Sun roof assembly - 3 door (page 2 of 2)

8. Remove sun roof tray seal. See this section.
9. Mask up roof and sun roof aperture.
10. Cover interior trim with protective sheet.
11. Make a cut through the sealer at the back of the sun roof, a 90° bend in the cutting tool will help.

CAUTION: Take care not to damage paint or roof aperture flange when cutting out sunroof.

12. Using suitable cutting wire, cut through PU sealer securing sunroof to roof.

NOTE: Multi-strand cutting wire is advised, as a sawing action may be required on the corners. Single strand wire may overheat and break during sawing action.

13. Remove section of sunroof.

Refit

1. Clean surrounding area with solvent.
2. Use a vacuum cleaner to clear away dust and debris.
3. Cut sealer on roof flange down to a smooth even finish.
4. Etch prime and paint any damaged areas.
5. Apply primer over etch primer on flange.
6. Apply activator over old sealer on flange.
7. Allow activator to cure.
8. Fit pre-cut nozzle to sealer cartridge, remove lid and shake out crystals, install in applicator gun.

NOTE: Modify nozzle as required.

9. Apply a continuous bead of sealer around roof flange as shown. Make bead slightly thicker at the corners.

NOTE: Sealer bead should be 8 mm by 8 mm.

10. Check for breaks and air bubbles in the sealer.
11. With assistance position sunroof and align to roof aperture.
12. Fit sun roof tray seal. See this section.
13. Position sunroof clamping plates, fit and tighten screws.
14. Connect drain tubes and secure with NEW cable ties.
15. Remove body and trim protection.
16. Position wind deflectors, fit and tighten screws.
17. Fit ’T’ bar and glass panels.
18. Fit headlining. See Interior trim components.