Sunroof / Moonroof Panel: Service and Repair
Glass Roof Panel
This is a "Trustmark Authoring Standards (TAS) Repair Procedure"
- TAS style procedures can be identified by steps that have no accompanying step text and the magenta color of the electrical connectors and fasteners such as nuts, bolts, clamps or clips.
- TAS removal and installation procedures use a sequence of color illustrations to indicate the order to be followed when removing/disassembling or installing/assembling a component.
- Many of the TAS procedures will have the installation information within the removal steps.
- The TAS color illustrations use a variety of symbols to indicate important details of the procedures. It is important to understand these symbols in order to properly used the TAS procedures.
Refer to How to Use TAS Procedures and TAS Symbol Glossary at Vehicle | Description and Operation for additional information on these TAS procedures.
For additional information, refer to How to Use TAS Procedures How to Use TAS Procedures
Removal
CAUTION: Always protect paintwork and glass when removing exterior components.
CAUTION: Always protect the interior components when removing body glass.
CAUTION: Measure all gaps between the glass roof panels before prior to removal to help aid installation.
CAUTION: Lay the glass on felt covered supports. Do not stand on edge as this can cause chips which subsequently develop into cracks.
NOTE:
The cutting blades used in this procedure are from the standard BTB glass removal kit.
NOTE:
Some variation in the illustrations may occur, but the essential information is always correct.
NOTE:
Removal steps in this procedure may contain installation details.
For additional information, refer to Glass Roof Panel Blind
CAUTION: Protect the surrounding paintwork to avoid damage.
CAUTION: Protect the surrounding components.
WARNING: Wear safety goggles and protective gloves.
CAUTION: The glass roof panel adhesive is uneven as there are 6 raised Torx bolts that may catch the BTB blade (measure and mark the area before cutting. Use the rear front stud as a fixing point to take measurements from, as indicated) on cutting the adhesive.
CAUTION: Make sure that a Velcro stick on pad (WK11VEL from the BTB kit) is installed to the bottom of the blade, to prevent damage to the paintwork.
CAUTION: Protect the surrounding paintwork and body from the movement of the cutting blades, using WK11PP.
NOTE:
Glass roof panel shown removed for clarity.
Cut between points 1 and 4, use a WK28RS blade first the blade WK28RM, cut with the flat side against the body, not the roof panel cassette.
Cut between points 2 and 3, use a WK28RS blade first the blade WK28RM, cut with the flat side against the body, not the roof panel cassette.
Cut between points 1 and 2, use a WK28RS blade first the blade WK28RM, cut with the flat side against the body, not the roof panel cassette.
Cut between points 3 and 4, use a WK28RS blade first the blade WK28RM, cut with the flat side against the body, not the roof panel cassette.
WARNING: This step requires the aid of another technician.
1 Cut any excessive adhesive, use a WK6 winged blade.
Installation
CAUTION: Make sure that the 10 spacers are correctly installed prior to installation.
CAUTION: Make a note of the orientation of the spacers.
CAUTION: Make sure that the mating faces are clean and free of foreign material.
Prepare the glass roof panel, glass roof panel flange and trimmed PU adhesive in accordance with the instructions included with the PU adhesive kit.
CAUTION: Touching the adhesive surface will impair rebonding.
NOTE:
Install new spacers as necessary.
NOTE:
Make sure that the spacers are installed to noted position.
NOTE:
Apply a small amount of PU to the spacers to help maintain their position for installation.
Apply a continuous bead of sealant to the glass roof panel.
CAUTION: Note the orientation of the locating pins prior to installation.
NOTE:
Make sure that the front locating pin is installed first.
WARNING: This step requires the aid of another technician.
CAUTION: Make sure that the component is correctly located on the locating dowels.
CAUTION: Make sure that equal pressure is applied to the full length of the component.
CAUTION: To make sure the glass roof panel adhesive is not touched or smeared during installation, more technicians may be required to assist with this step.
CAUTION: Make sure that the glass roof panel blind mounting brackets are not damaged during installation.
With assistance, install and align the glass roof panel.
CAUTION: Do not hit the glass roof panel while installing to the vehicle.
CAUTION: Pressure is only to be applied to the outer edge of the glass roof panel.
Lightly press the glass roof panel to seat the sealer.
Secure the glass roof panel in position using tape.
If the ambient temperature falls below 10 degrees C, apply warm air (25 degrees C) continuously for 15 minutes.
CAUTION: Make sure that no excess sealant residue is evident.
CAUTION: Make sure that the sealant is allowed to dry in accordance with the instructions included with the PU adhesive kit.
CAUTION: If using heat to dry the water from the vehicle after water testing the glass roof panel, do not use excessive heat.
If water is used as a means for the leak check, then allow sealant to dry before testing.
NOTE:
Use a suitable sealant remover if any excessive sealant is applied to the glass roof panel seal and surrounding areas.
Spray water around the glass roof panel, mark any area that leaks. Dry the glass roof panel and sealant before applying additional sealant.
For additional information, refer to Glass Roof Panel Blind