Part 1

SLIDING ROOF / CONVERTIBLE: METAL TOP ROOF: INSTALLATION

PART 1

1. TEMPORARILY TIGHTEN LUGGAGE COMPARTMENT DOOR HINGE ASSEMBLY LH

(a) Temporarily install the luggage compartment door hinge assembly LH with the 2 bolts (B) and 4 nuts (A).

HINT
* Reinstall the original shims in this step.
* Install the hinges so that they can be moved forward/rearward and left/right.
* Pull the emergency cable and manually raise the link all the way to the top.

(b) If the nut, bracket and cushion have been removed due to manual operation in an emergency, insert the guide of the bracket into the hole, install the cushion and nut, and then tighten them.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

HINT
The bracket is equipped with a guide.

Text in Illustration

HINT
Return the cable to its original position after use.

(d) Install the earth bolt (C).

(e) Connect the 2 connectors.

2. INSTALL DECK SIDE TRIM BRACKET (for LH Side)

(a) Install the deck side trim bracket with the 2 bolts.

3. TEMPORARILY TIGHTEN LUGGAGE COMPARTMENT DOOR HINGE ASSEMBLY RH

(a) Temporarily install the luggage compartment door hinge assembly RH with the 2 bolts (B) and 4 nuts (A).

HINT
* Reinstall the original shims in this step.
* Install the hinges so that they can be moved forward/rearward and left/right.
* Pull the emergency cable and manually raise the link all the way to the top.

(b) If the nut, bracket and cushion have been removed due to manual operation in an emergency, insert the guide of the bracket into the hole, install the cushion and nut, and then tighten them.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

HINT
The bracket is equipped with a guide.

Text in Illustration

HINT
Return the cable to its original position after use.

(d) Connect the 2 connectors.

(e) Engage the 4 clamps.

(f) Install the push pull cable to the luggage compartment door lock assembly.

(g) Install the pin to the luggage compartment door lock assembly.

(h) Connect the wire with the earth bolt (A).

(i) Engage the push pull cable, confirm that the nut (B) is not contacting the bracket, and then tighten the nut (C) until it just contacts the bracket.

Torque : 2 Nm (20 kgf-cm, 18 in-lbf)

(j) Tighten the nut (B).

Torque : 20 Nm (203 kgf-cm, 14 ft-lbf)

4. INSTALL DECK SIDE TRIM BRACKET (for RH Side)

HINT
Use the same procedure for the RH side and LH side.

5. TEMPORARILY TIGHTEN PACKAGE TRAY TRIM BRACKET

(a) Temporarily install the package tray trim bracket with the 4 nuts.

(b) Engage the clamp.

(c) Connect the connector.

6. TEMPORARILY TIGHTEN SLIDE ROOF MOTOR ASSEMBLY (for LH Side)

(a) Temporarily install the slide roof motor assembly with the 3 bolts.

HINT
* Reinstall the original shims in this step.
* Install the slide roof motor assembly so that it can be moved forward/rearward and left/right.

7. TEMPORARILY TIGHTEN SLIDE ROOF MOTOR ASSEMBLY (for RH Side)

HINT
Use the same procedure for the RH side and LH side.

8. TEMPORARILY TIGHTEN NO. 2 ROOF PANEL STRENGTH SUB-ASSEMBLY

(a) Temporarily install the No. 2 roof panel strength sub-assembly with the 4 bolts.

HINT
* Reinstall the original shims in this step.
* Install the No. 2 roof panel strength sub-assembly so that it can be moved forward/rearward and left/right.

(b) Engage the clamp.

(c) Install the earth bolt.

Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)

(d) Connect the connector.

(e) Using a T40 "TORX" socket wrench, temporarily install the 2 bolts.

HINT
Install the No. 2 roof panel strength sub-assembly so that it can be moved up/down and left/right.

9. TEMPORARILY TIGHTEN ROOF PANEL STRENGTH SUB-ASSEMBLY

HINT
Use the same procedure for the RH side and LH side.

10. TEMPORARILY TIGHTEN REMOVABLE ROOF PANEL STOPPER LH

(a) Using a T30 "TORX" socket wrench, temporarily install the removable roof panel stopper LH with the 2 bolts.

HINT
Install the removable roof panel stopper LH to the upper back window frame sub-assembly so that the stopper can be moved up/down and left/right.

