Body - Sunroof Popping/Creaking/Knocking Noises
L-SB-0065-09May 29, 2009
Panoramic Moonroof Glass/Deflector Noise
Service Category
Vehicle Exterior
Section
Sliding Roof/Convertible
Applicability
Introduction
Customers may explain that the panoramic moonroof glass makes noises when driving on rough road surfaces. A popping/creaking/knocking noise may be present when the front wind deflector is opened or when the sliding moon roof glass is in an open or closed position. The following repair procedures have been developed to address this condition.
Production Change Information
This TSIB applies to vehicles produced BEFORE the Production Change Effective VIN shown.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Lexus Comprehensive Warranty. This warranty is in effect for 48 months or 50,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to correction of a problem based upon a customer's specific complaint.
Parts Information
Repair Procedure
1. Overview and Components:
NOTE
Figure 1 shows the left hand side of the vehicle.
2. Remove the Sliding Roof Deflector Arm Sub-Assembly LH.
A. Fully open the No.2 sliding roof glass sub-assembly.
B. Using a T20 TORX driver remove the screw.
NOTE
The deflector arm is pushed up due to the reaction force of the spring. Be sure to hold it down when removing the screw.
C. Insert a small flat blade screwdriver between the e-ring and the post and rotate counter-clockwise to remove the e-ring.
NOTE
Be careful not to lose the E-ring in the moonroof assembly, as this may result in abnormal noise.
D. Remove the pin and then remove the collar.
NOTE
Be careful not to drop or lose the cushion in the moonroof assembly, as this may result in abnormal noise.
E. Remove the sliding roof deflector arm sub-assembly with the cushion attached.
3. Install the Sliding Roof Deflector Arm Sub-Assembly LH.
A. Wipe and clean the No.1 sliding roof glass deflector tab by removing debris and any lubricant present.
B. Apply grease (supplied in kit) to NEW pin and NEW collar.
NOTE
Use only NEW pin and NEW collar from kit.
C. Prepare a NEW sliding roof deflector arm sub-assembly LH.
NOTE
Use only NEW sliding LH roof deflector arm sub-assembly. The sliding roof deflector arm sub-assembly LH can be installed into the right hand side of the vehicle. Refer to the illustration shown when installing. Make sure deflector arms are oriented in the correct direction when installing.
D. Insert a NEW cushion to the NEW sliding roof deflector arm as shown in the illustration.
NOTE
Use only the supplied NEW LH sliding roof deflector arm sub-assembly and NEW cushion.
E. Hold the cushion to prevent it from falling out and attach the deflector arm to the No. sliding roof glass protector.
F. Insert the NEW collar from the outside of the vehicle inward.
NOTE
Use NEW collar only. Do not insert the collar from the inside of the vehicle.
G. Ensure that the NEW collar has been inserted securely.
H. Insert a NEW pin and assure that it is inserted securely.
I. Install a NEW E-ring.
NOTE
Use NEW E-ring only. Be careful not to drop or lose the NEW E-ring.
J. Align the protrusion of the deflector arm with the hole in the sliding roof housing assembly.
K. Using a T20 TORX driver tighten the sliding roof deflector arm with the NEW screw.
Torque: 2.0 N*m (20 kg.cm, 1.8 in*lbf)
NOTE
^ Use only NEW screw.
^ The deflector arm will be pushed up due to the reaction force of the spring. Be sure to press the NEW screw down with a TORX driver when installing it.
^ Be careful not to lose the NEW screw.
L. Replace the sliding roof deflector arm sub-assembly RH. Use the same procedure as that described for the LH side.
4. Install New Felt Pads.
A. Remove sliding roof side garnish.
(1) Fully open the No. 2 sliding roof sub-assembly.
(2) Using a T25 TORX driver remove the screw and sliding roof side garnish.
B. Remove No.2 sliding roof glass sub-assembly.
(1) Fully close the No.2 sliding roof glass sub-assembly.
