Body - Moonroof Groaning/Grinding Noise

NVH
NV004-05

Title:
MOON ROOF
GRINDING/GROANING NOISE

Models:
'04 Solara

April 11, 2005

Introduction

Some customers may experience a grinding/groaning noise from the moon roof (sliding roof) when tilting or opening the glass assembly. The drive cable sub-assembly has been modified to improve this condition.

Applicable Vehicles

^ 2004 model year Solara vehicles produced BEFORE the Production Change Effective VINs shown below.





Production Change Information





Parts Information





Warranty Information

Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.

* Warranty application is limited to correction of a problem based upon a customer's specific complaint.

Repair Procedure

Replace Moon Roof Drive Cables.

NOTE:
Refer to the Technical Information System (TIS): 2004 model year Solara Repair Manual: Exterior/Interior Trim: Roof Headlining Assembly: Replacement (Solara).

1. Disconnect the battery.

2. Remove the roof headlining assembly.





3. Remove the RH/LH sliding roof side garnishes. Disengage the claw (A) and 4 claws (B).

4. Remove the sliding roof glass sub-assembly using a torx driver (T25). Remove the 4 screws and roof glass.





5. Remove the sliding roof gear sub-assembly.

A. Remove the nut.

B. Disengage the claw and remove the bracket.

C. Remove the 2 bolts and drive gear.

6. Disconnect the sliding roof drain hoses.





7. Remove the sliding roof housing sub-assembly. Remove the 4 bolts, 7 nuts, and sliding roof housing.

8. Remove the sunshade trim sub-assembly.

9. Remove the sliding roof drip channel (rear).

10. Remove sliding roof drive cable sub-assembly.





A. Remove the 2 screws and 2 stoppers for both the RH and LH track assemblies.





B. Slide both the RH and LH drive cables backward and remove them from the housing.





11. Install the new sliding roof drive cable LH using a taped screwdriver. Install the drive cable by sliding it forward.

12. Install the new sliding roof drive cable RH using a taped screwdriver. Install the drive cable by sliding it forward.





13. Install the roof drip channel (rear) as shown in the illustration.





14. Adjust fully closed position by moving the sliding roof drive cable to align the matchmarks.

15. Install the sliding roof gear sub-assembly (1 nut and 2 bolts).

Torque: 5.5 N.m (55 kgf.cm, 49 in.lbf)

16. Install the sliding roof housing sub-assembly using the 7 nuts and 4 bolts.

Torque: 5.5 N.m (55 kgf.cm, 49 in.lbf)

17. Install the sliding roof glass sub-assembly using a torx wrench (T25). Tighten the 4 screws.

Torque: 4.5 N.m (45 kgf.cm, 40 in.lbf)





18. Adjust the sliding roof glass sub-assembly. Check for clearance between the roof glass and roof panel. Using a torx wrench (T25), loosen the 4 screws and adjust the sliding roof panel position.

Difference: 0+1-mm (0+1- 0.055 in.)


NOTE:

The clearance between the roof glass and roof panel should be even around the perimeter of the glass.

19. Check for water leaks and adjust the moon roof glass assembly as necessary.

20. Reinstall the headliner.

21. Initialize the sliding roof motor. If the battery was disconnected, refer to TSB No. PDOO6-03, "Pre-Delivery Service (PDS) Information For Solara,"for additional initialization procedures.





A. Turn ignition switch to the "ON" position.

B. Push and hold the moon roof switch to the "TILT UP" side until the moon roof tilts all the way up and then tilts down slightly (approximately 10 mm at rear of glass).

C. Check for proper operation of the "One-touch slide open and close" and "One-touch tilt up and down" functions by pushing the switch briefly to the "SLIDE OPEN" and "TILT UP" positions.

NOTE:
The jam protection function becomes effective through the above initialization procedure.