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Home >> Lexus >> 2011 >> IS 250C V6-2.5L (4GR-FSE) >> Repair and Diagnosis >> Body and Frame >> Roof and Associated Components >> Convertible Top >> Service and Repair >> Removal and Replacement >> Installation >> Part 2

Part 2





SLIDING ROOF / CONVERTIBLE: METAL TOP ROOF: INSTALLATION

PART 2

34. INSPECT FITTING OF FRONT SLIDE ROOF PANEL SUB-ASSEMBLY

(a) Check that the removable roof locks are released.





(b) If necessary, use a 5 mm hexagon wrench to turn the sliding roof drive gear sub-assembly counterclockwise to release the locks.

NOTICE:
* Insert the hexagon wrench all the way in and turn it with both hands.
* Do not apply excessive force after the drive gear stops turning.

HINT
The locks will release when the wrench is turned approximately 360 degrees.

(c) Fully close the front slide roof panel sub-assembly manually.





NOTICE:
* Perform this operation using 2 persons.
* Synchronize the movement of the left and right sides of the roof panels when moving them.

HINT
Slowly close the roof panels while checking that the guide pins on the roof panel and the sockets on the pillars are aligned.

(d) Using a 5 mm hexagon wrench, turn the sliding roof drive gear sub-assembly clockwise to engage the lock of the rear slide roof panel sub-assembly.





NOTICE:
* Insert the hexagon wrench all the way in and turn it with both hands.
* Do not apply excessive force after the drive gear stops turning.

HINT
The locks will engage when the wrench is turned approximately 360 degrees.

(e) Engage the U-hooks of the front slide roof panel sub-assembly with the links of the rear slide roof panel sub-assembly.





(f) Check that the eccentric bolt lightly contacts the bottom edges of the engaged U-hooks at location *b shown in the illustration.





Text in Illustration





HINT
If the contact is not as indicated, loosen the lock bolt, adjust the eccentric bolt, and then tighten the lock bolt.

Torque : 15.5 Nm (158 kgf-cm, 11 ft-lbf)

(g) Using a 5 mm hexagon wrench, turn the sliding roof drive gear sub-assembly clockwise to engage the locks of the front slide roof panel sub-assembly.





NOTICE:
* Insert the hexagon wrench all the way in and turn it with both hands.
* Do not apply excessive force after the drive gear stops turning.

HINT
The locks will engage when the wrench is turned approximately 360 degrees.

(h) Unlock the locks and check the fit of the guide pins.





HINT
The fit can be adjusted using the removable roof auxiliary catch assembly Installation.

Text in Illustration





(i) Measure the clearance between the front header and front slide roof panel sub-assembly (A) and then make the adjustment for the lengthwise direction.





(j) Remove the 4 centering bolts and install the 4 original bolts using a T40 "TORX" socket wrench.





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

(k) Tighten the adjustment screw so that the clearance between the roof panel strength assembly and adjustment screw is the standard value of 0 mm (0 in.) mm, then turn the adjustment screw a further 90° and tighten the lock bolt to lock the adjustment screw.





Standard Clearance:

0 mm (0 in.)

Text in Illustration





(l) Using a 5 mm hexagon wrench, turn the sliding roof drive gear sub-assembly counterclockwise to release the locks of the front slide roof panel sub-assembly.





NOTICE:
* Insert the hexagon wrench all the way in and turn it with both hands.
* Do not apply excessive force after the drive gear stops turning.

HINT
The locks will release when the wrench is turned approximately 360 degrees.

(m) Using a 5 mm hexagon wrench, turn the sliding roof drive gear sub-assembly clockwise to close the lock while measuring the roof lock stroke (C). C (Roof lock stroke) = A - B





Standard:

1.5 mm (0.059 in.)

HINT
* If the roof lock stroke (C) is not within the specified range, adjust it by turning the adjustment screw of the roof panel strength sub-assembly. Loosen the lock screw before turning the adjustment screw.
* When tightening the adjustment screw of the roof panel strength sub-assembly, the distance (A) between the front header and the front slide roof panel sub-assembly will become larger, and when loosening it, the distance (A) will become smaller.
* After the adjustment, tighten the lock screw.

