Sunroof - Repair Procedure
Applies To 5000S Group
5000S TURBO
5000S WAGON 60
1984 - 1985
Subject Key Points
Number
Electric Sunroof Sunroof repair procedure
85-60-01
Part Identifier
C June 14, 1985
Electric Sunroof:
Electric sunroof
If repairing sunroofs on vehicles up to VIN F-100 000
Qty. - install the following parts:
Reqd. Part No. Description
1 443 877 779 Buffer disc
Up to F-072 001
1 443 898 015A Guides with cable
1 443 877 151 B Guide, left
1 443 877 152B Guide, right
1 823 877 777 Pinion Up to F-072 001
1 443 877 401 Gasket
1 443 877 687 Gasket
- Local purchase Loctite 326 and Silicone Grease
1 443 877 297 B (01C) Seal
Modified Sunroof Parts:
Note
To identity new parts, compare differences at arrows.
Sunroof, RemovingWork Sequence:
- tilt sunroof up at rear
- push flap (1) downwards
- unhook both tension springs (2) from flap
Removal Tool:
Note
To make spring removal easier, make special removal tool
^ a = approx. 300 mm (12.0 in)
- dip hook in paint to prevent damage to vehicle
Sunroof, RemovingWork Sequence:
- reach into flap opening and unclip trim panel (3) by pulling toward back
- push trim panel back into roof
Sunroof, RemovingWork Sequence:
- open sunroof far enough that cap (4) is accessible
- carefully pry off cap (4) with screwdriver (arrow)
Sunroof, RemovingWork Sequence:
- unscrew nut for support (arrow)
Remove Mounting Screws (A, B, C) and Nut:
- close sunroof
- remove mounting screws (A, B, C) and nut (arrow)
- carefully lift sunroof from vehicle
CAUTION
Put masking tape around front and rear of sunroof opening to protect paint when removing sunroof pieces.
Unscrew Cover (Arrow):
- remove sunroof trim and sunroof lid from vehicle
- unclip courtesy lamp and disconnect electrical connectors
- unscrew cover (arrow) and push forward to remove
Remove Screws (1) and (2):
- disconnect motor electrical connectors
- remove screws (1) and (2) noting position of washer under screw (2) located between motor and roof
- remove motor
Wind Deflector Actuator:
- push rear guides with cables and sunroof support back far enough to expose deflector mounting screws (arrow)
- remove screws on both sides
Unscrew Wind Deflector Screws:
- unscrew wind deflector screws (arrows)
- remove wind deflector (15)
Remove Six M4 x 16 Oval Head Screws:
- remove six M4 x 16 oval head screws (arrows)
- move complete sunroof assembly up and forward out of sunroof opening
- remove sunroof headliner from vehicle
Note
The following repairs are performed with sunroof assembly on bench.
Remove Circlip (17) and Pull Off Lever (18):
- remove circlip (17) and pull off lever (18)
- push spring (arrow) downward and pull from guide
- remove guide plate/tilt bracket
Remove Screws:
- remove screws (arrows) and remove front rail cover
- pull sunroof support forward and out of guide rails
Side Rail Cover Screw:
- remove side rail cover screw (arrow) from both sides
- remove side rail covers
Guide Rail:
- remove cable guide tubes (arrow) from guide rail
Front Cable Guide Support:
- remove cable guide tubes from front cable guide support
- remove sunroof cables
Electric Sunroof:
CAUTION Check front cable guide support for broken metal clip. Replace clip if necessary. Check for burrs on guide tube ends (internal) and guide rail cut-outs (ill. page 1). If present, remove with appropriate file, blow out filings. Clean all cable guide tubes, tracks and rails before reassembling.
Note
Assemble sunroof on bench and then install complete sunroof assembly in vehicle.
- lightly lubricate new sunroof cables with mineral oil
Guide Tubes:
- install cables into guide rail (arrow) on both sides
- install cables into guide tubes and push guide tubes into guide rail
Front Cable Guide:
- install cable guide tubes into front cable guide support
Side Rail Covers:
- install side rail covers (both sides)
- put Loctite on screws and tighten
^ 1.0 +/- 0.2 N-m
Installation Procedure:
- slide sunroof support on to guide rails
- install front rail cover
- coat screws with Loctite and tighten
^ 1.0 +/- 0.2 N-m
Note Lubricate all contact areas of sliding items with silicone grease
Installation Procedure:
- install guide plate/tilt bracket over pin on sunroof cable
- install O-ring and clip (16)
- attach rain deflector lever (18) to guide plate/tilt bracket
- install O-ring and clip (17)
Installation Procedure:
- slide cables A (guide plate/tilt bracket attached) rearward until aligned with marking line on guide rail (arrow)
CAUTION
When lining up cables to guide rail, always move cables from front of vehicle rearward to marking lines. Do not move cables from rear of vehicle forward to marking lines.
