Hyundai Tucson: Exterior / Panoramaroof Repair procedures

Hyundai Tucson (LM) 2010-2015 Service Manual / Body (Interior and Exterior) / Exterior / Panoramaroof Repair procedures

Replacement
Glass Replacement
1.
Open the glass.
2.
Loosen the mounting screw (A).

3.
After loosening the mounting screws, then remove the glass (A).
   
•
Do not damage the screw.

4.
Install in the reverse order of removal.
Motor Replacement
1.
Remove the roof trim.
(Refer to Interior - "Roof Trim")
2.
Disconnect the connector (B).
3.
Remove the panoramaroof motor after removing screws from the motor (A).

4.
Install in the reverse order of removal.
   
•
Make sure to initialize the motor.
Wind Deflector Replacement
1.
Open the glass fully.
2.
Using a star wrench, the wind deflector (A) loosening the mounting screw.
   
•
Do not damage the screw.

3.
After loosening the mounting screws, then remove the wind deflector (A).

4.
Install in the reverse order of removal.
Roll Blind Replacement
Removal
1.
Remove the glass.
2.
Remove the mechanism rail assembly loosening the mounting screw, and then remove the mechanism rail assembly (A).
   
•
Do not damage the screw.

3.
Cut the tension wire (A) to prevent the injury.

4.
After loosening the roll blind mounting screws and removing the rivet, remove the roll blind (A).
   
•
Do not damage the screw.

Installation
1.
Installation is the roll blind (A).
   
•
Insert the part of fabric both ends to guide.

2.
Install the wire (A) in arrow direction.

3.
Install the wire (B) in arrow direction.
   
•
Insert the wire into the cover completely when installing.

4.
Pull the wire (A) as below picture.
5.
Lay down the wire (A) slowly after removing the clip (B).

   
•
Satisfy the coherence condition of roll blind is 6.9~25.5 N.m ( 0.7~2.6 kgf.m, 5.1~18.8 lb-ft )
Front Fixed Glass Replacement
Removal
1.
Using a screwdriver or remover, remove the roof rack cover (A).
2.
After loosening the mounting nuts, then remove the roof rack (B).
3.
Using a screwdriver or remover, remove the molding (C).

4.
Disconnect front fixed glass weatherstrip (A).
   
•
Replace any damage front fixed glass weatherstrip.

5.
Cut off the sealant on the side (A-A) while pulling a wire (B) front rixed glass.
   
•
Put on gloves to protect your hands.
•
Heat may occur when working on the wires. Be careful not to burn your hands.
•
Be careful not to disconnect the wire.
   
•
When using a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts to prevent damage.
•
Take care not to scratch the body surface.
   
•
Two or more people should work on the wires.

6.
Open the space between chassis and front fixed glass using flathead screwdriver, and then cut the sealant (B) of edge using a cutter knife (A).

7.
Remove the front fixed glass (A).

Installation
   
•
Do not reuse the fixed glass.
1.
With a knife, scrape the old adhesive smooth to a thickness of about 2mm (0.08 in.) on the bonding surface around the entire panoramaroof opening flange :
A.
Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
B.
Remove the rubber dam and fasteners from the body.
C.
Mask off surrounding surfaces before painting.

2.
With a sponge, apply a light coat of body primer to the original adhesive remaining around the windshield opening flange. Let the body primer dry for at least 10 minutes :
A.
Do not apply glass primer to the body, and be careful not to mixup glass and body primer sponges.
B.
Never touch the primed surfaces with your hands.
C.
Mask off the dashboard before painting the flange.

3.
Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Put the cartridge in a caulking gun, and run a bead of sealant (B) around the edge of the panoramaroof frame as shown. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner.

4.
Insert the SST (09816-2S100) (B) between the fixed glass and each panel side to install the fixed glass (A) as shown below picture.

5.
Check the Clearance and gap for each side after installing the panoramaroof.
 
Section
Gap
Clearance
Front edge
A-A
5mm
(0.1969 in.)
0mm
Rear edge
B-B
7mm
(0.2756 in.)
1.2mm
(0.0472 in.) 
Side edge
C-C
0mm 
0mm

6.
Install the roof molding (C).
7.
Install the roof rack (B) and roof rack cover (A).

Panoramaroof Assembly Replacement
Removal
   
•
In order to remove the panorama sunroof assembly, use the tools shown in the following figure:
[Tooling Diagram]

Square wire
Insert-type wire grip
[Tooling Assembly Diagram]
•
Insert and affix square wire into the insert hole of the wire grip .

