SLIDING ROOF HOUSING SUB-ASSY (From July, 2003): Replacement

WARNING: This page is about a different car, the 2004 Lexus ES 330. However, it is still accessible from the selected car via links, so may be relevant.

HINT:

Installation is in the reverse order of removal. However, when there is a special point concerning installation, it is indicated.
Use the same procedures on the RH side as on the LH side.
A bolt without a torque specification is shown in the standard bolt chart (see SPECIFIED TORQUE FOR STANDARD BOLTS ).

REMOVE ROOF HEADLINING ASSY
REMOVE SLIDING ROOF GUIDE RAIL COVER RH
1. Using a screwdriver, remove the sliding roof guide rail cover.
  HINT:
  
  Tape up the screwdriver tip before use.
REMOVE SLIDING ROOF GUIDE RAIL COVER LH
1. Use the same manner described above to the other side.
  
  Fig 1: Removing Sliding Roof Guide Rail Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SLIDING ROOF SIDE GARNISH RH
1. Using a screwdriver, remove the sliding roof side garnish.
  HINT:
  
  Tape up the screwdriver tip before use.
REMOVE SLIDING ROOF SIDE GARNISH LH
1. Use the same manner described above to the other side.
  
  Fig 2: Removing Sliding Roof Side Garnish
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SLIDING ROOF GLASS SUB-ASSY
1. Using a Torx wrench (T25), remove the 4 Torx screws and sliding roof glass.
REMOVE SLIDING ROOF WEATHERSTRIP
REMOVE SLIDING ROOF DRIVE GEAR SUB-ASSY
1. Remove the 2 bolts.
2. Disconnect the clamp and then remove the sliding roof drive gear.
REMOVE SLIDING ROOF HOUSING SUB-ASSY
1. Disconnect the 4 drain hoses from the housing.
2. Remove the 6 nuts and 8 bolts, then remove the housing as shown in the illustration.
  
  Fig 3: Removing Sliding Roof Housing Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SUNSHADE TRIM SUB-ASSY
1. Remove the screw and stopper.
2. Use the same manner described above to the other side.
3. Remove the sunshade trim.
ADJUST FULLY CLOSED POSITION
1. By using a screwdriver whose tip is taped around, make the drive cable of the sliding roof slide align the match-mark.
  
  Fig 4: Aligning Match-Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SLIDING ROOF HOUSING SUB-ASSY
1. Install the housing with the 6 nuts and 8 bolts.
  Torque:
  
  Bolt: 5.5 N.m (56 kgf.cm, 49 in.lbf)
  
  Nut: 5.5 N.m (56 kgf.cm, 49 in.lbf)
2. Install the 4 drain hoses to the housing.
  
  Fig 5: Installing Sliding Roof Housing Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SLIDING ROOF GLASS SUB-ASSY
1. Check for a difference in level between the sliding roof (weatherstrip) and roof panel.
  Corner of rear side:
  
  0 +/- 1.5 mm (0 +/- 0.059 in.)
  
  Fig 6: Checking Difference In Level Between Sliding Roof (Weatherstrip) And Roof Panel
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check for a difference in level between the sliding roof (glass) and roof panel.
  NOTE: The clearance should be thoroughly even.
  
  Fig 7: Checking Difference In Level Between Sliding Roof (Glass) And Roof Panel
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Adjust the roof panel.
  1. Using a torque driver T25, loosen a screw to adjust the sliding roof panel position.
    When the adjustment has done, tighten the screw there.
INSTALL SLIDING ROOF DRIVE GEAR SUB-ASSY
1. Install the sliding roof drive gear with the 2 bolts.
  Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
INSTALL SLIDING ROOF GLASS SUB-ASSY
1. Using a Torx wrench (T25), install the sliding roof glass with the 4 Torx screws.
  Torque: 4.0 N.m (41 kgf.cm, 36 in.lbf)
RESET SLIDING ROOF POSITION
1. Reset the zero point for sliding roof by pushing and holding the switch on the "TILT UP" side until the sliding roof tilts all the way up and down a little automatically.
  NOTE: When the battery negative (-) terminal is disconnected due to the repair, the sliding roof position memory is erased. After reconnecting the battery negative (-) terminal, make sure to reset the zero point.
  
  If the reset is not performed, the sliding roof automatic operation will not function.
INSPECT FOR LEAKS
1. Adjusting the sliding roof, check there is no water leak.
2. In case of water leak, readjust the sliding roof.