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Section 443 (Sliding Roof): Replacement

WARNING: This page is about a different car, the 2003 Toyota 4Runner. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:

The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated.

  1. REMOVE ROOF HEADLINING ASSY (See  REMOVING ROOF HEADLINING COMPONENTS  ) 
  2. REMOVE SLIDING ROOF GUIDE RAIL COVER LH 
    NOTE:

    Tape the screwdriver tip before use.

    Using a screwdriver, pry out the rail cover.

  3. REMOVE SLIDING ROOF GUIDE RAIL COVER RH 
    NOTE:

    Use the same procedures described above for the LH side.

  4. REMOVE SLIDING ROOF SIDE GARNISH LH 
    NOTE: Tape the screwdriver tip before use.

    Using a screwdriver, pry out the garnish.

  5. REMOVE SLIDING ROOF SIDE GARNISH RH 
    NOTE:

    Use the same procedures described above for the LH side.

  6. REMOVE SLIDING ROOF GLASS SUB-ASSY 
    1. Using a torx wrench (T25), remove the 4 screws.
      Fig 1: Identifying Screw
      G02814170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pull the glass upward to remove it.
  7. REMOVE SLIDING ROOF HOUSING SUB-ASSY 
    1. Disconnect the 4 drain hoses from the housing.
    2. Remove the 8 bolts and 4 brackets.
      Fig 2: Removing 8 Bolts And 4 Brackets
      G02814171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 6 nuts and housing sub-assy.
  8. REMOVE SLIDING ROOF DRIVE GEAR SUB-ASSY 
    1. Disconnect the connector.
    2. Remove the 2 bolts and drive gear sub-assy.
  9. REMOVE SLIDING ROOF SUNSHADE STOPPER 
    NOTE:

    Tape the screwdriver tip before use.

    Using a screwdriver, remove the sliding roof sunshade stopper.

  10. REMOVE SUNSHADE TRIM SUB-ASSY 
  11. REMOVE SUNSHADE TRIM KNOB 

    Remove the 2 screws and trim knob.

  12. REMOVE ROOF DRIP CHANNEL REAR 

    Slide the drip channel backward and remove it.

  13. REMOVE SLIDING ROOF DRIVE CABLE SUB-ASSY 
    NOTE:

    Tape the screwdriver tip before use.

    Using a screwdriver, slide the drive cable backward and remove it.

  14. REMOVE ROOF WIND DEFLECTOR PANEL SUB-ASSY 
  15. INSTALL ROOF WIND DEFLECTOR PANEL SUB-ASSY 
  16. INSTALL SLIDING ROOF DRIVE CABLE SUB-ASSY 
  17. ADJUST FULLY CLOSED POSITION 
    NOTE:

    Tape the screwdriver tip before use.

    Using a screwdriver, slide the drive cable of the sliding roof to align the matchmarks.

    Fig 3: Aligning Matchmarks Of Slide Drive Cable Of Sliding Roof
    G02814172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL ROOF DRIP CHANNEL REAR 
  19. INSTALL SUNSHADE TRIM KNOB 

    Install the trim knob with the 2 screws.

  20. INSTALL SUNSHADE TRIM SUB-ASSY 
  21. INSTALL SLIDING ROOF SUNSHADE STOPPER 
  22. INSTALL SLIDING ROOF HOUSING SUB-ASSY 
    1. Install the housing sub-assy with the 6 nuts.
    2. Install the 4 brackets with the 8 bolts.
      Fig 4: Installing 4 Brackets With 8 Bolts
      G02814173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the 4 drain hoses.
  23. INSTALL SLIDING ROOF DRIVE GEAR SUB-ASSY 
    1. Install the drive gear with the 2 bolts.

      Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf) 

    2. Connect the sliding roof motor switch connector.
  24. ADJUST SLIDING ROOF GLASS SUB-ASSY 
    1. Check the difference in level between the sliding roof (weatherstrip) and roof panel.
      Fig 5: Checking Difference In Level Between Sliding Roof (Weatherstrip) And Roof Panel
      G02814174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Dimension (Circumference): 

      0 +/- 2.0 mm (0 +/- 0.079 in.) 

      2. NOTE: The clearance should be even all around.
      Fig 6: Checking Difference In Level Between Sliding Roof (Glass) And Roof Panel Front End And Rear End
      G02814175Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check the difference in level between the sliding roof (glass) and roof panel front end and rear end.
  25. INSTALL SLIDING ROOF GLASS SUB-ASSY 
    1. Using a torx wrench T25, loosen a screw to adjust the sliding roof panel position. When the adjustment has been done, tighten the screw there.

      Torque: 4.0 N.m (40 kgf.cm, 35 in..lbf) 

    2. Reset the sliding roof drive gear (See RESET )
    3. Check the sliding roof operation function (See ON-VEHICLE INSPECTION )
    NOTE:

    If the jam protection function is not activated, reset the sliding roof drive gear again.

  26. CHECK FOR WATER LEAKS 

    Adjusting the sliding roof, check that there is no water leak.

    If a leak is found, readjust the sliding roof.

  27. INSTALL ROOF HEADLINING ASSY (See  ROOF HEADLINING REPLACEMENT  ) 
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