1.
Remove the following items :
A.
Front seat
(Refer to Seat & Power Seat - "Fron Seat")
B.
Rear seat
(Refer to Seat & Power Seat - "Rear Seat")
C.
Interior trim
(Refer to Interior - "Interior Trim")
D.
Roof trim
(Refer to Interior - "Roof Trim")
E.
Roof rack & Roof molding
(Refer to Exterior - "Body Side Moldings")
F.
Front fixed glass
   
•
To protect the interior, cover the interior before starting removing the panoramaroof.
2.
Remove the panoramaroof panel mounting bracket (A) loosening the mounting bolts.
Tightening torque :
19.6 ~ 29.4 N.m (2.0 ~ 3.0 kgf.m, 14.5 ~ 21.7 lb-ft )

3.
Remove the panoramaroof mounting nuts (A).
Tightening torque :
19.6 ~ 29.4 N.m (2.0 ~ 3.0 kgf.m, 14.5 ~ 21.7 lb-ft )

4.
Disconnect the ground wire (A) by removing the bolt.
Tightening torque :
10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 lb-ft )

5.
Disconnect the connector(A) and wiring (B).

6.
Pull the square wire (A) to the left and right, then apply a force in the direction of the arrow to cut off the residual sealant on front edge (B).
   
•
Make sure that you put on gloves to protect your hands from potential injury.
•
Be careful about potentially burning your hands due to the heat generated from the wire in use.
•
Be careful when working with wiring because it may be cut.
   
•
Be careful not to damage the body.
   
•
Make sure that two or more people work together when using wires.

7.
Push wire (A) from the outside of the body toward the face of edge (B) in the direction of the arrow.

8.
When wire lead is visible inside body, pull wire lead (A) toward inside.

9.
Pull the square wire (B) to the left and right, then apply a force in the direction of the arrow to cut off the residual sealant on front section (A-A).
A.
B(1): Work inside car
B.
B(2): Work outside car
   
•
Make sure that you put on gloves to protect your hands from potential injury.
•
Be careful about potentially burning your hands due to the heat generated from the wire in use.
•
Be careful when working with wiring because it may be cut.
   
•
Be careful not to damage the body.
   
•
Make sure that two or more people work together when using wires.

   
•
When using wires to remove the residual sealant, there may be an interference between the nut hole and device hole. Thus, perform sealant removal work as shown in the following figure:
Use a scraper or flathead driver to lift up a region between the body and panorama sunroof.
Turn and pull out wire (A) between the nut hole and device hole (B) in the direction of the arrow. Next, cut off the residual sealant again.
   
•
Be careful to avoid damaging the nut hole (C).
•
Be careful to avoid damaging the device hole (D).

10.
Pull the square wire (B) to the left and right, then apply a force in the direction of the arrow to cut off the residual sealant on side section (A-A).
A.
B(1): Work inside car
B.
B(2): Work outside car
   
•
Make sure that you put on gloves to protect your hands from potential injury.
•
Be careful about potentially burning your hands due to the heat generated from the wire in use.
•
Be careful when working with wiring because it may be cut.
   
•
Be careful not to damage the body.
   
•
Make sure that two or more people work together when using wires.

11.
Pull the square wire (B) to the left and right, then apply a force in the direction of the arrow to cut off the residual sealant on rear section (A-A).
A.
B(1): Work inside car
B.
B(2): Work outside car
   
•
Make sure that you put on gloves to protect your hands from potential injury.
•
Be careful about potentially burning your hands due to the heat generated from the wire in use.
•
Be careful when working with wiring because it may be cut.
   
•
Be careful not to damage the body.
   
•
Make sure that two or more people work together when using wires.

   
•
When using wires to remove the residual sealant, there may be an interference between the nut hole and device hole. Thus, perform sealant removal work as shown in the following figure:
Use a scraper or flathead driver to lift up a region between the body and panorama sunroof.
Turn and pull out wire (A) between the nut hole and device hole (B) in the direction of the arrow. Next, cut off the residual sealant again.
   
•
Be careful to avoid damaging the nut hole (C).
•
Be careful to avoid damaging the device hole (D).

12.
Cut the tape between the panoramaroof and the body. Remove the panoramaroof (A).
   
•
When removing and installing the panoramaroof, an assistant is necessary.

Installation
   
•
In order to mount the panorama sunroof assembly, use the tools shown in the following figure:
[Tooling Diagram]

Sealant nozzle
Adhesive sealant for car windows
Sealant gun
1.
With a knife, scrape the old adhesive smooth to a thickness of about 2mm (0.08 in.) on the bonding surface around the entire panorama sunroof opening flange.
   
•
Do not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding.
•
Remove the rubber dam and fasteners from the body.
•
Mask off surrounding surfaces before painting.

2.
Clean the body bonding surface with a sponge dampened in alcohol. After cleaning, keep oil, grease and water from getting on the clean surface.

3.
With a sponge, apply a light coat of body primer to the original adhesive remaining around the windshield opening flange. Let the body primer dry for at least 10 minutes:
A.
Do not apply glass primer to the body, and be careful not to mixup glass and body primer sponges.
B.
Never touch the primed surfaces with your hands.
C.
Mask off the dashboard before painting the flange.