11. TEMPORARILY TIGHTEN REMOVABLE ROOF PANEL STOPPER RH

HINT
Use the same procedure for the RH side and LH side.

12. INSTALL REAR ROOF HEADLINING GARNISH

(a) Engage the 5 clips to install the rear roof headlining garnish.

13. INSTALL REAR ROOF SIDE RAIL WEATHERSTRIP RETAINER LH

(a) Install the rear roof side rail weatherstrip retainer LH with the 5 screw.

14. INSTALL REAR ROOF SIDE RAIL WEATHERSTRIP RETAINER RH

HINT
Use the same procedure for the RH side and LH side.

15. INSTALL BACK WINDOW CHANNEL WEATHERSTRIP

(a) Clean the upper back window frame sub-assembly surface.

(1) Using a heat light, heat the upper back window frame sub-assembly surface.

(2) Remove any double-sided tape or butyl tape from the upper back window frame sub-assembly.

(3) Wipe off any tape adhesive residue with cleaner.

(b) Set the removable roof garnish LH

(1) Using a moulding remover, pry the removable roof garnish LH in the direction shown in the illustration to make a gap so that the back window channel weatherstrip can be installed.

NOTICE:
Pry the removable roof garnish LH without dislodging the butyl tape or double-sided tape. If the butyl tape or double-sided tape comes loose, it is necessary to replace the removable roof garnish LH with a new one.

Text in Illustration

HINT
Use the same procedure for the RH side and LH side.

(c) Set the back window lower outside moulding.

(1) Using a moulding remover, pry the back window lower outside moulding in the direction shown in the illustration to make a gap so that the back window channel weatherstrip can be installed.

NOTICE:
Pry the back window lower outside moulding without dislodging the double-sided tape. If the double-sided tape comes loose, it is necessary to replace the back window lower outside moulding with a new one.

(d) Apply new butyl tape to the upper back window frame sub-assembly as shown in the illustration.

Text in Illustration

(e) Remove the release paper of the butyl tape.

HINT
After removing the release paper, keep the exposed adhesive free from foreign matter.

(f) Temporarily install a new back window channel weatherstrip to the upper back window frame sub-assembly. Then, remove the release paper from the double-sided tape and butyl tape of the back window channel weatherstrip, and firmly press it to the upper back window frame sub-assembly to install it.

Text in Illustration

(g) Engage 4 new clips.

(h) Install the 4 screws.

16. INSTALL QUARTER PILLAR GARNISH LH

17. INSTALL QUARTER PILLAR GARNISH RH

HINT
Use the same procedure for the RH side and LH side.

18. SET SLIDE ROOF MOTOR ASSEMBLY

(a) Manually move the slide roof motor assembly to the position shown in the illustration.

19. TEMPORARILY TIGHTEN UPPER BACK WINDOW FRAME SUB-ASSEMBLY

HINT
Use 2 centering bolts (90109-08155) to determine the appropriate position for the upper back window frame sub-assembly.

(a) Temporarily tighten the upper back window frame sub-assembly with the 2 centering bolts.

(b) Using a T40 "TORX" socket wrench, temporarily install the upper back window frame sub-assembly with the 4 bolts.

(e) Stow the upper back window frame sub-assembly in the luggage compartment.

NOTICE:
* Perform this operation using 2 persons.
* Synchronize the movement of the left and right sides of the upper back window frame sub-assembly when moving it.
* Make sure that the luggage compartment door hinge assemblies are not stowed.

20. INSTALL NO. 3 ROOF SIDE WEATHERSTRIP RETAINER SUB-ASSEMBLY

(a) Install the No. 3 roof side weatherstrip retainer sub-assembly with the 4 screws.

21. INSTALL NO. 4 ROOF SIDE WEATHERSTRIP RETAINER SUB-ASSEMBLY

(a) Install the No. 4 roof side weatherstrip retainer sub-assembly with the 4 screws.

22. INSTALL BACK WINDOW LOCK ASSEMBLY

(a) Using a T30 "TORX" socket wrench, install the back window lock assembly with the 9 bolts in the order shown in the illustration.

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

HINT
The 3 bolts for the motor installation base can be installed in any order.

(b) Engage the clamp.

23. INSTALL SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY

(a) Install the sliding roof drive gear sub-assembly with the 2 bolts.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

(b) Engage the 3 clamps.

