New Guide Rail Kit Installation

1. Ensure both yellow timing pegs are in place before assembly.

2. Check cables for kinks.

CAUTION:
DO NOT REMOVE YELLOW TIMING PEGS. Check that the yellow timing pegs are not pushed through the guide rails too far. They may impede location of the guide rail assembly when fitting.

3. Carefully feed the cable of each new guide rail assembly into the guide tube assembly.

4. Verify that the cable end of the guide rail assembly is fully located into the guide tube end, and that the holes in the guide rail line up with the holes in the upper frame before refitting the guide rail screws.

5. Install eight guide rail screws and torque to 2.5 Nm (22 lbf. in.).

6. Locate sunroof glass in upper frame, complete with cap nuts and gasket, and loosely fit four retaining screws.





7. Turn sunroof assembly over and place two 6.5 mm (1/4 inch) spacers between front edge of the glass and the upper frame assembly, approximately 230 mm (9 inches) from either side of the centerline of the glass (Figure 5 positions A and B).

8. With glass correctly positioned tighten glass screws to 3.0 to 3.5 Nm (27 to 31 lbf. in.).

9. Check glass clearance with 6.5 mm (1/4 inch) spacers at positions A and B (Figure 5) after tightening screws.

10. Obtain four felt pads from guide rail kit.

11. Thoroughly clean the flat area inboard of the fastener locations where the pads are to be applied.





12. Remove backing from pad and press firmly into place (Figure 6).

13. Install sunroof assembly as follows:

^ Position upper frame assembly into roof aperture.

* ^ Position latest configuration clamping/lower frame assembly (STC1686) and reconnect drain tubes. *

^ Loosely fit 14 screws and center the upper frame and clamping/lower frame assemblies.





^ Before starting the tightening sequence, ensure clamping/lower frame is located on the front edge and engages the rear locating pin illustrated as position 15 in Figure 7.

^ Tighten screws to 2.0 to 3.0 Nm (18 to 27 lbf. in.) in sequence shown in Figure 7.