Rear Shelf: Service and Repair

Package Tray Trim Assy:

OVERHAUL




1. MOVE ROOF PANEL TO HALF
a. Referring to the manual operation procedures.




2. REMOVE REAR SEAT CUSHION ASSEMBLY
a. Pull up the front portion of the seat cushion assembly, then remove it.

NOTE: In the case, hold the base of the clip up to prevent the cushion frame from being distorted.




3. REMOVE REAR SEAT HEADREST PLATE COVER
a. Using a screwdriver, remove the rear seat headrest plate cover.

HINT: Tape the screwdriver tip before use.

b. Use the same manner described above to the other side.

4. REMOVE WIND DEFLECTOR BOARD ASSEMBLY
a. Remove the 4 bolts and wind deflector board assembly.




5. REMOVE REAR SEAT HEADREST PLATE
a. Using a screwdriver, remove the rear seat headrest plate.

HINT: Tape the screwdriver tip before use.

b. Use the same manner described above to the other side.




6. REMOVE REAR SEAT HEADREST ASSEMBLY
a. Remove the 2 nuts and rear seat headrest assembly.
b. Use the same manner described above to the other side.




7. REMOVE REAR SEAT BACK ASSEMBLY
a. Remove the 2 nuts, 2 bolts and rear seat back assembly.




8. REMOVE REAR SEAT BACK BOARD
a. Remove the bolt.
b. Release the 2 clips, then remove the back board.




9. REMOVE DOOR SCUFF PLATE ASSEMBLY RH
a. Using a screwdriver, remove the door scuff plate assembly RH.

HINT: Tape the screwdriver tip before use.

10. REMOVE DOOR SCUFF PLATE ASSEMBLY LH




11. REMOVE QUARTER TRIM PANEL ASSEMBLY FRONT RH
a. Using a screwdriver, release the 4 claws and remove the rear seat outer belt garnish.

HINT: Tape the screwdriver tip before use.




b. Remove the 6 screws and clip.
c. Release the 4 clips and remove the quarter trim panel assembly front RH.

12. REMOVE QUARTER TRIM PANEL ASSEMBLY FRONT LH




13. RAISE PACKAGE TRAY TRIM ASSEMBLY
a. Place both hands under the rear part of the package tray in the positions close to both ends and raise the package tray gradually at 30° to 45°.

NOTE:
- Place both your hands on the slide board in the positions close to the both ends.
- Do not apply direct force to the side board as it is operated in connection with the main board.
- Do not place the hands on the edges of the main board.




b. Disconnect the joints of the cables from the package tray trim gear box.

CAUTION: Take cave not to injure your hands when disconnect the joints.

NOTE:
- As the cable is coated with grease, carefully prevent the seat, seat belt or other parts from being contact with it.
- Be careful to prevent the removed cable from being excessively pressed against the package tray gear box.




c. Raise the package tray gradually until it stops.

NOTE: Do not apply direct force to the side board as it is operated in connection with the main board.




14. REMOVE PACKAGE TRAY TRIM ASSEMBLY
a. Disconnect the limit switch connectors.
b. Remove the 3 bolts.

NOTE:
- Depending on the angle of the package tray, the side board may interfere with the bolt. In this case, adjust the angle to move the side board so that the bolt can be viewed.
- Do not move the side board directly. Be sure to move the main board for adjustment.
- The main board is operated in connection with the side board.

c. Use the same manner described above to the other side.




d. Remove the package tray trim assembly as shown in the illustration.

HINT: Store the right and left shims for the package tray trim assembly separately.




15. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY
a. As shown in the illustration, mark the nut position on the arm of the bracket.

HINT: When replacing the bracket with a new one, mark the arm position on the side board.

b. Remove the 2 nuts and package tray trim panel assembly.

16. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY NO.2
a. Mark the nut position on the arm of the bracket.

HINT: When replacing the bracket with a new one, mark the arm position on the side board.

b. Remove the 2 nuts and package tray trim panel assembly No.2.




17. REMOVE PACKAGE TRAY TRIM UNDER COVER
a. Remove the 9 screws and cover.




18. REMOVE PACKAGE TRAY PANEL ASSEMBLY CENTER
a. As shown in the illustration, mark the nut position on the bracket.

HINT: When replacing the bracket with a new one, mark the bracket position on the panel assembly side.

b. Remove the 4 nuts and panel assembly.




19. REMOVE SLIDE ROOF LIMIT SWITCH
a. Remove the bolt and protector.
b. Remove the 2 screws and limit switch.




20. REMOVE SLIDE ROOF LIMIT SWITCH
a. Remove the bolt and protector.
b. Remove the 2 screws and limit switch.




21. REMOVE BACK WINDOW GLASS WEATHERSTRIP RH
a. Remove the back window glass weatherstrip RH from the swing package tray panel RH.

22. REMOVE BACK WINDOW GLASS WEATHERSTRIP LH




23. REMOVE BACK WINDOW GLASS WEATHERSTRIP CENTER
a. Remove the back window glass weatherstrip center from package tray trim panel sub-assembly.

24. REMOVE PACKAGE TRAY TRIM BRACKET
a. Remove the 2 bolts and bracket.




25. REMOVE PACKAGE TRAY TRIM LINK LH MOTOR ASSEMBLY
a. Using a clip remover, release the 2 clips of drive cable.
b. Remove the 2 drive cable.

HINT: Turn the attachment on the drive cable end and remove the drive cable from the motor.

c. Disconnect the connector, then remove the 2 bolts and motor.

26. INSTALL PACKAGE TRAY TRIM LINK LH MOTOR ASSEMBLY
27. INSTALL PACKAGE TRAY TRIM BRACKET
28. INSTALL BACK WINDOW GLASS WEATHERSTRIP CENTER
29. INSTALL BACK WINDOW GLASS WEATHERSTRIP LH
30. INSTALL BACK WINDOW GLASS WEATHERSTRIP RH
31. INSTALL SLIDE ROOF LIMIT SWITCH
32. INSTALL SLIDE ROOF LIMIT SWITCH




33. INSTALL PACKAGE TRAY PANEL ASSEMBLY CENTER
a. Install the panel so that the nuts is in marked position.

HINT: When replacing the bracket, install it by correctly positioning to the mark on the panel.

34. INSTALL PACKAGE TRAY TRIM UNDER COVER
35. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY NO.2
36. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY




37. INSTALL PACKAGE TRAY TRIM ASSEMBLY
a. Temporarily tighten 6 bolts and package tray trim assembly.

HINT: The shims that has been stored.

b. Fully open the roof.
c. Close the luggage door.
d. Move the package tray trim back and forth to adjust the position.

HINT:
- If the standard value is not satisfied, adjust the installation position of the slide panel.
- For vertical adjustment, change the number of the shims to be inserted.

e. Open the luggage door from the front and set the package tray to an upright position.
f. Completely install the 6 bolts.

38. INSTALL QUARTER TRIM PANEL ASSEMBLY FRONT LH
39. INSTALL QUARTER TRIM PANEL ASSEMBLY FRONT RH
40. INSTALL DOOR SCUFF PLATE ASSEMBLY LH
41. INSTALL DOOR SCUFF PLATE ASSEMBLY RH
42. INSTALL REAR SEAT BACK BOARD
43. INSTALL REAR SEAT BACK ASSEMBLY
44. FULLY CLOSE ROOF PANEL

Torque:
Bolt: 18 N.m (184 kgf.cm, 13 ft.lbf)
Nut: 7.0 N.m (71 kgf.cm, 63 in.lbf)

a. Referring to the manual operation procedures, full close the roof.