Page 719 of 1007

SUNROOF
76-6-6 REPAIRS
8.Remove 3 Torx screws securing motor.
9.Disconnect 2 Lucars and 1 multiplug from
motor.
10.Release motor from sunroof assemby, lower
through headlining and remove motor.Refit
1.Position motor to sunroof assembly and fit 1
Torx screw.
2.Connect 2 Lucars to motor assembly.
3.Inch glass panel to maximum tilt by depressing
sunroof switch.
CAUTION: Care must be taken not to exceed
maximum tilt.
4.Connect multiplug to motor.
5.Remove Torx screw and release motor from
sunroof assembly.
6.Depress sunroof switch in open position, keep
button depressed until motor stops (motor and
lifting assemblies are then timed together).
7.Position motor to sunroof assembly, fit and
tighten Torx screws to 6 Nm (4.4 lbf.ft).
8.Carefully reposition headlining.
9.Fit sunroof finisher.
+ SUNROOF, REPAIRS, Finisher -
flange to headlining - front.
10. Up to 04MY: Position front interior lamp and
connect multiplug.
11. Up to 04MY: Fit Torx bolts securing interior
lamp and tighten to 6 Nm (4.4 lbf.ft).
12. Up to 04MY: Fit lens to front interior lamp.
13. From 04MY: Fit and secure front interior lamp
to headlining.
Page 720 of 1007

SUNROOF
REPAIRS 76-6-7
Drive cables & slide assemblies - sun/
sliding roof - front - 5 door
$% 76.84.09
Remove
1.Remove glass panel.
+ SUNROOF, REPAIRS, Glass panel -
sun/sliding roof - front - 5 door.
2.Open sun roof.
3.Release and remove wind deflector.
4.Position sun roof in tilt mode.
If sun roof motor is inoperative, use a tool to
manually tilt sun roof.
5.Remove sun roof motor.
+ SUNROOF, REPAIRS, Motor - sun/
sliding roof - front - 5 door.
6.Remove 4 Torx screws securing lifting
assembly to roof.
7.Collect rear cam guide.
8.Slide assembly forward, remove cable guide
clamp.
9.Remove lifting assembly and cable.Refit
1.Ensure cable tubes are in position, lightly
grease the end of cable tube.
2.Engage cable in tube and fit lifting assembly to
roof.
3.Fit cable guide clamp, place lifting assembly in
tilt mode.
4.Fit rear cam guide.
5.Fit and tighten Torx screws securing lifting
assembly to roof.
6.Fit sun roof motor.
+ SUNROOF, REPAIRS, Motor - sun/
sliding roof - front - 5 door.
7.Open sun roof.
8.Position wind deflector and secure to sun roof.
9.Fit glass panel.
+ SUNROOF, REPAIRS, Glass panel -
sun/sliding roof - front - 5 door.
Page 721 of 1007
SUNROOF
76-6-8 REPAIRS
Drain tube - sun/sliding roof - front - each
- 5 door
$% 76.84.20
Remove
1.Remove headlining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 5 door.
2.Remove scrivet and 5 Torx screws securing
front carpet retainer and remove carpet
retainer.
3.Release drain tube from wheel arch grommet.
4.Disconnect drain tube from sun roof and
discard cable tie.
5.Attach draw string and remove drain tube.Refit
1.Attach draw string to drain tube and pull into
position.
2.Connect drain tube to sun roof and secure with
new cable tie.
3.Connect drain tube to wheel arch grommet.
4.Secure wheel arch grommet.
5.Fit carpet retainer and secure with Torx screws
and scrivet.
6.Fit headlining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 5 door.
Page 722 of 1007
SUNROOF
REPAIRS 76-6-9
Drain tube - sun/sliding roof - rear - each
- 5 door
$% 76.84.21
Remove
1.Remove headlining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 5 door.
2.Release drain tube from wheel arch grommet
and 3 securing clips.
3.Disconnect drain tube from sun roof and
discard cable tie.
4.Remove drain tube.
Refit
1.Position drain tube.
2.Connect drain tube to sun roof and secure with
new cable tie.
3.Connect drain tube to wheel arch grommet and
secure in clips.
4.Secure wheel arch grommet.
5.Fit headlining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 5 door.
Finisher - flange to headlining - front
$% 76.84.25
Remove
1.Release sun roof surround finisher from sun
roof aperture and remove finisher.
Refit
1.Position sun roof surround finisher and secure
in position, ensure locating lug is in position at
the front of finisher.
Page 723 of 1007
SUNROOF
76-6-10 REPAIRS
Wind deflector - sun/sliding roof - 5 door
$% 76.84.28
Remove
1.Open sun roof.
2.Carefully release wind deflector retaining pegs
from roof.
3.Release wind deflector from lifting assemblies.
4.Remove wind deflector.
Refit
1.Position wind deflector to lifting assemblies and
secure in position.
2.Carefully locate retaining pegs under roof.
3.Close sun roof.
Sun blind - front - one - 5 door
$% 76.84.30
Remove
1.Remove headlining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 5 door.
2.Remove 2 blind stops.
3.Remove 2 rubber buffers.
4.Slide blind to the rear of sun roof and remove
from guides.
Refit
1.Lubricate guides with isoflex grease.
2.Fit blind to guides and slide into position.
3.Fit blind stops and rubber buffers.
4.Fit headlining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 5 door.
Page 724 of 1007
SUNROOF
REPAIRS 76-6-11
Switch - sun/sliding roof - front
$% 76.84.40
Remove
1.Release switch from front console.
2.Disconnect multiplug and remove switch.
Refit
1.Position switch and connect multiplug.
2.Fit switch to front console.
Seal - tray - sun /sliding roof - front - 5
door
$% 76.84.61
Remove
1.Remove sun roof assembly.
+ SUNROOF, REPAIRS, Sun/sliding
roof - complete - front - 5 door.
2.Remove sun roof tray seal.
Refit
1.Clean old adhesive from tray.
2.Remove backing from new seal and fit seal to
tray.
3.Fit sun roof assembly.
+ SUNROOF, REPAIRS, Sun/sliding
roof - complete - front - 5 door.
Page 767 of 1007
PANEL REPAIRS
77-2-12 REPLACEMENT PANELS
Roof assembly - 5 door
1Roof assembly (with sunroof)
2Roof assembly (without sunroof)
Page 816 of 1007

