Repeat this step for the other rail holder A.
13. Move the cable assembly slider forward, and release the drain channel rod slider by detaching the drain channel rod stop from the guide rail through the cutout. Repeat this step for the other drain channel rod slider.
14. Slide the sunshade forward on the guide rails, then remove it.
15. Remove the flange nut, and lift oft the guide rail and cable mount from the frame stud. Repeat this step for the other guide rail and cable mount.
16. Remove the screw, then remove the cable tube and the ground plate from the frame. Repeat this step for the other cable tube and ground plate.
17. Carefully remove the cable assembly from the frame, taking care not to bend the cable tubes or guide rails.
18. Apply Super High Temperature Urea Grease to each slider of the new cable assembly, then install the sliders into the guide rails.
19. Fill the groove of each cable grommet with 3M Flexiclear Body Seam Sealer, then seat the grommets into the frame grooves.
20. Install the cable tubes and the ground plates to the frame.
21. Mount the guide rails and the cable mounts onto the studs in the frame, and secure them with the flange nuts. Torque the flange nuts to 9 N~m (7 lb-ft).
22. Reinstall the sunshade.
23. Reinstall the drain channel rod sliders to the guide rails, and lock the sliders in place by rotating the drain channel rod stops.
24. Reinstall the two rail holders A. Torque the flange nuts to 9 N~m (7 lb-ft).
25. Reinstall the glass brackets to the sliders.
26. Reinstall the two rail holders B. Torque the flange nuts to 9 N.m (7 lb-ft), then reinstall the rail holder covers.
27. Reinstall the drain channel and the frame seal.
28. Turn over the frame, and attach the wire harness to the underside of the frame with the blue adhesive tapes. Attach the harness clips, and connect the connectors.
29. Reinstall the frame to the vehicle. Torque the mounting bolts to 9.8 N.m (7.2 lb-ft).
30. Reconnect the four drain tubes.
31. Carefully reinstall the glass and shims to the glass brackets. Torque the flange nuts to 9 N.m (7 lb-ft). Reinstall the glass bracket covers.
32. Do the opening drag check and switch plate adjustment (see pages 20-38 thru 40 of the service manual).
33. Reconnect the ground wire, attach the harness clips, and connect the connectors.
34. Reinstall the moonroof motor, while making sure both sliders are parallel. Torque the mounting bolts and flange nuts to 9.8 N.m (7.2 lb-ft).
35. Do the closing force check.
36. Reinstall the headliner and all previously removed components. Refer to the service manual for torque specifications.