Файл: 92FWD_23.pdf

(3)Remove bolts holding sunroof motor to motor bracket.

(4)Disconnect wire connector.

(5)Separate motor and drive gear from drive cables.

MOTOR AND DRIVE GEAR INSTALLATION

(1)Verify that sunroof is in vent position. Push mechanism forward on both sides to align drive cables.

(2)Engage drive gears onto drive cables.

(3)Install motor and drive gear screws and tighten to 5 NIm (44 in-lbs.).

(4)Install head lining.

Fig. 5 Sunroof Motor and Drive Gear

DRIVE CABLES

DRIVE CABLES REMOVAL (FIG. 6)

(1)Open sunroof to vent position.

(2)Remove head lining, wind deflector, mechanism covers, glass panel, side glass adjustment brackets, motor and drive cable locators.

(3)Lift cable out of cable retainer and pull forward. Separate cable from assembly.

DRIVE CABLES INSTALLATION

Verify sunroof is in vent position. Push mechanism forward on both sides to align drive cables. Reverse the preceding operation.

SUNSHADE

SUNSHADE REMOVAL (FIG. 7)

(1)Remove wind deflector, mechanism covers and glass panel.

(2)Position system to full rearward position.

(3)Slide sunshade panel full forward and release the front tabs from track assembly.

(4)Pull rear retaining clip inboard and lift sun shade out.

Fig. 6 Drive Cables

SUNSHADE INSTALLATION

Reverse the preceding operation.

Fig. 7 Sunshade Assembly

GUIDE ASSEMBLY

GUIDE ASSEMBLY REMOVAL (FIG. 8)

(1)Remove wind deflector, mechanism covers, glass panel, drain channel, sunshade and drive cable locator as necessary.

(2)Move glass carriage to vent position.

(3)Remove front slide from guide assembly.

(4)Remove screws holding front and center guide track to unit.

(5)Pull cable out of groove for cable end.

(6)Pull guide outward to release from housing. Separate rear end of guide from clips. Slide guide out of unit.

GUIDE ASSEMBLY INSTALLATION

(1)Install guide cable into rear of guide assembly.

(2)Install guide assembly at an angle so the rear portion slips under finger clips at rear of module housing.

SAFETY PRECAUTIONS AND WARNINGS

WARNING: DO NOT USE URETHANE ADHESIVE OR PRIMER IN CLOSED WORK AREA, PERSONAL INJURY CAN RESULT.

PROTECT SKIN FROM COMING IN CONTACT WITH URETHANE, PERSONAL INJURY CAN RESULT.

WEAR EYE AND HAND PROTECTION WHEN WORKING WITH GLASS, PERSONAL INJURY CAN RESULT.

CAUTION: Protect all painted or trimmed surfaces from coming in contact with urethane or primers, damage will result.

Do not damage painted surfaces when removing mouldings or cutting urethane around windshield.

It is difficult to salvage a windshield during the removal operation. The windshield is part of the structural support for the roof. The urethane bonding used to secure the windshield to the fence is difficult to cut or clean from any surface. If the mouldings are set in urethane, it would also be unlikely they could be salvaged. Before removing the windshield, check the availability of the windshield and mouldings from the parts supplier.

WINDSHIELD REMOVAL

(1)Remove inside rear view mirror.

(2)Remove cowl cover.

(3)Remove windshield mouldings using a suitable hook tool and trim stick (Fig. 1).

(4)Cut urethane bonding from around windshield using a suitable sharp cold knife. A pneumatic cutting device can be used if available (Fig. 2).

(5)Separate windshield from vehicle.

WINDSHIELD INSTALLATION

CAUTION: Open the left front door glass before installing windshield to avoid pressurizing the pas-

Fig. 1 Windshield Mouldings

Fig. 2 Cut Urethane Around Windshield

senger compartment if a door or the trunk lid is slammed before urethane bonding is cured. Water leaks can result.

Allow the urethane at least 4 hours to cure before returning the vehicle to use.

The windshield fence should be cleaned of old urethane bonding material. Support spacers should be cleaned and properly installed on weld studs or repair screws at bottom of windshield opening.

Fig. 3 Center Windshield and Mark at Support

Spacers

Fig. 4 Work Surface Set-up and Mouldings

Installation

(1)Place replacement windshield into windshield opening and position glass in the center of the opening against the support spacers. Mark the glass at the support spacers with a grease pencil or pieces of masking tape and ink pen to use as a reference for installation. Remove replacement windshield from windshield opening (Fig. 3).

(2)Position the windshield inside up on a suitable work surface with two padded, wood 10 cm by 10 cm by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed parallel 75 cm (2.5 ft.) apart (Fig. 4).

(3)Clean inside of windshield with Mopart Glass Cleaner and lint-free cloth.

(4)Apply clear glass primer 25 mm (1 in.) wide around perimeter of windshield and wipe with clean/dry lint-free cloth.

(5)Install mouldings on windshield (Fig. 4).

(6)Apply black-out primer 15 mm (.75 in.) wide on top and sides of windshield and 25 mm (1 in.) on bottom of windshield. Allow at least three minutes drying time.

Fig. 5 Position Urethane Compression Spacers

Fig. 6 Lower Windshield Into Position

(7)Position windshield bonding compression spacers on lower fence above the support spacers at the edge of the windshield opening (Fig. 5).

(8)Apply a 10 mm (0.4 in.) bead of urethane around perimeter of windshield along the inside of the mouldings.

(9)With the aid of a helper, position the windshield over the windshield opening. Align the reference marks at the bottom of the windshield to the support spacers.

(10)Slowly lower windshield glass to windshield opening fence. Guide the top moulding into proper position if necessary. Push windshield inward to fence spacers at bottom and until top moulding is flush to roof line (Fig. 6).

(11)Clean access urethane from exterior with Mopart, Super Clean or equivalent.

(12)Install cowl cover and wipers.

(13)Install inside rear view mirror.

(14)After urethane has cured, water test windshield to verify repair.