LEMON Manuals: Even more car manuals for everyone
Home >> Lexus >> 2002 >> SC 430 >> Repair and Diagnosis >> Body & Frame >> Sun Roof/T-Top/Convertible Top >> Sliding Roof System >> Roof Panel RH Link Sub-ASSY >> Overhaul

Roof Panel RH Link Sub-ASSY: Overhaul

HINT:

COMPONENTS: See Figure, Figure or Figure.

  1. MOVE ROOF PANEL TO HALF 
  2. REMOVE ROOF SIDE RAIL GARNISH ASSY RH [62430 / 98-89] (See  OVERHAUL  ) 
  3. REMOVE ROOF SIDE RAIL GARNISH ASSY LH [62440 / 98-89] (See  OVERHAUL   ) 
  4. REMOVE SUN ROOF / REMOVABLE ROOF HEADLINING ASSY [63320 / 98-90] (See  OVERHAUL   ) 
  5. REMOVE SLIDING ROOF / REMOVABLE ROOF PANEL SUB-ASSY [63201A / 98-87] (See  OVERHAUL   ) 
  6. REMOVE ROOF SIDE GARNISH INNER RH [62471A / 98-89] (See  OVERHAUL   ) 
  7. REMOVE ROOF SIDE GARNISH INNER LH [62472A / 98-89] (See  OVERHAUL   ) 
  8. REMOVE ROOF HEADLINING ASSY REAR [63320E / 98-90] (See  OVERHAUL   ) 
  9. REMOVE BACK WINDOW FRAME SUB-ASSY UPPER [63105D / 98-87] (See  OVERHAUL   ) 
  10. REMOVE REAR SEAT CUSHION ASSY (See  REAR SEAT  ) 
  11. REMOVE REAR SEAT HEADREST PLATE COVER [71952 / 98-98] (See REAR SEAT  ) 
  12. REMOVE WIND DEFLECTOR BOARD ASSY [63230D / 98-98] (See  REAR SEAT  ) 
  13. REMOVE REAR SEAT HEADREST PLATE [71944A / 98-98] (See  REAR SEAT  ) 
  14. REMOVE REAR SEAT HEADREST ASSY [71940A / 98-98] (See  REAR SEAT  ) 
  15. REMOVE REAR SEAT BACK ASSY (See  REAR SEAT  ) 
  16. REMOVE REAR SEAT BACK BOARD [71881A / 98-98] (See  OVERHAUL  ) 
  17. REMOVE DOOR SCUFF PLATE ASSY RH [67910 / 98-89] (See  OVERHAUL  ) 
  18. REMOVE DOOR SCUFF PLATE ASSY LH [67920 / 98-89] (See  OVERHAUL  ) 
  19. REMOVE QUARTER TRIM PANEL ASSY FRONT RH [62510P / 98-89] (See  OVERHAUL  ) 
  20. REMOVE QUARTER TRIM PANEL ASSY FRONT LH [62520P / 98-89] (See  OVERHAUL  ) 
  21. RAISE PACKAGE TRAY TRIM ASSY (See  OVERHAUL  ) 
  22. REMOVE PACKAGE TRAY TRIM ASSY (See  OVERHAUL  ) 

    HINT:

    Store the right and left shims for the package tray trim ashy separately.

  23. REMOVE REAR FLOOR FINISH PLATE [58387 / 98-91] 
    1. Using a screwdriver, remove the rear floor finish plate

      HINT:

      Tape the screwdriver tip before use.

      Fig 1: Removing Rear Floor Finish Plate
      G01173136Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE SPARE WHEEL COVER ASSY [64770 / 98-91] 
  25. REMOVE LUGGAGE COMPARTMENT FLOOR MAT [64711 / 98-91] 
  26. REMOVE LUGGAGE COMPARTMENT TRIM COVER RH [64712 / 98-91] 
    1. Using a clip remover, remove the 3 clips.
    2. Remove the luggage trim cover RH.
      Fig 2: Removing Luggage Compartment Trim Cover Clips
      G01173137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE LUGGAGE COMPARTMENT TRIM COVER LH [64713 / 98-91] 
  28. REMOVE TOOL BOX COVER [75219C / 98-91] 
  29. REMOVE LUGGAGE HOLD BELT STRIKER ASSY [58460H / 98-91] 
    1. Remove the 2 bolts and luggage hold belt striker ashy.
      Fig 3: Removing Luggage Hold Belt Striker Assembly Bolts
      G01173138Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE LUGGAGE COMPARTMENT TRIM COVER SUB-ASSY REAR [64706B / 98-91] 
    1. Using a clip remover, remove the 4 clips.
    2. Remove the luggage compartment trim cover sub-assy rear.
      Fig 4: Removing Luggage Compartment Trim Cover Sub-Assembly Rear Clips
      G01173139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE TONNEAU COVER STOPPER SUB-ASSY RH [64907C / 98-91] 
    1. Remove the cushion.
    2. Using a screwdriver release the 2 covers.

