Sunroof - Vibration
SECTION8
GROUP
83
NO.
919
DATE
April 1997
RE:
Preventing vibration from sunroof
960 1995-
REFERENCE: TP 8202201, SECTION 8 (82-86,88) BODY FITTINGS, EXTERIOR; 700/900 1982-
Preventing vibration from sunroof
Background:
This service bulletin describes how to adjust and clean the sun roof mechanism.
In case of customer complaints about vibration from the sun roof while driving the instructions in this Service Bulletin can be of assistance.
Read through the whole operation before starting any work to modify the sunroof.
Materials:
*) During spring 1997 the brackets will be replaced by a modified version with pre-drilled holes. Operation for drilling holes in brackets (operation 2) can then be stopped.
Tools: Drill 3.5 mm (9/64")
Drill 5.0 mm (13/64")
Index: Vibrations from sun roof when opened first 100 mm (4").
Vibrations from sun roof when opened from half open to fully open position.
Vibrations when sunroof is opened the first 100 mm (4")
The side piece can jam and cause vibrations if there is dirt in the sun roof slide rail.
Corrective action:
Open the sunroof fully and clean slide rail with a rag and a weatherstrip tool, (a cotton bud is also good).
Apply new grease in slide rail, P/N 1161247-0.
Vibrations from sun roof when opened from half open to fully open position
Note:
When drilling, protective eyewear should be worn.
Preparations:
Remove headlining according to Service Manual
Section 8 (82-86,88) Interior trim, exterior
700/900 1982-
4-door: Section DE 1
5-door: Section DE 12
Leave the headlining in the car, resting on the front seat head restraints. The sun visors can hang from their cabling.
Method:
Slacken off the 2 rear mountings [A, B] for the sunroof base on one side.
Remove bracket for the rear mounting [B].
Take out the new bracket.
Drill a 5 mm (13/64") hole in the bracket stamp [D] for the mounting in the sun roof base plate.
Install bracket [C] on sun roof base plate so far back that it is in contact with the plastic part of the sun roof base plate.
Important:
Place a protective plate between the outer roof and the sun roof base plate so that the drilling will not damage the outer roof. Ensure that the plate also covers the area between the outer roof and the base plate where it is mounted.
Drill a 5 mm (13/64") hole in the sun roof base plate with the drilled hole in the bracket as a template.
Remove bracket.
Install spring nut P/N 1369265-2 by the 2 rear mountings on the sun roof cavity.
Install the bracket on the front mounting [B] and screw into place on sun roof base plate with screw P/N 972079-8.
The rear mounting bracket needs to be adjusted before installation.
Cut off 4 mm of the bracket to be mounted on the roof member, see arrow in the illustration [C].
Screw the bracket onto the sun roof base plate P/N 972079-8.
Press sun roof base plate up and screw into in both front mountings.
Check that the protective plate covers the area between the outer roof and the roof member at the rear bracket.
Drill a 3.5 mm (9/64") hole in the roof member with the bracket as a template.
Remove the protective plate [E].
Install the rear bracket to the roof member with screw P/N 969005-8
Repeat for other side of sun roof base plate.
Check that the rear edge of the sun roof base plate follows the lateral roof member profile.
If necessary slacken off the rear mountings for the sun roof base plate and press up the base plate so that the correct profile is retained.
Screw brackets to base plate.
Operate sun roof forwards and backwards a few times and check that there is no noise or vibration.
Finishing work:
Reinstall headlining according to Service Manual Section 8 (82-86, 88) interior trim, exterior
700/900 1982-
4-door: Section DE 9 DE 11
5-door: Section DE 13
WARRANTY STATEMENT: Claims may be submitted under the New Car Limited Warranty when a manufacturing defect is present using claim type: 01
Operation No. Labor description Time allowance
83925-2 Cleaning sun roof gutter 0.2 hr
83926-2 Corrective action to counter
vibrations from sun roof 3.5 hr