Repair Procedure A: Metal Top Roof Panel Alignment
1. Completely close the roof.
2. Loosen the set screw holding the panel No. 1 to panel No. 2 adjustment screw on the left and right side of the roof.
3. Loosen the roof panel No. 1 to panel No. 2 adjustment screw until the adjustment screw is not contacting the roof panel.
4. Open the roof halfway.
5. Remove the rubber stoppers on both sides.
6. Completely close the roof.
7. Manually release the 2/3 Lock (turn counterclockwise approx. 360°).
Click Paperclip to Watch Supplemental Video
8. Manually release the header lock (turn counterclockwise approx. 360°).
9. Attach tape on the roof panels (between the roof header and roof panel No. 1) and make a mark on each piece to measure the distance (in mm) between each panel (A).
Driver Side: A = _________ mm
Passenger Side: A = ________ mm
10. Manually lock the header lock (turn clockwise approx. 360°).
11. Manually lock the 2/3 Lock (turn clockwise approx. 360°).
12. Measure the same location as in step 9 on both sides to get measurement B.
13. Using the formula below, insert the measurements from steps 9 and 12 to determine the header latch distance adjustment or C.
Driver Side: 1.5 mm - (A ______ - B _______) = C_______
Passenger Side: 1.5 mm - (A ______ - B _______) = C_______
14. Open the roof halfway.
15. Mark (with white paper correction fluid) around the three header lock receiver bolts and scribe lines to indicate the distance the receiver needs to move (towards the front of the vehicle [C mm] and towards the outside of the vehicle [1 mm]).
HINT
Use a feeler gauge to help scribe the movement distance.
16. Loosen the header lock receiver bolts and adjust the brackets position in accordance with the lines scribed.
17. Tighten the header lock catch bolts.
Torque: 12 N-m (122 kgf-cm, 9 ft-lbf)
18. Completely close the roof.
19. Measure the cinch dimension using steps 7 - 12 to get measurements A and B.
Driver Side: A - B = D
Passenger Side: A - B = D
Header Lock Cinch Dimension (D) = 1.5 - 2.0 mm
- If D is NOT between 1.5 - 2.0 mm, return to step 7.
- D must be within 0.5 mm between driver and passenger side. If out of specification, return to step 7.
20. Measure the gap between the front window header and front roof panel No. 1.
21. Tighten the roof panel No. 1 to panel No. 2 adjustment screw until it contacts the No. 2 roof panel, then rotate the screw clockwise 90° to 135° (90+45°) on both sides until roof panel No. 1 and roof panel No. 2 are flush (±1.5 mm). Click Paperclip to Watch Supplemental Video
22. Tighten the lock screw of the adjustment screw on both right and left sides.
23. Measure the height difference between the roof No. 1 and No. 2 panels.
24. Confirm the U-shaped hook contacts the eccentric pin on the strength arms (both right and left sides).
Click Paperclip to Watch Supplemental Video
If there is a gap, adjust the eccentric pin until it contacts the bottom of the U-shaped hook.
25. On roof panel No. 3, loosen the 2 bolts holding the 2-3 lock striker (on both right and left sides).
Click Paperclip to Watch Supplemental Video
NOTE
With the roof closed, the 2/3 lock striker can only be accessed from the rear seat area.
26. Pull the striker bracket's external side towards the front of the vehicle, and temporarily tighten one bolt on the external side (on right and left bracket sides).
27. Pull the striker bracket's internal side towards the front of the vehicle, and tighten both bolts (on right and left brackets).
28. Confirm that the rubber stopper where the 2/3 Lock contacts the striker is tight and will not rotate (tightly clasped) (on right and left sides).
29. Open the roof halfway.
30. Manually lock the 2/3 Lock (turn clockwise approx. 360°).
31. Remove the 2/3 Lock cable (on right and left sides).
32. Loosen the 3 bolts attaching the 2/3 Lock to the roof panel No. 2 and install a 1 mm shim (P/N 90201-11011) on the bottom 2 bolts in between the 2/3 Lock and the roof panel and tighten the bolts (on right and left sides).
Torque: 12 N-m (122 kgf-cm, 9 ft-lbf)
NOTE
Do NOT remove the shim attached to the 2/3 Lock. The new shims are an addition to the existing shim(s).
33. Install the 2/3 Lock cable (on right and left sides).
34. Manually release the 2/3 Lock (turn counterclockwise approx. 360?).
35. Install the rubber stoppers on both sides.
36. Apply chalk to roof panel contact points below on both sides.
NOTE
Please use chalk as it is easy to remove and reapply.
A. 2/3 Lock striker.
B. Panel No. 1 to No. 2 adjustment screw.
C. Header lock pins.
37. Completely close the roof.
38. Open the roof halfway and inspect the chalk transfer marks on each contact point.
A. Header lock.
If header pins have poor contact with the latch, return to step 1.
NOTE
Chalk needs to be transferred on upper portion of triangle shaped catch.
B. Panel No. 1 to No. 2 adjustment screw.
If adjustment screw has poor contact, return to step 21.
C. 2/3 Lock.
If striker does not contact both sides. remove shimes from steps 31-33 and return to step 25.
39. Completely close the roof.
40. Confirm the gaps between the roof panels.
A. Front windshield header to roof panel No. 1.
B. Roof panel No. 1 to roof panel No. 2.
C. Roof panel No. 2 to back window frame assembly.
D. If any of the measurements are outside of the specified range, follow the Repair Manual for convertible top panel adjustments.
Refer to TIS, 2010 IS 250C/350C Repair Manual:
- Vehicle Exterior - Sliding Roof/Convertible - "Sliding Roof/Convertible: Metaltop Roof: Installation"