- slide sunroof headliner into guide rails from rear
Install Acoustic Gasket:
- install acoustic gasket on front rail cover (arrows)
^ gasket P/N 443 877 401
Install Acoustic Gasket:
- install acoustic gasket on rain deflector plate (arrows)
^ gasket P/N 443 877 687
Note
Be sure that lip of rear acoustic gasket faces front of vehicle.
Sunroof, Installing:
Sunroof, installing
Work sequence
- install entire sunroof assembly into vehicle
- coat six M4 x 16 mm screws with Loctite and tighten (arrows)
^ 1.0 - +/- 0.2 N-m
Sunroof Wind Deflector:
- install sunroof wind deflector (15)
- coat screws (arrows) with Loctite and tighten
^ 1.0 - +/- 0.2 N-m
Install Wind Deflector Actuators:
- install wind deflector actuators
- coat screws (arrow) with Loctite and tighten
^ 1.0 +/- 0.2 N-m
- remove duct tape from around sunroof opening
Align Sunroof Cable Pin:
- align sunroof cable pin with arrow on guide plate/ tilt bracket
- do this on both sides
Sunroof Cover:
- place sunroof cover in opening
- start screws A, B, C and nut (arrow)
Note
Do not torque screws at this time.
On vehicles up to VIN F-072001, Production date January, 1985
Sunroof Pinion:
- remove C clip from sunroof pinion
- install cone shape washer
^ P/N 433 877 779
- install new pinion
^ P/N 823 877 777
- install C clip
On vehicles after VIN F-072001
Do not install washer
Replace pinion only, if damaged
Sunroof Motor:
- disengage sunroof motor from drive gear by moving lever (B) in direction of arrow cast on motor
- insert hand crank into drive pinion (A) and turn to right
Drive Pinion:
- turn drive pinion until tab aligns with hole in cam according to illustration (closed position of sunroof)
- engage sunroof motor to drive gear by moving lever (B) in opposite direction of arrow cast on motor
- recheck alignment
- readjust if necessary
Spacer Location:
CAUTION
A spacer must be installed between sunroof motor and roof at location of screw number 2.
- wrap electrical connectors with foam rubber
- apply Loctite to sunroof motor screws
- tighten screws, (1) then (2)
^ 1.0 +/- 0.2 N-m
WARNING
Do not route electrical wires for sunroof or courtesy lamp on top of or near light bulb.
- install cover for sunroof motor and courtesy lamp
Sunroof, adjusting:
Sunroof, adjusting
Height adjustment, front
Note
Apply Loctite to all screws.
- loosen nut (D)
- loosen screws (A ) and (B) Adjust front sunroof height by turning screw (E) until sunroof is even or 1.0 mm below roof opening. (Clockwise lowers panel, counter clockwise raises panel).
Note: Adjustment screw (E) must be threaded at least three turns into roof threads for proper support. Tighten screw (A) and (B) to 5.0 +/- 2 N-m. Tighten nut (D) to 5.0 +/- 2 N-m. Recheck front height adjustment.
Guide Plate Mounting Screws:
Height Adjustment, Rear
- loosen guide plate mounting screws (arrows)
- lift sunroof until it is 1.0 mm above sunroof cutout
- tighten screws (arrows)
Screws for Sunroof Fine Adjustment:
- loosen screws for sunroof fine adjustment (arrows)
- apply Loctite
- tighten screws
Support:
- open sunroof until support (5) is accessible
- start nut (arrow) on stud (apply Loctite)
CAUTION
Do not tighten nut until secure or front guide will not move freely.
Tighten Nut:
- place finger between cover and front guide (see illustration)
- tighten nut until pressure is felt against finger
- install cover
- close sunroof
- check height adjustment
- readjust if necessary
- pull headliner forward until clips are fully engaged in sunroof support
- tilt sunroof up at rear and install springs
- test sunroof movement in this order:
^ 5 times up and down
^ 5 times back and forth
- check height adjustment (readjust if necessary)
- road test vehicle and check for wind noise and rattles
Labor Operation
Diag.
Repair Ouality
Check Check
60 05 51 0 Remove and install 20 130 * 25
sunroof repair as per instruction. Includes:
complete removal, checking of components
*Includes road test
For Warranty, use damage code: 60 05 66 00 01