Design

Design

Sun roof components




The sun roof consists of:
1. Cassette
2. Gutter
3. Glass
4. Sun screen
5. Apron molding / anti-trapping device
6. Wind deflector
7. Electric motor with integrated control module
The opening mechanism for the sun roof is integrated in the cassette. In the event of a fault in the opening mechanism, the entire cassette must be replaced.
The electric motor with the integrated control module is connected to the electrical system of the vehicle and can be replaced separately.

Sun roof cassette




The sun roof cassette is used to hold together and to provide stability for all the sun roof components. The legs on the cassette constitute guide rails (1) for the opening mechanism. The center post (2) is riveted between the rails to provide extra stability for the cassette. The center post holds the edge molding that runs around the opening facing into the passenger compartment. On the front part of the cassette is the installation site (3) for the electric motor together with the integrated control module. between the electric motor and the opening mechanism are two drive cables (4). The drive cables are the screw type and move backwards and forwards when the motor gears turn. The rear end of the cables is secured in the opening mechanism (5).
A plastic drainage channel (6) is installed on the opening mechanism. The drainage channel slides backwards together with the glass when the sun roof is opened. The drainage channel leads any rainwater that may enter, for example when the sun roof is in the angled position, to the cassette gutter. The cassette gutter then leads the rainwater to the drain hoses in the four corners.
The cassette is installed in the vehicle roof using ten screws. Four in the front section and three in each guide rail.

Glass




The glass, along with the sun screen, is the most visible part of the sun roof. The pane is made of toughened glass, of the same type as used for the other windows in the vehicle. The glass is tinted for a more comfortable climate in strong sunshine. The glass is encased, i.e. there is a metal reinforcement around the glass. Rubber trim is installed around the casing. The rubber trim provides a seal against the cassette when the sun roof is closed. The glass is installed in the opening mechanism using two screws on either side. A plastic sharks tooth strip is installed along the bottom rear edge of the glass.

Sun visor




A sun visor is installed under the glass, facing into the passenger compartment. Four slides are screwed to the short sides of the sun visor, two on either side. The slides run in a rail on either side of the cassette. The sun visor is pushed backwards and forwards by hand. When the glass is slid back, the sun visor automatically follows. The sun visor handle has ventilation holes to increase ventilation when the sun roof is in the angled position.

Apron molding / anti-trapping device




The apron molding / anti-trapping device is a plastic component that is installed with two clips, one in the cassette and one in the short side of the glass. There is an apron molding / anti-trapping device on each short side of the sun roof.

Warning! It is important that the apron molding is in place to ensure that nobody is trapped when opening or closing the sun roof.

Wind deflector




The wind deflector is located at the front edge of the sun roof. The wind deflector is made of plastic with metal mountings. The mountings are inserted in grooves, one on either side of the cassette. The wind deflector angles up when the sun roof is opened.

Electric motor with integrated control module




The control module contains software that governs the electric motor. This software controls the anti-trapping function, calibration of the sun roof and the opening mechanism.

Anti-trapping function
The anti-trapping function is a safety requirement to prevent people from being injured by the sun roof when it is closed. The maximum closing force may not exceed 100 N at a speed of 50 km/h. At speeds above 50 km/h, the closing force is adjusted according to the vehicle speed to compensate for the wind strength.

Calibration of sun roof
The sun roof is calibrated to locate the glass in its neutral position and to ensure that the anti-trapping function works satisfactorily.

Warning! Calibration must be performed every time the sun roof has been serviced.When installing a new electric motor / control module, new calibration must be carried out according to the method, see INFORMATION/REPAIR/CLEANING, CHECKING AND ADJUSTING/Bodywork and interior trim/Doors and hatches/Sun roof.When installing a previously mounted electric motor / control module, recalibration must be carried out according to the method, see INFORMATION/REPAIR/CLEANING, CHECKING AND ADJUSTING/Bodywork and interior trim/Doors and hatches/Sun roof.

Opening mechanism
The main positions of the glass panel are programmed in the control module and are: angled, closed and fully open sun roof. The position is determined in the control module using a gear wheel and two Hall sensors. The Hall sensors register the number of turns made by the gear wheels to move the glass to its position.
In order to control the above functions, the control module receives three signals from the central electronic module (CEM):
- X-supply
- the vehicle speed
- closing / calibration signal.
The control module is also linked to battery voltage and the controls for the sun roof.
The control module, which is integrated with the sun roof electric motor, checks the voltage to the electric motor. The nominal value of the voltage is 12 V and the maximum load during normal operation is 5 A.
The electric motor drives a gear wheel which is aligned with the drive cables. The gear wheel causes the cables to move.
The electric motor with the integrated control module is installed using three screws on the front section of the cassette.





Emergency closing screw
There is an emergency closing screw (1) on the electric motor. The screw can be turned to the right or left using an Allen key to open or close the sun roof respectively.

Drainage




Sleeves are installed in the four corners of the sun roof cassette. Drain hoses are installed in these sleeves.
The front drain hoses are routed down through either A-post and run out on top of the cowl member. A sound plug (1) is pressed into place in the ends of the front drain hoses.
The rear drain hoses are routed down through either C-post and run out below the tail lamps. A sound trap (2) is pressed into place in the end of the left rear drain hose, the C30 has a sound plug (3). A sound plug (3) is pressed into place in the end of the right rear drain hose.
It is important to check the seals on the sun roof drainage system after carrying out any work that can affect the sun roof drainage system.