Page 2233 of 2585

(3) Connect the timed sunroof assembly to a
power source and assure proper operation before
installing the sunroof assembly into the vehicle.
ADJUSTMENTS
ADJUSTMENT
CAUTION: THE IS NO ADJUSTMENT AVAILABLE
FOR A NORMALLY OPERATING SUNROOF. THIS
PROCEDURE IS USE TO SET SUNROOF MOTOR TO
SUNROOF ASSEMBLY TIMING.
(1) Manually push the sunroof guide assembly to
the full forward position until it is locked into posi-
tion. This is verified by attempting to push the guide
assembly rearward. (Fig. 3)
NOTE: The guide rail will be raised above the
U-frame assembly when in the lock position.
(2) Remove the sunroof glass (Refer to 23 - BODY/
SUNROOF/GLASS PANEL - REMOVAL).
(3) Manually move the guide piviot inside the
guide rail cam slot until it is centered between the
etched timing marks on both rails. (Fig. 4)
(4) Verify that the white marking is visible in the
new motor window. If the mark is not visible, connecta power source to the motor and cycle the switch
until the motor is in the closed position (white mark
in window). (Fig. 5)
Fig. 3 SUNROOF GUIDE LOCK POSITION
1 - SUN SHADE
2-U-FRAME
3 - U- FRAME SLOT
4 - GUIDE RAIL
5 - GUIDE RAIL PIVIOT
6 - WIND DEFLECTOR
Fig. 4 SUNROOF GUIDE PIVOT
1 - TIMING MARKS
2 - GUIDE RAIL
3 - GUIDE RAIL PIVIOT
4 - U-FRAME
5 - WIND DEFLECTOR
Fig. 5 SUNROOF MOTOR
1 - SUNROOF MOTOR TIMING WINDOW
2 - SUNROOF MOTOR
23 - 122 SUNROOFRS
SUNROOF MOTOR (Continued)
Page 2234 of 2585

(5) Install the sunroof motor and verify proper
sunroof operation (Refer to 23 - BODY/SUNROOF/
DRIVE MOTOR - INSTALLATION).
(6) Install the sunroof glass, leaving the retaining
bolts loose.
(7) Install the sunroof assembly into the vehicle
(Refer to 23 - BODY/SUNROOF/MODULE ASSEM-
BLY - INSTALLATION).
(8) Flush the sunroof glass into the vehicle roof
opening and check sunroof glass alignment (Refer to
23 - BODY/SUNROOF/GLASS PANEL - ADJUST-
MENTS).
SUNROOF SWITCH
REMOVAL
(1) Disconnect the negative battery cable.
(2) Separate the overhead console from the head-
liner, by carefully pulling down on the front portion,
toward the windshield, to release the retaining clips
(Fig. 6).
(3) Release the sunroof switch retaining tab, dis-
connect the electrical connector and remove the
switch from the console (Fig. 6).
INSTALLATION
(1) Position the switch against the overhead con-
sole and push the switch to seat properly in retaining
clip.(2) Install the overhead console.
(3) Connect the negative battery cable.
Fig. 6 OVERHEAD CONSOLE
1 - OVERHEAD CONSOLE
2 - POWER SUNROOF SWITCH
3 - SUNROOF SWITCH RETAINING CLIP (PART OF CONSOLE)
4 - OVERHEAD CONSOLE RETAINING CLIPS
RSSUNROOF23 - 123
SUNROOF MOTOR (Continued)
Page 2235 of 2585
BODY STRUCTURE
TABLE OF CONTENTS
page page
GAP AND FLUSH
SPECIFICATIONS - GAP AND FLUSH
MEASUREMENTS....................124
OPENING DIMENSIONS
SPECIFICATIONS - BODY OPENING
DIMENSIONS........................127
SEALER LOCATIONS
SPECIFICATIONS - BODY SEALING
LOCATIONS.........................130STRUCTURAL ADHESIVE LOCATIONS
SPECIFICATIONS - STRUCTURAL ADHESIVE
LOCATIONS.........................156
WELD LOCATIONS
SPECIFICATIONS - WELD LOCATIONS.....166
GAP AND FLUSH
SPECIFICATIONS - GAP AND FLUSH
MEASUREMENTS
INDEX
DESCRIPTION FIGURE
GAP & FLUSH MEASUREMENTS 1
23 - 124 BODY STRUCTURERS
Page 2236 of 2585
Fig. 1 GAP & FLUSH MEASUREMENTS
RSBODY STRUCTURE23 - 125
GAP AND FLUSH (Continued)
Page 2237 of 2585