(2) Using a T25 TORX driver remove the 3 screws.
(3) Remove the No.2 sliding roof glass sub-assembly.
C. Install New Felt Pads.
(1) Turn glass over and lay on soft cloth or protective blanket.
(2) Completely remove the 2 felt pads located on rear underside of the moonroof glass.
NOTE
Clean the panel after removing the 2 felt pads.
(3) Cut 2 new pieces of felt in the shape and size as shown in Figure 19. Use 1.0 mm thick felt.
(4) Install the 2 new felt pads on the rear side of the moon roof glass (LH and RH side).
5. Install Pad (Teflon Tape).
A. With moonroof glass removed clean and degrease the No. 2 Sliding Roof Glass Protector with the adhesion primer packets.
HINT
Use a screwdriver or similar tool wrapped in a shop rag or a clean towel to clean both the top and bottom surfaces of the No.2 sliding roof glass protector.
B. Apply pad to the cleaned sections.
NOTE
Before installing pads, inspect that there is proper clearance between the protector and the moonroof glass.
(1) If the edge of the No.2 sliding roof glass protector is in contact with the sliding roof glass insert a screwdriver to create a gap of 0.5mm (0.02 in).
(2) Refer to Figure 23 and obtain a NEW pad for the left hand side.
NOTE
^ LH pad will not install on the RH moonroof glass protector.
^ Use only NEW pad.
(3) Peel half of the backing paper off the NEW pad as shown in the illustration.
NOTE
Do not peel all the backing paper off the pad.
(4) Insert the NEW pad into the gap between the No.2 sliding roof glass protector and the sliding roof glass.
Do not touch the adhesive surface, as it may reduce the adhesive capability of the pad.
(5) While viewing the pad from the top of the sliding roof glass align the protrusion points of the NEW pad with the edge of the sliding roof glass.
(6) Attach the NEW pad to the bottom of the No.2 sliding roof glass protector using a round tool (i.e. screwdriver dowel).
(7) Roll the remaining portion of the new pad over the glass protector.
NOTE
When attaching the NEW pad, take care to prevent lifting and wrinkling in the section that will be in contact with the deflector arm.
C. Install the Pad (RH Side).
HINT
Use the same procedure for the LH side.
6. Reinstall Moonroof Glass.
A. Fully close the No. 2 sliding roof glass sub-assembly.
B. Using a T25 TORX driver install the 3 screws.
NOTE
Use the same procedure for the RH side and the LH side.
7. Adjusting Sliding Roof Glass Sub-Assembly (No. 1 No. 2).
A. Adjust the position of the No.2 sliding roof glass sub-assembly so that the measurements are within the standard values shown in Figure 30.
HINT
"+" represents the distance that the glass is above the panel level. ~ represents the distance that the glass is below the panel level.
Using a T25 TORX driver fully tighten the 6 screws to install the No.2 sliding roof glass sub-assembly.
Torque: 4.0 N*m (41 kgf*cm, 35 in*lbf)
B. Adjusting the No. 1 sliding roof glass sub-assembly:
(1) Adjust the position of the No. 1 sliding roof glass sub-assembly so that the measurements are within the standard values shown in the illustration.
(2) Using a T20 TORX driver fully tighten the 6 screws to install the No. 1 sliding roof glass sub-assembly.
Torque: 2.0 N*m (20 kgf*cm, 18 in*lbf)
C. Temporarily install the sliding roof side garnish LH.
Using a T20 TORX driver install the sliding roof side garnish LH with the screw.
Torque: 4.0 N*m (41 kgf*cm, 35 in*lbf)
D. Install Sliding Roof Side Garnish (RH).
HINT
Use the same procedure for the RH side and the LH side.
8. Inspect For Water Leaks.
A. If there are any leaks re-adjust the sliding roof glass sub-assembly.
9. Reinitialize moonroof (if necessary).