Sunroof / Moonroof Frame: Service and Repair

Panoramic Glass Roof Housing Replacement

NOTE:

- Wear eye protection while cutting the housing adhesive with a piano wire.
- Have an assistant help you when removing and installing the housing.
- Put on gloves to protect your hands.
- Take care not to scratch the body or the related parts.

1. Remove these items:

- Sunshade drive assembly Panoramic Glass Roof Sunshade Drive Assembly Replacement
- Glass drive assembly Panoramic Glass Roof Drive Assembly Replacement
- Front fixed glass panel Front Fixed Glass Panel Replacement
- Rear fixed glass panel Service and Repair

2. Remove the bolts securing the housing (A).






3. Remove the ground bolt, and detach the harness clips (A).






4. Apply protective tape around the housing. Make a hole with an awl through the adhesive from inside the vehicle at a corner of the housing. Push a piece of piano wire through the hole, and wrap each end around a piece of wood.

5. With a helper on the outside, pull the piano wire (A) back and forth in a sawing motion. Hold the piano wire as close to the housing (B) as possible to prevent damage to the body. Carefully cut through the adhesive (C) around the entire housing.






Cutting positions





6. Carefully remove the housing.

7. Scrape smooth the original adhesive with a knife until there is a thickness of about 2 mm (0.08 in) on the bonding surface around the entire housing opening flange. Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.

8. Clean the body bonding surface with a shop towel dampened with isopropyl alcohol. After cleaning, do not allow oil, grease, and water to contact the clean surface.

9. Carefully apply a light coat of body primer along the edge of the housing (A) as shown. Let the body primer dry for at least 10 minutes.

NOTE: Never touch the primed surfaces with your hands.






10. Carefully apply a light coat of body primer to any exposed paint or metal around the flange where the new adhesive will be applied. Let the body primer dry for at least 10 minutes:

- Do not apply body primer to any remaining original adhesive on the flange.
- Never touch the primed surfaces with your hands.





11. Cut a "V" in the end of the nozzle (A) on the adhesive cartridge as shown.






12. Put the cartridge in a caulking gun, and run a continuous bead of the adhesive (A) along the edge of the housing (B) as shown or along the original adhesive path on the body. Apply the adhesive within 30 minutes after applying the body primer. Make a slightly thicker bead at each corner.






13. Hold the housing over the opening, align the datum pin spacers (A) with the body holes (B), and set it down on adhesive. Lightly push on the housing until the side spacers (C) and the datum pin spacers are fully seated to the body and the housing edges are fully seated on adhesive all the way around.

NOTE: Do not open or close any of the doors for about an hour until adhesive is dry.






14. Install the bolts securing the housing (A).






15. Install the harness clips (A) and the ground bolt.





16. Remove the excess adhesive with a putty knife or a shop towel dampened with isopropyl alcohol.

17. Wait at least an hour for the adhesive to dry. Let the vehicle stand for at least 4 hours after housing installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly.

18. Reinstall all remaining removed parts.

NOTE: Advise the client not to do the following things for 2 to 3 days:

- Slam the doors with all the windows rolled up.
- Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).