Sliding Roof / Removable Roof Panel Sub-ASSY: Overhaul

HINT:

COMPONENTS: See Figure.

1. MOVE ROOF PANEL TO HALF 
   1. Referring to the manual operation procedures, half-open the roof.
      Fig 1: Half-Opening Roof

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. REMOVE ROOF SIDE RAIL GARNISH ASSY RH [62430 / 98-89] 
   1. Using a screwdriver, disengage the 4 clips and remove the roof side rail garnish RH.

      HINT:

      Tape the screwdriver tip before use.

      Fig 2: Disengaging Clips And Removing Roof Side Rail Garnish RH

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. REMOVE ROOF SIDE RAIL GARNISH ASSY LH [62440 / 98-89] 
4. REMOVE SUN ROOF / REMOVABLE ROOF HEADLINING ASSY [63320 / 98-90] 
   1. Remove the 5 clips.
   2. Disengage the 3 clips, then remove the sun roof / removable roof headlining.
      Fig 3: Disengaging Clips, Removing Sun Roof/Removable Roof Headlining

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. REMOVE SLIDING ROOF / REMOVABLE ROOF PANEL SUB-ASSY [63201A / 98-87] 
   1. Disconnect the limit switch connector and sliding roof drive gear connector.
   2. Using a clip remover or screwdriver, disengage the v harness clamps.

      HINT:

      Tape the screwdriver tip before use.

      Fig 4: Disconnecting Limit Switch Connector And Sliding Roof Drive Gear Connector

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Using a torx socket, remove the 8 screws.

      Torx socket (T40): 09042-00020 

   4. Remove the sliding roof / removable roof panel sub-assy.
      Fig 5: Using Torx Socket, Removing Roof Panel Assembly Screws

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. REMOVE ROOF SIDE RAIL WEATHERSTRIP RH [62381G / 98-87] 
   1. Using a clip remover, remove the 2 screws and 2 clips.
   2. Remove the roof side rail weatherstrip RH.
      Fig 6: Removing Roof Side Rail Weatherstrip Screws

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. REMOVE ROOF SIDE RAIL WEATHERSTRIP LH [62382F / 98-87] 
8. REMOVE ROOF SIDE RAIL WEATHERSTRIP RETAINER CENTER RH [62363B / 98-106] 
   1. Remove the 6 screws and center roof side rail weatherstrip retainer RH.
      Fig 7: Removing Roof Side Rail Weatherstrip Retainer Center RH Screws

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. REMOVE ROOF SIDE RAIL WEATHERSTRIP RETAINER CENTER LH [62364B / 98-106] 
10. REMOVE REMOVABLE ROOF LOCK SUB-ASSY [63203P / 98-87] 
    1. Using a torx socket, remove the 9 screws.

       Torx socket (T40): 09042-00020 

    2. Remove the removable roof lock sub-assy.
       Fig 8: Removing Removable Roof Lock Sub-Assembly Screws

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. REMOVE SLIDING ROOF DRIVE GEAR SUB-ASSY [63206G / 98-87] 
    1. Remove the 2 bolts.
    2. Remove the sliding roof drive gear from the removal roof lock sub-assy.
       Fig 9: Removing Sliding Roof Drive Gear Sub-Assembly Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. REMOVE SLIDE ROOF LIMIT SWITCH [84742 / 98-129] 
    1. Remove the screw.
    2. Remove the slide roof limit switch from the removable roof lock sub-assy.
       Fig 10: Removing Sliding Roof Limit Switch Screw

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. INSTALL SLIDE ROOF LIMIT SWITCH [84742 / 98-129] 
14. INSTALL SLIDING ROOF DRIVE GEAR SUB-ASSY [63206G / 98-87] 

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

15. INSTALL ROOF SIDE RAIL WEATHERSTRIP RETAINER CENTER LH [62364B / 98-106] 
16. INSTALL ROOF SIDE RAIL WEATHERSTRIP RETAINER CENTER RH [62363B / 98-106] 
17. INSTALL ROOF SIDE RAIL WEATHERSTRIP LH [62382F / 98-87] 
18. INSTALL ROOF SIDE RAIL WEATHERSTRIP RH [62381G / 98-87] 
19. INSTALL SLIDING ROOF / REMOVABLE ROOF PANEL SUB-ASSY [63201A / 98-87] 

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

20. INSTALL REMOVABLE ROOF LOCK SUB-ASSY [63203P / 98-87] 
    1. Temporary tighten the 9 screws to install the removable roof lock sub-assy.
    2. Tighten 6 screws of lock side.

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

       Fig 11: Tightening Roof Lock Sub-Assembly Screws

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Fully open the roof.

       HINT:

       Check that the guide pin on the edge of the roof panel is aligned with the catch on the pillar.

    4. Let the switch of the roof to the lock position.
       1. Insert the tip of the wrench.
       2. Turn it counterclockwise, viewing from the bottom.
       NOTE: After the rotation is stopped, do not apply excessive force to the drive gear shaft.
       Fig 12: Aligning Guide Pin On Roof Panel With Catch On Pillar

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       HINT:

       Approx. one full rotation makes it unlock.

    5. Tighten the rest of screws.

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

    6. Release the lock to return it to half-open condition.
21. INSTALL SUN ROOF / REMOVABLE ROOF HEADLINING ASSY [63320 / 98-90] 
22. INSTALL ROOF SIDE RAIL GARNISH ASSY LH [62440 / 98-89] 
23. INSTALL ROOF SIDE RAIL GARNISH ASSY RH [62430 / 98-89]