(n) Check the metal top for movement.





(1) Apply approximately 200 N (20 kgf, 45 f) of force to part A in the direction shown in the illustration, and measure the amount of roof panel movement at location B.

Standard:

Less than 1.0 mm (0.039 in.)

HINT
* If the roof panel movement is not within the specified range, turn the adjustment screw on the roof panel strength sub-assembly to adjust the amount of movement. Loosen the lock screw before turning the adjustment screw.
* When tightening the adjustment screw of the roof panel strength sub-assembly, the distance (A) between the front header and the front slide roof panel sub-assembly will become larger, and when loosening it, the distance (A) will become smaller.
* After the adjustment, tighten the lock screw.

(o) Apply tape as shown in the illustration.





(p) Measure the clearance between the front window shield header and front slide roof panel sub-assembly at points A, B and C and adjust it to the standard.





Standard:

Clearance (a)





Difference (b)





HINT
* If any result is out of the standard, adjust it by moving the No. 2 roof panel strength sub-assembly.
* If the No. 2 roof panel strength sub-assembly is adjusted, temporarily secure it with the bolts.

(q) Measure the clearance between the front slide roof panel sub-assembly and the rear slide roof panel sub-assembly at points A, B and C and adjust it to the standard.





Standard:

Clearance (a)





Difference (b)





HINT
If any result is out of the standard, adjust it by moving the No. 2 roof panel strength sub-assembly.

35. SET METAL TOP ROOF

(a) Using a 5 mm hexagon wrench, turn the sliding roof drive gear sub-assembly counterclockwise to release the lock of the rear slide roof panel sub-assembly.





NOTICE:
* Insert the hexagon wrench all the way in and turn it with both hands.
* Do not apply excessive force after the drive gear stops turning.

HINT
The locks will release when the wrench is turned approximately 360 degrees.

(b) Using a 5 mm hexagon wrench, turn the sliding roof drive gear sub-assembly counterclockwise to release the locks of the front slide roof panel sub-assembly.





NOTICE:
* Insert the hexagon wrench all the way in and turn it with both hands.
* Do not apply excessive force after the drive gear stops turning.

HINT
The locks will release when the wrench is turned approximately 360 degrees.

(c) Manually move the roof to the position shown in the illustration.





NOTICE:
* Perform this operation using 2 persons.
* Synchronize the movement of the left and right sides of the roof when moving it.

36. FULLY TIGHTEN NO. 2 ROOF PANEL STRENGTH SUB-ASSEMBLY

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





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

37. FULLY TIGHTEN ROOF PANEL STRENGTH SUB-ASSEMBLY

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

38. INSTALL SLIDING ROOF PANEL STOPPER (for LH Side)

(a) Using a T25 "TORX" socket wrench, install the sliding roof panel stopper with the bolt.





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

39. INSTALL REAR ROOF SIDE RAIL GARNISH LH

(a) Install the rear roof side rail garnish LH with the 4 screws.





40. INSTALL ROOF SIDE INNER GARNISH COVER LH

(a) Engage the guide.





(b) Engage the claw to install the roof side inner garnish cover LH.

(c) Install the 2 screws.

41. INSTALL SLIDING ROOF PANEL STOPPER (for RH Side)

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

42. INSTALL REAR ROOF SIDE RAIL GARNISH RH

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

43. INSTALL ROOF SIDE INNER GARNISH COVER RH

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

44. SET METAL TOP ROOF

(a) Fully close the front slide roof panel sub-assembly manually.





NOTICE:
* Perform this operation using 2 persons.
* Synchronize the movement of the left and right sides of the roof panels when moving them.

HINT
Slowly close the roof panels while checking that the guide pins on the roof panel and the sockets on the pillars are aligned.

(b) Using a 5 mm hexagon wrench, turn the sliding roof drive gear sub-assembly clockwise to engage the locks of the front slide roof panel sub-assembly.





NOTICE:
* Insert the hexagon wrench all the way in and turn it with both hands.
* Do not apply excessive force after the drive gear stops turning.

