Body - Sunroof Assembly Replacement procedure

Group
60 - BODY

Number
97-60-001

Date
01-1997

Model
Tiburon 1997

Subject
TIBURON SUNROOF ASSEMBLY REPLACEMENT PROCEDURE

DESCRIPTION:

This bulletin provides a procedure for sunroof assembly removal and installation on the 1997 Tiburon.

REMOVAL PROCEDURE:





1. Open the rear hatch and remove the luggage area cover.

2. Remove the five phillips head screws (per side) from the shelf side covering trim.





3. Fold the rear seat back forward and remove two (per side) 12 mm hex head bolts in order to remove the seat backs (13-19 lb.ft).

4. Remove the two 12 mm hex head bolts holding the rear seat lower cushion in place (13-19 lb.ft). Pull up on the front edge to release the clips, remove the cushion.





5. Remove the driver's side hatch gas strut by prying off the plastic cover with a plastic trim tool. Remove the 10 mm acorn nut/washer and support the hatch by positioning the loose end of the gas strut in the rear suspension strut tower area.





6. Remove the rear seat belt upper anchor by first removing the plastic center cap, then remove the 14 mm bolt (29-40 lb.ft).





7. Using a plastic trim tool, pry off the left rear speaker grille. (Pry the top of the grille. The lower end of the grille has hooks.) Remove the left rear speaker grille.

8. Remove the seat back hinge by removing two 10 mm bolts.





9. Remove four (4) phillips head screws from the quarter trim panel. Remove the trim panel.

10. Using a plastic trim removal tool, carefully pry off the plastic cover and remove the upper anchor bolt for the front seat belt.





NOTE
When reassembling the vehicle, torque all seat belt 14 mm belts to 40 lb.ft.





11. Remove the upper quarter inner trim panel (there are two screws for the front seat belt guide, one for the coat hanger and two at the bottom of the panel).

12. Remove the rear header trim panel by prying off the metal spring clips.





13. Remove the A-pillar trim panel (contains only metal spring clips). Start from the B-pillar area and work your way forward.





NOTE
The very lower end of the A-pillar area of the trim panel has a hook designed on it. Be sure to insert this hook first in the reinstallation process.

14. Remove the sunroof inner trim panel by pulling and releasing the plastic clips holding the panel onto the metal sunroof panel.

NOTE
Make sure that the pin at the rear of the sunroof is located first when reinstalling.





15. Remove the felt trim around the sunroof opening.

NOTE
When re-installing, make sure that the 'joint' goes in the back.

16. Remove the sunglass holder/map light/sun roof switch assembly (four screws). Two of the screws are accessed by carefully prying off the map light lenses.





NOTE
When re-installing this unit, make sure to align the sunroof front bracket with the holes in the front header structure to allow attachment of the unit. Tuck the large wiring connector under the bracket.

17. Remove the sunvisors/clips (three screws per side). Remove the passenger side grab handle (two 10 mm bolts) by first carefully prying off the bolt trim cover.

18. Remove the headliner as follows:

1. Carefully bend back the metal clips around the sunroof opening (be careful not to break the clips).





2. Pull loose the two plastic clips (Christmas Tree) at the front and the two at the back.

19. Remove the passenger side grab handle bracket (two 10 mm bolts).





NOTE
When re-installing, make sure that the washer fluid hose is behind this bracket as well as the sunroof mounting brackets.

20. Disconnect the four drain hoses from the sunroof assembly.

21. Remove the sunroof unit by removing twelve (12) 10 mm bolts and loosen the four sunroof height adjusting nuts.

INSTALLATION PROCEDURE:

1. Install the new sunroof unit by loosely installing the twelve (12) 10 mm bolts and the four adjusting nuts.

2. Route the sunroof main wiring harness through the center hole of the front bracket.

3. Adjust the sunroof by tightening the sunroof adjusting nuts until the sunroof sheet metal panel and the roof panel are completely flush (only the panel needs to be flush, not the rubber seal).

4. Tighten the twelve (12) mounting bolts and check the flushness of the sunroof again. If not flush, repeat the above steps until the sunroof is flush at all corners.

NOTE
Adjusting the four nuts so that the sunroof is slightly underflush may result in a completely flush condition when the twelve nuts are tightened.

5. Re-install the interior trim in reverse order. Make sure all bolts, nuts, clips, seals and plugs are installed correctly and to the proper torque specified in this bulletin. Check the function of all items affected in the repair, especially the sunroof unit.

NOTE
The seat belt anchor belts must be hand torqued to 40 lb.ft.

6. Clean the interior of any contamination caused by the repair procedure.





WARRANTY INFORMATION