      HINT:

      Tape the screwdriver tip before use.

    3. Using a torx socket wrench, remove the screw.

      Torx socket (T40): 09042-00020 

    4. Remove the 2 bolts.
    5. Remove the tonneau cover stopper sub-assy RH.
      Fig 5: Remove Tonneau Cover Stopper Sub-Assembly Bolts RH
      G01173140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE TONNEAU COVER STOPPER SUB-ASSY LH [64909B / 98-91] 
    1. Using a screwdriver release the 2 covers.

      HINT:

      Tape the screwdriver tip before use.

    2. Using a torx socket wrench, remove the screw.

      Torx socket (T40): 09042-00020 

    3. Remove the 2 bolts.
    4. Remove the tonneau cover stopper sub-assy LH, then disconnect the connector.
  33. REMOVE TONNEAU COVER ASSY [64910N / 98-91] 
    1. Using a screwdriver, remove the 2 covers.

      HINT:

      Tape the screwdriver tip before use.

    2. Remove the 2 nuts and tonneau cover ashy.
      Fig 6: Removing Tonneau Cover Assembly
      G01173141Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE LUGGAGE COMPARTMENT TRIM COVER INNER LOWER [64723A / 98-91] 
    1. Using a clip remover, remove the 6 clips.
    2. Remove the luggage compartment trim cover inner lower.
      Fig 7: Removing Luggage Compartment Trim Cover Inner Lower
      G01173142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE LUGGAGE COMPARTMENT TRIM COVER FRONT [64717A / 98-91] 
    1. Using a clip remover, remove the 4 clips.
    2. Employ the same manner described above to the other side.
      Fig 8: Removing Luggage Compartment Trim Cover Front
      G01173143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a clip remover, remove the 4 clips.
    4. Remove the luggage compartment trim cover front.
      Fig 9: Removing Luggage Compartment Trim Cover Front
      G01173144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE REAR FLOOR FINISH SIDE PLATE RH [64753B / 98-91] 
    1. Using a screwdriver, release the clamp and remove the rear floor finish side plate RH.

      HINT:

      Tape the screwdriver tip before use.

      Fig 10: Removing Rear Floor Finish Side Plate RH
      G01173145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE REAR FLOOR FINISH SIDE PLATE LH [64754B / 98-91] 
  38. REMOVE LUGGAGE COMPARTMENT LAMP ASSY NO. 1 [81330 /98-119] 
    1. Using a screwdriver, release the claw.

      HINT:

      Tape the screwdriver tip before use.

    2. Remove the luggage compartment lamp ashy No. 1 and disconnect the connector.
      Fig 11: Removing Luggage Compartment Lamp Assembly No. 1
      G01173146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE LUGGAGE COMPARTMENT TRIM COVER SIDE RH [64714D / 98-91] 
    1. Using a clip remover, remove the 4 clips.
    2. Remove the luggage compartment trim cover side RH.
      Fig 12: Removing Luggage Compartment Trim Cover Side RH
      G01173147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE DOOR INSIDE HANDLE BEZEL [69277D / 98-88] 
    1. Using a screwdriver, release the clamp and remove the door inside handle bezel.

      HINT:

      • Tape the screwdriver tip before use.
      • Pressing the parts indicated in the illustration (around the service hole) release the claw fitting.
        Fig 13: Removing Door Inside Handle Bezel
        G01173148Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE LUGGAGE COMPARTMENT TRIM COVER SIDE LH [64715D / 98-91] 
  42. REMOVE ROOF SIDE RAIL GARNISH REAR RH [62451C / 98-89] 
    1. Loosen the nut, then disconnect the cable.
      Fig 14: Loosening Nut, And Disconnecting Cable
      G01173149Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 screws.
    3. Release the claws and remove the roof side garnish rear RH.
      Fig 15: Releasing Claws And Removing Roof Side Garnish Rear RH
      G01173150Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE ROOF PANEL RH LINK SUB-ASSY [63021C / 98-87] 
    1. Disconnect the connector.
    2. Using a torx wrench, remove the 2 screws and nut.

      Torx socket (T40): 09042-00020 

    3. Remove the roof panel RH link sub-assy.

      HINT:

      Store the right and left shims for the roof panel RH link sub-assy separately.

      Fig 16: Removing Roof Panel Link Sub-Assembly RH
      G01173151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE SLIDING ROOF DRIVE GEAR ASSY RH [63240D / 98-87] 
    1. Remove the 3 bolts and sliding roof drive gear ashy RH.
      Fig 17: Removing Sliding Roof Drive Gear Assembly Bolts RH
      G01173152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE SLIDE ROOF LIMIT SWITCH [84742B / 98-129] 
    1. Remove the 2 screws and sliding roof limit switch.
      Fig 18: Removing Slide Roof Limit Switch Screws
      G01173153Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSTALL SLIDE ROOF LIMIT SWITCH [84742B / 98-129] 
    1. Install the slide roof limit switch and 2 screws. 