24. INSTALL REAR REMOVABLE ROOF WEATHERSTRIP

(a) Clean the rear slide roof panel sub-assembly surface.

(1) Using a heat light, heat the rear slide roof panel sub-assembly surface.

(2) Remove any double-sided tape or butyl tape from the rear slide roof panel sub-assembly.

(3) Wipe off any tape adhesive residue with cleaner.

(b) Apply new butyl tape to the rear slide roof panel sub-assembly as shown in the illustration.

Text in Illustration

(c) Remove the release paper of the butyl tape.

HINT
After removing the release paper, keep the exposed adhesive free from foreign matter.

(d) Remove the release paper of the double-sided tape from the rear removal roof weatherstrip.

HINT
After removing the release paper, keep the exposed adhesive free from foreign matter.

Text in Illustration

(e) Install a new rear removable roof weatherstrip.

(f) Engage 4 new clips.

(g) Install the 6 screws.

25. SET ROOF PANEL STRENGTH SUB-ASSEMBLY

(a) Manually move the roof panel strength sub-assembly to the position shown in the illustration.

(b) If a new No. 2 roof panel strength sub-assembly is being installed, apply double-sided tape to each shim installation position and install the 2 shims that were removed from the old No. 2 roof panel strength sub-assembly. Align the holes of the shims with the installation holes of the No. 2 roof panel strength sub-assembly.

26. INSTALL REAR SLIDE ROOF PANEL SUB-ASSEMBLY

HINT
Use 2 centering bolts (90109-08155) to determine the appropriate position for the rear slide roof panel sub-assembly.

(a) Install the rear slide roof panel sub-assembly to the No. 2 roof panel strength sub-assembly with the 2 centering bolts.

Torque : 40 Nm (408 kgf-cm, 29 ft-lbf)

(b) Using a T40 "TORX" socket wrench, install the rear slide roof panel sub-assembly with the 4 bolts.

Torque : 40 Nm (408 kgf-cm, 29 ft-lbf)

(c) Attach each wire to its side of the back window lock assembly.

(d) Engage the wires to the back window lock assembly and install the 2 wire brackets with the 2 bolts using a T30 "TORX" socket wrench.

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

HINT
* If the wires are too tight, using a 5 mm hexagon socket, turn the sliding roof drive gear sub-assembly counterclockwise to loosen the wires.
* Do not turn the sliding roof drive gear sub-assembly more than one revolution.

(e) Connect the 2 connectors.

27. INSTALL REMOVABLE ROOF LOCK SUB-ASSEMBLY

(a) Using a T30 "TORX" socket wrench, install the removable roof lock sub-assembly with the 9 bolts in the order shown in the illustration.

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

HINT
The 3 bolts for the motor installation base of the removable roof lock sub-assembly can be installed in any order.

(b) Engage the 3 clamps.

28. INSTALL SLIDING ROOF DRIVE GEAR SUB-ASSEMBLY

(a) Install the sliding roof drive gear sub-assembly with the 2 bolts.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

(b) Engage the 3 clamps.

29. INSTALL CENTER ROOF SIDE RAIL WEATHERSTRIP RETAINER LH

(a) Install the center roof side rail weatherstrip retainer LH with the 6 screws.

30. INSTALL CENTER ROOF SIDE RAIL WEATHERSTRIP RETAINER RH

HINT
Use the same procedure for the RH side and LH side.

31. INSTALL ROOF SIDE RAIL WEATHERSTRIP LH

(a) Install the roof side rail weatherstrip LH with the 2 screws.

(b) Engage 2 new clips.

32. INSTALL ROOF SIDE RAIL WEATHERSTRIP RH

HINT
Use the same procedure for the RH side and LH side.

33. TEMPORARILY TIGHTEN FRONT SLIDE ROOF PANEL SUB-ASSEMBLY

HINT
Use 2 centering bolts (90109-08155) to determine the appropriate position for the front slide roof panel sub-assembly.

(a) Temporarily tighten the front slide roof panel sub-assembly with the 2 centering bolts.

Torque : 40 Nm (408 kgf-cm, 29 ft-lbf)

(b) Using a T40 "TORX" socket wrench, temporarily install the 6 bolts.

Torque : 40 Nm (408 kgf-cm, 29 ft-lbf)

(c) Engage the 2 clamps.

(d) Connect the 2 connectors.