HINT
The locks will engage when the wrench is turned approximately 360 degrees.

45. SET UPPER BACK WINDOW FRAME SUB-ASSEMBLY

(a) Manually close the upper back window frame sub-assembly.





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.

(b) Using a 5 mm hexagon wrench, turn the sliding roof drive gear sub-assembly clockwise to engage the lock of the rear slide roof panel sub-assembly.





NOTICE:
* Insert the hexagon wrench all the way in and turn it with both hands.
* Do not apply excessive force after the drive gear stops turning.

HINT
The locks will engage when the wrench is turned approximately 360 degrees.

46. INSPECT FITTING OF UPPER BACK WINDOW FRAME SUB-ASSEMBLY





(a) Measure the clearance between the rear slide roof panel sub-assembly and the upper back window frame sub-assembly at points A, B and C and adjust it to the standard





Standard:

Clearance (a)





Difference (b)





HINT
* Loosen the bolts for the back window frame sub-assembly upper and removable roof panel stopper LH or move the slide roof motor assembly when making adjustments.
* If the removable roof panel stopper LH is loosened for an adjustment, temporarily tighten it after the adjustment is completed.

47. FULLY TIGHTEN SLIDE ROOF MOTOR ASSEMBLY (for LH Side)

(a) Fully tighten the 3 bolts of the slide roof motor assembly.





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

(1) Using a T40 "TORX" socket wrench, install the slide roof motor assembly to the No. 2 roof panel strength sub-assembly with the 2 bolts.





Torque : 15 Nm (153 kgf-cm, 11 ft-lbf)

(2) Engage the clamp.





(3) Connect the 2 connectors.

48. FULLY TIGHTEN SLIDE ROOF MOTOR ASSEMBLY (for RH Side)

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

49. FULLY TIGHTEN UPPER BACK WINDOW FRAME SUB-ASSEMBLY

(a) Using a T40 "TORX" socket wrench, fully tighten the 4 bolts of the upper back window frame sub-assembly in the order shown in the illustration.





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

(b) Remove the 2 centering bolts and install the 2 original bolts using a T40 "TORX" socket wrench.





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

50. FULLY TIGHTEN REMOVABLE ROOF PANEL STOPPER LH

(a) Check that the removable roof panel stopper LH and back window lock assembly contact each other at the 3 points shown in the illustration.





Text in Illustration





(b) Using a T30 "TORX" socket wrench, fully tighten the bolt of the removable roof panel stopper LH.





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

51. FULLY TIGHTEN REMOVABLE ROOF PANEL STOPPER RH

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

52. SET UPPER BACK WINDOW FRAME SUB-ASSEMBLY

(a) Using a 5 mm hexagon wrench, turn the sliding roof drive gear sub-assembly counterclockwise to release the lock of the rear slide roof panel sub-assembly.





NOTICE:
* Insert the hexagon wrench all the way in and turn it with both hands.
* Do not apply excessive force after the drive gear stops turning.

HINT
The locks will release when the wrench is turned approximately 360 degrees.

(b) Manually move the upper back window frame sub-assembly to the position shown in the illustration.





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.

53. FULLY TIGHTEN REMOVABLE ROOF PANEL STOPPER LH

(a) Using a T30 "TORX" socket wrench, fully tighten the bolt of the removable roof panel stopper LH.





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

54. FULLY TIGHTEN REMOVABLE ROOF PANEL STOPPER RH

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

55. ROOF HALF-OPEN

(a) 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.

(b) Using a 5 mm hexagon wrench, turn the sliding roof drive gear sub-assembly counterclockwise to release the lock of the front slide roof panel sub-assembly.





NOTICE:
* Insert the hexagon wrench all the way in and turn it with both hands.
* Do not apply excessive force after the drive gear stops turning.

HINT
The locks will release when the wrench is turned approximately 360 degrees.

(c) Manually move the roof to the position shown in the illustration.





NOTICE:
* Perform this operation using 2 persons.
* Synchronize the movement of the left and right sides of the roof when moving it.

56. INSTALL ROOF SIDE INNER GARNISH LH Installation
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