      HINT:

      Install the limit switch with wire harness to which white tape is attached so that it will be positioned inside the vehicle.

  47. INSTALL SLIDING ROOF DRIVE GEAR ASSY RH [63240D / 98-87] 

    Torque: 19 N.m (194 kgf.cm, 14 ft.lbf) 

  48. TEMPORARY TIGHTEN ROOF PANEL RH LINK SUB-ASSY [63021C / 98-87] 
    1. Temporarily tighten nut and 2 screws and roof panel RH link sub-assy.

      HINT:

      • The shims that has been stored.
      • Insert 3 shims generally, however, the number of shims is changeable depending on the situation.
        Fig 19: Temporarily Tightening Roof Panel RH Link Sub-Assembly Nuts And Screws
        G01173154Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. INSTALL ROOF SIDE RAIL GARNISH REAR RH [62451C / 98-89] 
    1. Install the roof side garnish rear RH.
    2. Connect the cable and tighten the nut.

      Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf) 

      Fig 20: Installing Roof Side Rail Garnish Rear RH
      G01173155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSTALL BACK WINDOW FRAME SUB-ASSY UPPER [63105D / 98-87] (See  OVERHAUL  ) 

    Torque: 40 N.m (408 kgf.cm, 30 ft.lbf) 

  51. INSTALL ROOF HEADLINING ASSY REAR [63320E / 98-90] 
  52. INSTALL ROOF SIDE GARNISH INNER LH [62472A / 98-89] (See  OVERHAUL  ) 
  53. INSTALL ROOF SIDE GARNISH INNER RH [62471A / 98-89] (See  OVERHAUL  ) 
  54. INSTALL SLIDING ROOF / REMOVABLE ROOF PANEL SUB-ASSY [63201A / 98-87] (See  OVERHAUL  ) 

    Torque: 40 N.m (408 kgf.cm, 30 ft.lbf) 

  55. INSTALL REMOVABLE ROOF LOCK SUB-ASSY [63203P / 98-87] (See  OVERHAUL  ) 

    Torque: 6.9 N.m (70 kgf.cm, 61 in.lbf) 

  56. INSTALL SUN ROOF / REMOVABLE ROOF HEADLINING ASSY [63320 / 98-90] (See  OVERHAUL  ) 
  57. INSTALL ROOF SIDE RAIL GARNISH ASSY LH [62440 / 98-89] (See  OVERHAUL  ) 
  58. INSTALL ROOF SIDE RAIL GARNISH ASSY RH [62430 / 98-89] (See  OVERHAUL  ) 
  59. ADJUST ROOF LINE 
    NOTE: In order to prevent the roof from floating up at the rear side when driving at a high speed, adjustment of the roof panel link sub-assy adjusting screw is necessary. Be sure to perform the following adjustment procedure.
    1. Using a torx driver, remove the stopper cushion from the roof panel RH link sub-assy.
      Fig 21: Removing Stopper Cushion From Roof Panel
      G01173156Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a hexagon wrench, loosen the lock screw and adjust the protrusion "a" of the roof panel RH & LH link sub-assy adjusting screw.

      Standard value: "a" = 8 mm (0.31 in.) 

      Fig 22: Identifying Lock Screw & Adjusting Screw
      G01173157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Let the roof manually close of its own weight several times from the half-open position.
      Fig 23: Allowing Roof Close Using Its Own Weight From Half-Open Position
      G01173158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Let the roof close of its own weight from the half-open position and place a SST without locking the roof.

      SST 09802-00010

      HINT:

      • Place the SST without contact with the roof panel.
      • Place the SST in alignment with line "a" between the body panel and quarter window moulding.
    5. Check that the reference dot line "b" on the upper part of the SST aligns with the roof line.
      Fig 24: Identifying Reference Lines
      G01173159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      • When the roof line is not aligned with the SST reference dot line "b" in the longitudinal direction, adjust the roof panel RH & LH link sub-assy forward or backward to align the roof line with the SST reference line.
      • When the roof line is not aligned with the SST reference dot line "b" in the vertical direction, adjust either by turning the adjusting screw or with roof panel RH & LH link sub-assy shims.
      • After adjustment, be sure to repeat checking from step  c.
    6. Using a hexagon wrench, fully tighter the roof panel RH link sub-assy with the two screws.

