Page 716 of 1007
SUNROOF
REPAIRS 76-6-3
Seal - tray - sun /sliding roof - front
$% 76.83.61
Remove
1.Remove side rail front end covers.
2.Remove 4 Torx bolts securing front of side rails.
3.Remove front and rear roof finishers.
4.Remove glass panels and 'T' bar.
5.Remove seal from inner part of tray.
6.Release seal from corners of tray and ease
from between roof and tray.
7.Remove tray seal.Refit
1.Position seal to roof.
2.Locate seal to corners of tray and fit between
roof and tray.
3.Fit seal to inner part of tray.
4.Fit 'T' bar and roof glass.
5.Fit roof finishers.
6.Ensure gaskets and in position on side rails. Fit
rails and secure Torx bolts to 22 Nm (16 lbf.ft).
7.Fit side rail end covers.
Page 717 of 1007
SUNROOF
76-6-4 REPAIRS
Sun/sliding roof - complete - front - 5
door
$% 76.84.01
Remove
1.Remove headlining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 5 door.
2.Disconnect drain tubes from sun roof.
3.Disconnect multiplug from sun roof motor.
4.With assistance, remove 6 nuts and 2 bolts
securing sun roof.
5.Remove sun roof.
Refit
1.Ensure plastic washer and tray seal are in
position.
2.With assistance position sun roof assembly, fit
and tighten nuts and bolts.
3.Connect multiplug to sun roof.
4.Connect drain tubes to sun roof and secure
with cable ties.
5.Fit headlining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 5 door.
Glass panel - sun/sliding roof - front - 5
door
$% 76.84.03
Remove
1.Open sun roof blind.
2.Remove covers from glass securing screws.
3.Remove 6 screws securing glass.
4.Remove glass.
Refit
1.Position glass, fit screws but do not tighten at
this stage.
2.Align glass to roof and tighten screws,
alignment points should be measured 300 mm
either side of the centre line.
3.Set front of glass, flush to roof panel to 1.0 mm
down.
4.Set rear of glass, flush to roof panel to 1.0 mm
up.
5.Fit screw covers.
6.Operate sunroof to check alignment.
7.Close sun roof blind.
Page 718 of 1007
SUNROOF
REPAIRS 76-6-5
Seal - panel glass - sun roof - 5 door
$% 76.84.05
Remove
1.Remove glass panel.
+ SUNROOF, REPAIRS, Glass panel -
sun/sliding roof - front - 5 door.
2.Release ends of seal from glass and remove
seal .
Refit
1.Clean adhesive from glass.
2.Position seal, apply adhesive to ends of seal
and secure to glass panel.
3.Fit glass panel.
+ SUNROOF, REPAIRS, Glass panel -
sun/sliding roof - front - 5 door.
Motor - sun/sliding roof - front - 5 door
$% 76.84.07
Remove
1.Ensure sunroof is in closed position.
2. Up to 04MY: Remove lens from front interior
lamp.
3. Up to 04MY: Remove 2 Torx screws securing
front interior lamp to body.
4. Up to 04MY: Release front interior lamp from
headlining, disconnect multiplug and remove
lamp.
5. From 04MY: Working from lamp forward edge,
release front interior lamp from headlining,
disconnect multiplug and remove lamp.
6.Remove headlining to sun roof finisher.
+ SUNROOF, REPAIRS, Finisher -
flange to headlining - front.
7.Carefully lower front of headlining to access
motor.
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.