SPECIFICATIONS
ITEM LOCATION GAP FLUSH
A HOOD TO FASCIA (VOYAGER ONLY)
8.0 2.0
PARALLEL WITHIN 2.0 RIGHT TO
LEFT2.5 OVER FLUSH TO HOOD
1.5 CONSISTENT WITHIN 2.0
B HEADLAMP MODULE TO
HOOD8.0 2.0
PARALLEL WITHIN 2.0 RIGHT TO
LEFT
C HOOD TO FENDER (FORE &
AFT)0.0 1.5
LEFT TO RIGHT WITHIN 1.5
D HOOD TO FENDER 4.0 1.5
PARALLEL WITHIN 2.5 AND
WITHIN 1.5 LEFT TO RIGHTUNDER FLUSH 2.0
E FENDER TO DOOR 5.0 1.5
PARALLEL WITHIN 2.0UNDER FLUSH 0.5 1.5
CONSISTENT WITHIN 2.0
F FRONT DOOR TO9A9PILLAR
COVERUNDER FLUSH 0.5 2.0
G9A9PILLAR COVER TO
SLIDING DOOR5.0 2.0
PARALLEL WITHIN 1.01.0 UNDER FLUSH 2.0
CONSISTENT WITHIN 1.0
H FRONT DOOR APPLIQUE TO
SLIDING DOOR GLASS5.0 2.0
PARALLEL WITHIN 2.01.0 OVER FLUSH 2.0
CONSISTENT WITHIN 3.0
I FRONT DOOR TO SLIDING
DOOR5.0 2.0
PARALLEL WITHIN 2.0 2.0 CONSISTENT WITHIN
2.0
J SLIDING DOOR TO REAR
APERTURE GLASS5.0 2.0
PARALLEL WITHIN 1.5 3.0 CONSISTENT WITHIN
3.0
K SLIDING DOOR TO REAR
APERTURE5.0 1.5
PARALLEL WITHIN 2.0 1.5 CONSISTENT WITHIN
1.5
L TAIL LAMP TO BODY SIDE
APERTURE1.0 1.0
PARALLEL WITHIN 1.5OVER FLUSH
M TAIL LAMP TO LIFTGATE 4.0 2.0 OVER FLUSH
N LIFTGATE TO BODY SIDE
APERTURE4.0 1.5 UNDER FLUSH 1.0 2.5
CONSISTENT WITHIN 2.0
O LIFTGATE TO ROOF 8.0 2.0 1.5
P LIFTGATE TO FASCIA 8.0 2.5
PARALLEL WITHIN 3.0
Q LIFTGATE TO REAR FASCIA UNDER FLUSH TO 1.0
MAXIMUM OVER FLUSH
R FUEL FILLER DOOR TO BODY
SIDE APERTUREUNDER FLUSH 0.5 1.0
NOTE: All measurements are in mm.
23 - 126 BODY STRUCTURERS
GAP AND FLUSH (Continued)
Page 2238 of 2585
OPENING DIMENSIONS
SPECIFICATIONS - BODY OPENING
DIMENSIONS
INDEX
DESCRIPTION FIGURE
WINDSHIELD OPENING 2
LIFTGATE OPENING 3
BODY SIDE OPENINGS 4
Fig. 2 WINDSHIELD OPENING
RSBODY STRUCTURE23 - 127
Page 2239 of 2585
Fig. 3 LIFTGATE OPENING
23 - 128 BODY STRUCTURERS
OPENING DIMENSIONS (Continued)
Page 2240 of 2585
Fig. 4 BODY SIDE OPENINGS
RSBODY STRUCTURE23 - 129
OPENING DIMENSIONS (Continued)