      Torque: 41 N.m (418 kgf.cm, 30 ft.lbf) 

      Fig 25: Adjustments With Link Sub Assembly
      G01173160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Let the roof close of its own weight from the half-open position.
      Fig 26: Allowing Roof Close Using Its Own Weight From Half-Open Position
      G01173161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Measure the retract amount of the roof lock.
      1. Let the roof close of its own weight from the half-open position and measure the distance (A) between the front header and roof panel at the point where the roof stops without locking.
        Fig 27: Measuring Retract Amount Of Retract (Unlocked)
        G01173162Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        HINT:

        • Measure the retract amount without contact with the roof panel.
        • Mark the point at which the measurement was performed.
      2. From the position in step (h)-(1), lock the roof and measure the distance (B) between the front header and roof panel.

      HINT:

      Measure at the same point as in step (h)-(1).

      C (Retract amount of roof lock) = A - B 

      Fig 28: Measuring Retract Amount Of Retract (Locked)
      G01173163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 29: Identifying Retract Measurements
      G01173164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Adjust removable roof auxiliary catch ashy.
      1. Using a torx socket, adjust the removable roof auxiliary catch ashy to make C (retract amount of the roof lock) satisfy the standard.

      Torx socket (T30): 09042-00010 

      Standard value: C = 3.5 +/- 1 mm (0.14 +/- 0.04 in.) 

      HINT:

      If C (retract amount of the roof lock) is outside the standard, adjust by turning the adjusting screw.

      Fig 30: Adjusting Removable Roof Auxiliary Catch Assembly
      G01173165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Place the SST and check that reference line "c" at the lower part of the SST aligns approximately with the roof line.

      SST 09802-00010

      Fig 31: Identifying Reference Lines
      G01173166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Depending on the vehicle condition, the roof line may not align with the SST reference line "c".

    11. Check the installation condition.

      HINT:

      If necessary, repeat the adjustment from step  b.

      Fig 32: Measuring Gaps
      G01173167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. INSTALL PACKAGE TRAY TRIM ASSY (See  OVERHAUL  ) 
  61. INSTALL QUARTER TRIM PANEL ASSY FRONT LH [62520P / 98-89] (See  OVERHAUL  ) 
  62. INSTALL QUARTER TRIM PANEL ASSY FRONT RH [62510P / 98-89] (See  OVERHAUL  ) 
  63. INSTALL DOOR SCUFF PLATE ASSY LH [67920 / 98-89] (See  OVERHAUL  ) 
  64. INSTALL DOOR SCUFF PLATE ASSY RH [67910 / 98-89] (See  OVERHAUL  ) 
  65. INSTALL REAR SEAT BACK BOARD [71881A / 98-98] (See  OVERHAUL  ) 
  66. INSTALL REAR SEAT BACK ASSY (See  REAR SEAT  ) 

    Torque: 

    Bolt: 18 N.m (184 kgf.cm, 13 ft.lbf) 

    Nut: 7.0 N.m (71 kgf.cm, 63 in.lbf) 

  67. INSTALL LUGGAGE COMPARTMENT TRIM COVER SIDE LH [64715D / 98-91] 
  68. INSTALL DOOR INSIDE HANDLE BEZEL [69277D / 98-88] 
  69. INSTALL LUGGAGE COMPARTMENT TRIM COVER SIDE RH [64714D / 98-91] 
  70. INSTALL LUGGAGE COMPARTMENT LAMP ASSY NO. 1 [81330 / 98-119] 
  71. INSTALL REAR FLOOR FINISH SIDE PLATE LH [64754B / 98-91] 
  72. INSTALL REAR FLOOR FINISH SIDE PLATE RH [64753B / 98-91] 
  73. INSTALL LUGGAGE COMPARTMENT TRIM COVER FRONT [64717A / 98-91] 
  74. INSTALL LUGGAGE COMPARTMENT TRIM COVER INNER LOWER [64723A / 98-91] 
  75. INSTALL TONNEAU COVER ASSY [64910N / 98-91] 
  76. INSTALL TONNEAU COVER STOPPER SUB-ASSY LH [64909B / 98-91] 
  77. INSTALL TONNEAU COVER STOPPER SUB-ASSY RH [64907C / 98-91] 
  78. INSTALL LUGGAGE COMPARTMENT TRIM COVER SUB-ASSY REAR [64706B / 98-91] 
  79. INSTALL LUGGAGE HOLD BELT STRIKER ASSY [58460F / 98-91] 
  80. INSTALL TOOL BOX COVER [75219C / 98-91] 
  81. INSTALL LUGGAGE COMPARTMENT TRIM COVER LH [64713 / 98-91] 
  82. INSTALL LUGGAGE COMPARTMENT TRIM COVER RH [64712 / 98-91] 
  83. INSTALL LUGGAGE COMPARTMENT FLOOR MAT [64711 / 98-91] 
  84. INSTALL SPARE WHEEL COVER ASSY [64770 / 98-91] 
  85. INSTALL REAR FLOOR FINISH PLATE [58387 / 98-91] 
scientia non olet · About LEMON Manuals