Repair Procedures
Replacement
Glass Replacement
1. Open the glass.
2. Loosen the mounting screw (A).
3. After loosening the mounting screw, then remove the glass (A).
CAUTION:
- Do not damage the screw.
4. Installation is the reverse of removal.
Motor Replacement
1. Remove the roof trim.
2. Remove the sunroof motor after removing screws from the sunroof motor (A).
3. Installation is the reverse of removal.
CAUTION:
- Make sure to initialize the motor.
Wind Deflector Replacement
1. Open the glass fully.
2. Using a star wrench, the wind deflector (A) loosening the mounting screw.
CAUTION:
- Do not damage the screw.
3. After loosening the mounting screws, then remove the wind deflector (A).
4. Installation is the reverse of removal.
Roll Blind Replacement
Removal
1. Remove the glass.
2. Remove the mechanism rail assembly loosening the mounting screw, and then remove the mechanism rail assembly (A).
CAUTION:
- Do not damage the screw.
3. Cut the tension wire (A) to prevent the injury.
4. After loosening the roll blind mounting screws, remove the roll blind (A).
Installation
1. Installation is the roll blind (A).
NOTE:
- Insert the part of fabric both ends to guide.
2. Install the wire (A) in arrow direction.
3. Install the wire (B) in arrow direction.
NOTE:
- Insert the wire into the cover completely when installing.
4. Pull the wire (A) as below picture.
5. Lay down the wire (A) slowly after removing the clip (B).
NOTE:
- Satisfy the coherence condition of roll blind is 25.5N.m (2.6kgf.m ~ 18.8lb-ft)
Panorama roof Assembly Replacement
Removal
1. Remove the following items :
A. Front seat
B. Rear seat
C. Interior trim
D. Roof trim
NOTE:
- To protect the interior, cover the interior before starting removing the panorama roof.
2. Remove the panorama roof panel mounting bracket (A) loosening the mounting bolt.
Tightening torque :
19.6 - 29.4 N.m (2.0 - 3.0 Kgf.m, 14.5 - 21.7lb-ft)
3. Remove the panorama roof mounting nut (A).
Tightening torque :
19.6 - 29.4 N.m (2.0 - 3.0 Kgf.m, 14.5 - 21.7lb-ft)
4. Disconnect the ground wire (A) by removing the bolt.
Tightening torque :
10.8 - 13.7 N.m (1.1 - 1.4 Kgf.m, 8.0 - 10.1lb-ft)
5. Remove the roof rack cover (A), roof rack (B), roof molding (C).
6. Open the space between chassis and sunroof using flathead screwdriver, and then cut the sealant (B) of edge using a tool(09816-2P130) (A).
NOTE:
- Be careful not to damage the sunroof when inserting tools between the chassis and sunroof.
7. Open the space between chassis and sunroof using flathead screwdriver, and then cut the sealant of edge using a tool(09816-2P121, 09816-2P122) (B).
NOTE:
- This blade has a inclination to push upward.
(09816-2P121, 09816-2P122)
- This blade has a inclination to push downward.
(09816-2P123, 09816-2P124)
8. Open the space between chassis and sunroof using flathead screwdriver, and then cut the sealant of edge using a tool(09816-2P121, 09816-2P122) (B).
NOTE:
- This blade has a inclination to push upward.
(09816-2P121, 09816-2P122)
- This blade has a inclination to push downward.
(09816-2P123, 09816-2P124)
9. Open the space between chassis and sunroof using flathead screwdriver, and then cut the sealant of edge using a tool(09816-2P125, 09816-2P126) (B).
10. Remove the panorama roof (A) carefully.
NOTE:
- When removing and installing the panorama roof, an assistant is necessary.
Installation
1. With a knife, scrape the old adhesive smooth to a thickness of about 2mm (0.08 in.) on the bonding surface around the entire panorama roof opening flange :
A. Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
B. Remove the rubber dam and fasteners from the body.
C. Mask off surrounding surfaces before painting.
2. Clean the body bonding surface with a sponge dampened in alcohol. After cleaning, keep oil, grease and water from getting on the clean surface.
3. Temporarily place the panorama roof (B) on the vehicle. Center the roof on the body and mark the position with a piece of tape (C) on each side.
