Sunroof - Retrofitting Steel with Glass
Date: July 1992Group: 77
Number: 280
SUBJECT:
MODEL 140
RETROFIT OF GLASS SLIDING/POP-UP ROOF PANEL
Model 140 vehicles originally equipped with a steel sliding/pop-up roof panel can now be retrofitted with the glass version.
The procedure for replacing the steel panel with the glass version is described in the attached Work Instructions No. 280.
Owners should be reminded that the retrofit installation of the glass panel is not a warranty item and is at the customer's expense.
Work Instructions
The following Work Instructions describes the retrofit installation of a glass sliding/pop-up roof panel in model 140 vehicles originally equipped with the steel sliding/pop-up roof.
The procedures for removing the steel sliding/pop-up roof panel and subsequent installation of the glass panel are described in the Service Microfiche System, group 77. An outline of the retrofit installation is provided along with additional information where necessary.
Owners should be reminded that the retrofit installation of the glass panel is not a warranty item and is at the customer's expense.
Procedure
1. Verify that all replacement parts and the required special tools are available (see Special Tools and Parts Information at end of article).
2. Remove the headliner of the steel sliding/pop-up roof and discard (see SMS, Job No. 77-050).
3. Remove steel sliding/pop-up sliding/roof panel (see SMS, Job No. 77-100).
4. Removing existing tilt bracket assembly and replace with version designed for glass sliding/pop-up roof (see SMS, Job No. 77-170).
5. Install glass roof panel (see SMS, Job No. 77-100). Two additional nuts are required (see Parts Information table).
6. Adjust the glass sliding/pop-up roof panel using clamping device, special 140 589 00 37 00 (see SMS, Job No. 77-110). If sliding roof does not fully pop up or fully retract, check motor sychronization as described in SMS, Job No. 77-140 adjustment procedure. An alignment tool, special tool 904 589 00 27 00, should be used for centering the motor drive.
7. Install new side trim ("bellows") pieces. Engage trim piece at front of roof panel onto tilt bracket assembly as shown in Figure 1.
Note:
For reasons of clarity, the photographs in this Work Instructions depict installation of the trim piece with the roof panel removed from the vehicle.
8. Slide rear of trim piece into clip on tilt bracket assembly until fully engaged (Figures 2 - 3).
9. Insert top of rubber trim ("bellows") into channel in roof panel (Figure 4).
10. Insert tab at rear of trim piece into the hole provided for it at the rear corner of the roof panel (Figure 5).
11. Install cover trim at front of roof panel.
12. Insert new headliner panel for glass sliding/pop-up roof panel. The new headliner panel slides fore/aft and, unlike the version for the steel roof panel, is not fastened with clips.
13. Verify proper operation of the glass sliding/pop-up roof.
Special Tools
Parts Information
Time Allowance Information
Operation:
Glass sliding/pop-up roof panel, retrofit installation.
Recommended Labor Time: 3.5 hrs.
Note:
The retrofit installation of the glass sliding/pop-up roof panel is at the customer's expense.