Sun/Sliding Roof - Complete - Front - 3 Door

76.83.01 Sun Sliding Roof - Complete - Front - 3 Door

Remove

1. Remove headlining.

WARNING: Wear protective gloves when handling glass, solvents and primers.







2. Remove and discard cable ties from drain tubes.
3. Disconnect drain tubes from sun roof.
4. Remove 4 Torx screws securing clamping plates and remove plates.







5. Remove glass panels and 'T' bar.
6. Remove 8 screws securing wind deflectors and remove wind deflectors.
7. Remove sun roof tray seal.







8. Mask up roof and sun roof aperture.
9. Cover interior of vehicle with protective sheet.
10. Make a cut through the sealer at the back of the sun roof, a 90 degrees bend in the cutting tool will help.

WARNING: Wear suitable eye protection when removing and refitting glass.

11. Using suitable cutting wire, cut through PU sealer securing sun roof to roof.

NOTE: If multi-strand cutting wire is used, a sawing action can be used to cut through heavy sealant deposits around corners.

12. Remove sun roof.

Refit

1. Clean surrounding area with solvent.

WARNING: Wear protective gloves when handling glass, solvents and primers.

2. Use a vacuum cleaner to clear away any waste.
3. Cut sealer on roof flange down to a smooth even finish.
4. Etch prime and paint any damaged areas.
5. Apply primer over etch primer on flange.
6. Apply activator over old sealer on flange.
7. Allow activator to cure.
8. Fit pre-cut nozzle to sealer cartridge, remove lid, shake out crystals and fit cartridge to applicator gun. If necessary modify the nozzle to achieve required bead section.
9. Apply a continuous bead of sealer around roof flange. Make bead slightly thicker at the corners.
10. Check for breaks and air bubbles in sealer.
11. With assistance position sunroof and align to roof aperture.
12. Fit sunroof tray seal.
13. Position sunroof clamping plates, fit and tighten screws.
14. Connect drain tubes and secure with new cable ties.
15. Remove body and trim protection.
16. Position wind deflectors, fit and tighten screws.
17. Fit 'T' bar and glass panels.
18. Fit headlining.