Body - Sunroof Inoperative/Binding/Noisy
09-001/99SUNROOF INOPERATIVE, BINDS OR NOISY OPERATION
Note:
This bulletin supersedes the following TSB(s): S002/99. Please update your records accordingly.
APPLICABLE MODEL(S)/VINs
All 1998-99 626 vehicles equipped with a factory sunroof.
DESCRIPTION
You may encounter a customer complaint for any of the following sunroof concerns:
^ Abnormal noise during sunroof operation.
^ Binding during operation. Opens only partially.
^ Will not fully close.
^ Will tilt open but will not slide open.
^ Will slide open but will not tilt open.
The above symptoms may be a result of one or more of the following:
^ Broken or missing sunroof glass panel bumper clips becoming lodged in the track. This may result in front and/or rear guide breakage.
^ Rear guide improperly secured (loose) to front guide. This may result in rear guide breakage.
^ Improper sunroof drive cable/motor timing setting from the factory.
Customers complaining of any of these concerns should have their vehicle repaired using to the following repair procedure.
REPAIR PROCEDURE
1. Verify customer complaint.
2. Remove the sunroof glass panel per the Workshop Manual (section 09) refer to GLASS PANEL REMOVAL/INSTALLATION.
3. Inspect for broken, missing, and/or loose sunroof glass panel bumper clips as shown.
4. If the clips are broken, missing, and/or loose, proceed to BUMPER CLIP REPLACEMENT.
5. If the clips are not broken, missing and/or loose, proceed to INSPECTION FRONT AND REAR GUIDES.
NOTE:
It is not necessary to remove the entire seal.
BUMPER CLIP REPLACEMENT
1. Set the sunroof glass panel upside down on a clean surface.
2. Partially remove the seal from the glass panel front corners near the bumper clip mounting area.
3. Remove any loose bumper clips from the sunroof glass panel.
NOTE:
If one or both bumper clips have fallen out or are missing, carefully inspect the sunroof track on the appropriate side for the loose part (s). Failure to remove this part(s) from the track could cause severe damage to the sunroof tracks or other components.
4. Carefully file the bumper clip seating area on the frame to remove any metal burrs or paint.
NOTE:
This will ensure proper glue adhesion.
5. Identify the type of glass panel frame.
NOTE:
The glass panel frame holes for the clips are slightly different depending upon vehicle production date. See illustration.
VINs 1YV GF22** W5 781664 (July 29, 1998) or BEFORE have the old style frame.
VINs 1YV GF22** W5 781665 (July 29, 1998) or AFTER have the new style frame. If the sunroof frame is the new style, proceed to STEP 6.
If the sunroof frame is the old style, then the new style glass bumper clip must be modified to fit the frame hole by carefully removing the alignment pin (by filing or other suitable means) as shown. Proceed to STEP 6.
CAUTION:
Be careful not to cut through the clip locking tabs (barbs) or the bumper face.
6. Thoroughly clean the area and allow it to dry.
7. Apply a small amount of Super Glue (or equivalent) to the bumpers mounting hole area of the glass panel frame.
8. Install the bumper clip(s) with the flat portion facing the front of the vehicle and allow the glue to dry.
9. Use black touch up paint to repair any bare spots on the glass panel frame near the bumpers that were made when the frame was filed and cleaned. Allow to dry.
10. Proceed to INSPECTING FRONT AND REAR GUIDES below.
INSPECTING FRONT AND REAR GUIDES
1. Inspect the front and rear guides for breakage.
^ If guide(s) is broken, replace it per the Workshop Manual (SUNROOF UNIT DISASSEMBLY and SUNROOF UNIT ASSEMBLY) and proceed to Step 2.
2. Inspect rear guides for looseness (not clipped securely to the front guide)
^ If the guide(s) is loose, re-secure it to the front guide.
Then proceed to DRIVE CABLES / MOTOR TIMING - SETTING PROCEDURES.
NOTE::
All damaged parts must be repaired or replaced and sunroof track area must be free of any excess or damaged parts before proceeding to next step.
DRIVE CABLES / MOTOR TIMING - SETTING PROCEDURES
1. Cycle the sunroof once (tilt position down, slide open, then slide completely closed).
2. Verify that the alignment holes in the drive unit and guide are aligned, and the sunroof motor pointers are lined up. Refer to illustration.
^ If the holes are properly aligned, proceed to STEP 3,
^ If the holes are not properly aligned or will not cycle as described in STEP A, then align per the following procedure.
3. Turn the ignition key off.
4. Remove the sunroof motor and align the motor per as shown. a 4 mm hex wrench can be used to line up the pointers if they are slightly mis-aligned.
NOTE:
Do not reinstall the motor at this time.
5. Verify that both left and right front sunroof guides are properly clipped onto their respective drive cables.
6. Align the left and right drive cables to front guides by gently moving the drive cable(s) until the alignment holes are centered.
CAUTION:
Do not push on the guides themselves or breakage may occur.
NOTE:
A mirror can be used to better judge the alignment hole centering.
7. Insert a 3 mm pin or equivalent tool into each alignment hole. Refer to illustration.
8. Reinstall the motor per the Workshop Manual (SUNROOF MOTOR INSTALLATION).
9. Remove the alignment pins/tools from both sides.
CAUTION:
Failure to remove alignment tools could result in severe damage to the sunroof guides and components.
10. Turn ignition key on.
11. Slide the sunroof fully open, then fully closed.
NOTE:
Do not use the tilt function at all during the above STEP or a false alignment indication may result.
12. Verify that the alignment holes are aligned with each other as shown in STEP B above.
13. Reinstall and adjust the sunroof glass panel per the Workshop Manual (GLASS PANEL REMOVAL/INSTALLATION and GLASS PANEL ADJUSTMENT.
14. Verify the repair.
PARTS INFORMATION
WARRANTY INFORMATION
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