4.
Apply a light coat of glass primer to the outside of the fasteners.
A.
Never touch the primed surface with your hand. If you do, the adhesive may not bond to the glass properly, causing a leak after the windshield glass is installed.
B.
Do not apply body primer to the glass.
C.
Keep water, dust, and abrasive materials away from the primer.

5.
Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Put the cartridge in a caulking gun, and run a bead of sealant (B) around the edge of the panoramaroof (A) as shown. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner.

6.
When intalling the panorama sunroof, match the body centering device hole (A) and place the panorama sunroof on the body flange.
[Front]

[Rear]

7.
After installing the panorama sunroof check the alignment and gap of each side.
x
Section
Alignment
Gap
Front
A-A
0 ± 1 mm
5 ± 1 mm
(0 ± 0.0394 in)
(0.1969 ± 0.0394 in)
Rear
B-B
0.7 ± 1 mm
5 ± 1 mm
(0.0276 ± 0.0394 in)
(0.1969 ± 0.0394 in)
Side
C-C
-
5 ± 1 mm
(0.1969 ± 0.0394 in)

8.
Install the panorama sunroof mounting nuts (A).
Tightening torque :
19.6 ~ 29.4 N.m (2.0 ~ 3.0 kgf.m, 14.5 ~ 21.7 lb-ft)

9.
Install the bolts (A), to the panoramaroof panal mounting bracket.
Tightening torque :
19.6 ~ 29.4 N.m (2.0 ~ 3.0 kgf.m, 14.5 ~ 21.7 lb-ft )

10.
Insert the SST (09816-2S100) (B) between the fixed glass and panel side to install the fixed glass (A) as shown below picture.

11.
Scrape or wipe the excess adhesive off with a putty knife or towel. To remove adhesive from a painted surface or the windshield, wipe with a soft shop towel dampened with alcohol.
12.
Let the adhesive dry for at least one hour, then spray water over the roof and check for leaks. If a leak occurs, let it dry, then seal with sealant :
A.
Let the vehicle stand for at least four hours after windshield installation. If the vehicle must be driven within 4 hours, it must be driven slowly.
B.
Keep the windshield dry for the first hour after installation.
13.
Reinstall all remaining removed parts. Install the rearview mirror after the adhesive has dried thoroughly. Advise the customer not to do the following things for two the three days:
A.
Slam the door with all the windows rolled up.
B.
Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads).
14.
Installation the following items.
A.
Front seat
(Refer to Seat & Power Seat - "Front Seat")
B.
Rear seat
(Refer to Seat & Power Seat - "Rear Seat")
C.
Interior trim
(Refer to Interior - "Interior Trim")
D.
Roof trim
(Refer to Interior - "Roof Trim")
E.
Roof rack & Roof molding
(Refer to Exterior - "Body Side Moldings")
Adjustment
Inspect Glass Alignment
1.
Check for abnormal noise or bending during operation.
2.
With the sunroof fully closed, check for water leakage.
3.
The roof panel (A) should be even with the glass (B) weatherstrip, to within the standard value "E" all the way around. If not, make the following adjustment.
Standard value "E" [mm(inch)]
Front edge : 1.2 mm (0.0472 in.)
Rear edge : 1.0 mm (0.0394 in.)

4.
If the position is not as specified, lightly loosen the glass adjusting screws (A) to adjust the glass height and tighten it.

How To Initialize Motor
Whenever the battery is disconnected, discharged or the related fuse is replaced or reinstalled, the panoramaroof system must be reset according to the procedure below.
1.
Turn the ignition key to the ON position and then close the panoramaroof completely.
2.
Release the panoramaroof control lever.ing the switch)
3.
Press and hold the CLOSE button for more than 10 seconds until the sunroof has moved slightly.
4.
Release the panoramaroof control lever.
5.
Press and hold the CLOSE button once again until the sunroof do as follows.
A.
Tilt > Slide Open > Slide Close
Then, release the lever.
6.
Reset procedure of panorama system is finished.
When To Initialize The Motor
1.
At the time of manufacture.
2.
If the Initial setting is erased due to loss of power.
3.
After using the manual handle.
Operating The Panoramaroof Emergency Handle
1.
Use the panoramaroof emergency handle to close and open the panoramaroof manually for the following case only.
A.
To close the panoramaroof before driving a vehicle in arainy day or on the highway if the panoramaroof can not be closed due to failure of the panoramaroof motor or controller.
2.
Operating method
A.
Remove the overhead console
B.
Push the emergency handle up into the hexagonal drive of the panoramaroof motor. You must push hard enough to disengage the motor clutch; otherwise the emergency handle will slip due to incomplete fit in the motor.
C.
Carefully turn the emergency handle clockwise to close the panoramaroof.
D.
After closing the panoramaroof, wiggle the handle back and forth as you remove the tool from the motor, to ensure the motor clutch reengages.
E.
A 5mm hex socket may be used in place of the emergency handle, with a” Speeder” type handle.
   
•
Do not use power tools to operate the panoramaroof.
Damaged to the components may occur.

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