4. Cut the tape between the panorama roof and the body. Remove the panorama roof.
5. With a sponge, apply a light coat of body primer (A) to the original adhesive remaining around the windshield opening flange. Let the body primer dry for at least 10 minutes :
A. Do not apply glass primer to the body, and be careful not to mixup glass and body primer sponges.
B. Never touch the primed surfaces with your hands.
C. Mask off the dashboard before painting the flange.
6. Apply a light coat of glass primer to the outside of the fasteners.
A. Never touch the primed surface with your hand. If you do, the adhesive may not bond to the glass properly, causing a leak after the windshield glass is installed.
B. Do not apply body primer to the glass.
C. Keep water, dust, and abrasive materials away from the primer.
7. Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Put the cartridge in a caulking gun, and run a bead of sealant (B) around the edge of the panorama roof (A) as shown. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner.
8. Installation is the panorama roof.
NOTE:
- When removing and installing the panorama roof, an assistant is necessary.
Standard value "E" [mm(inch)]
Front edge :
5.2 ± 1.5mm (0.2047 ± 0.0591 inch)
Rear edge :
5.2 ± 1.5mm (0.2047 ± 0.0591 inch)
9. Scrape or wipe the excess adhesive off with a putty knife or towel. To remove adhesive from a painted surface or the windshield, wipe with a soft shop towel dampened with alcohol.
10. Let the adhesive dry for at least one hour, then spray water over the roof and check for leaks. If a leak occurs, let it dry, then seal with sealant :
A. Let the vehicle stand for at least four hours after windshield installation. If the vehicle must be driven within 4 hours, it must be driven slowly.
B. Keep the windshield dry for the first hour after installation.
11. Reinstall all remaining removed parts. Install the rearview mirror after the adhesive has dried thoroughly. Advise the customer not to do the following things for two the three days :
A. Slam the door with all the windows rolled up.
B. Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).
Adjustment
Inspect Glass Alignment
1. Check for abnormal noise or bending during operation.
2. With the sunroof fully closed, check for water leakage.
3. The roof panel (A) should be even with the glass (B) weatherstrip, to within the standard value "E" all the way around. If not, make the following adjustment.
Standard value "E" [mm(inch)]
(1) Front edge :
2 + 1.0 mm (0.0787 + 0.0394 inch)/
2 - 2.0 mm (0.0787 - 0.0787 inch)
(2) Rear edge :
1 + 0, -1mm (0.0394 + 0, 0.0394 inch)
(3) Side edge :
1.0 ± 0.5 mm (0.0394 ± 0.0197 inch)
4. If the position is not as specified, lightly loosen the glass adjusting screw (A) to adjust the glass height and tighten it.
Tightening torque :
2.0 - 3.9N.m (0.2 - 0.4kgf.m, 1.4 - 2.9 lbf.ft)
How To Initialize Motor
1. Check that the glass has been installed.
A. Finished height adjustment.
2. Pull the FORWARD switch. (Press and hold)
A. After about 15 seconds, the window will move forward and back about 5mm.
3. After the window moved forward and back, release the switch and then push and hold it again. After about 5 seconds, the sunroof will open all the way and then close.
4. When the sunroof closes completely, release the switch.
Initialization is complete.
When To Initialize The Motor
1. At the time of manufacture.
2. If the Initial setting is erased due to loss of power.
3. After using the manual handle.
Operating The Sunroof Emergency Handle1. Use the sunroof emergency handle to close and open the sunroof manually for the following case only.
A. To close the sunroof before driving a vehicle in a rainy day or on the highway if the sunroof cannot be closed due to failure of the sunroof motor or controller.
4. Operating method
A. Remove the overhead console.
B. Push the emergency handle up into the hexagonal drive (A) of the sunroof motor. You must push hard enough to disengage the motor clutch; otherwise the emergency handle will slip due to incomplete fit in the motor.
C. Carefully turn the emergency handle clockwise to close the sunroof.
D. After closing the sunroof, wiggle the handle back and forth as you remove the tool from the motor, to ensure the motor clutch reengages.
E. A 5mm hex socket may be used in place of the emergency handle, with a" Speeder" type handle.
CAUTION:
- Do not use power tools to operate the sunroof.
- Damaged to the components may occur.