PANEL REPAIRS
REPAIRS 77-2-61
Front roof assembly - 3 door
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove LH and RH front roof panel finishers.
5.Remove headlining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 3 door.
6.Remove sunroof assembly.
+ SUNROOF, REPAIRS, Sun/sliding
roof - complete - front - 3 door.
7.Remove windscreen.
+ SCREENS, REPAIRS, Windscreen.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. There are
no plug welds used in this procedure, spot
welds only.
Refit
1.Fit windscreen.
+ SCREENS, REPAIRS, Windscreen.
2.Fit sunroof.
+ SUNROOF, REPAIRS, Sun/sliding
roof - complete - front - 3 door.
3.Fit headlining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 3 door.
4.Fit LH and RH front roof panel finishers.
5.Connect all ECUs.
6.Connect alternator.
7.Connect battery earth lead.
Rear roof assembly - 3 door
Remove
1.Disconnect battery earth lead.
2.Disconnect alternator.
3.Disconnect all ECUs.
4.Remove soft/hard top.
5.Remove LH and RH rear roof panel finishers.
6.Remove headlining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 3 door.
7.Remove sunroof.
+ SUNROOF, REPAIRS, Sun/sliding
roof - complete - front - 3 door.
8.Remove aerial.
+ IN CAR ENTERTAINMENT,
REPAIRS, Aerial - manual - 3 door.
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. There are
no plug welds used in this procedure, spot
welds only.
Refit
1.Fit aerial.
+ IN CAR ENTERTAINMENT,
REPAIRS, Aerial - manual - 3 door.
2.Fit sunroof.
+ SUNROOF, REPAIRS, Sun/sliding
roof - complete - front - 3 door.
3.Fit headlining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 3 door.
4.Fit LH and RH rear roof panel finishers.
5.Fit soft/hard top.
6.Connect all ECUs.
7.Connect alternator.
8.Connect battery earth lead.