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1989 Toyota 4Runner ENGINE PERFORMANCE Removal Overhaul And Installation

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Filed Under (Toyota Manuals) by admin on 26-10-2011

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CARBURETOR (COROLLA) REMOVAL 1) Drain cooling system. Disconnect air intake hose. Disconnect emission control hoses from air cleaner. Remove air cleaner mounting bolt and wing nut. Remove air cleaner. 2) Disconnect accelerator cable. Disconnect throttle cable (A/T). Disconnect carburetor wiring connector. Disconnect emission control hoses and tag for installation. Disconnect fuel inlet hose. Remove 4 carburetor mounting nuts and No. 1 vacuum pipe. Remove carburetor. DISASSEMBLY Air Horn 1) Remove air cleaner setting bolt. Remove fuel pipe clamp, union, fuel pipe and gaskets. Remove vacuum hoses. Remove pump and pivot screw and pump arm with connecting link. Disconnect choke link and choke opener link. 2 Remove 8 air horn screws and number plate, fuel pipe support and wire clamps. Remove air horn from carburetor body. Disconnect wiring from solenoid valves. 3) Remove float pivot pin, float and needle valve assembly. Remove air horn gasket, needle valve seat and gasket, power piston retainer, power piston and spring. Remove pump plunger and boot. See Fig. 2.
Fig. 1: Exploded View of Aisan Carburetor Main Body (Corolla) Courtesy of Toyota Motor Sales, U.S.A., Inc. Fig. 2: Exploded View of Air Horn Assembly (Corolla) Courtesy of Toyota Motor Sales, U.S.A., Inc. Main Body 1) Remove solenoid valves from carburetor body. Remove stopper gasket. Disconnect throttle positioner links and remove bracket attaching bolts. Remove accelerator pump retainer gasket and remove pump discharge weight, long spring and discharge large ball. See Fig. 1. 2) Remove pump dampening spring. Using tweezers, remove plunger retainer and check ball. Disconnect throttle positioner link and throttle position levers, washer and spring. Remove primary and secondary main passage plugs and gaskets. Remove primary and secondary main jets and gaskets. 3) Remove auxiliary acceleration pump (AAP) housing, spring and diaphragm. Remove AAP inlet plug and check ball. Remove outlet plug, short spring and small ball. Remove primary and secondary small venturies. 4) Remove sight glass retainer, sight glass and “O” ring. Remove throttle lever return spring and back spring. Remove throttle lever and fast idle cam. 5) Disconnect link and remove secondary throttle valve diaphragm assembly and gasket. Remove throttle position switch and bracket. Remove 3 body-to-flange screws and vacuum passage screw. Separate body from flange. See Fig. 3. Remove washer from throttle valve shaft. Remove idle mixture adjusting screw and idle speed adjusting screw.

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1998 Chevy Truck S10/ T10 Blazer 2WD Evaporator Core Service and Repair Manual

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Filed Under (Chevy Manuals) by admin on 14-05-2012

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Manual A/C REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the right side instrument panel sound insulator. 3. Remove the instrument panel storage compartment. 4. Disconnect the passenger side SIR. 5. Remove the lower right instrument panel mounting bolt. 6. Remove the left and right front speaker grilles. 7. Remove the center instrument panel sound insulator. 8. Remove the left side instrument panel sound insulator. 9. Disconnect the park brake release cable. 10. Remove the knee bolster. 11. Remove the lower left instrument panel mounting bolt. 12. Remove the BCM. 13. Disconnect the driver side SIR. 14. Remove the instrument panel cluster. 15. Remove the radio. 16. Remove the HVAC control assembly. 17. Remove the steering column retaining retaining nuts. 18. Lower the steering column. 19. Remove the instrument panel carrier. 20. Remove the left and right cowl vent grille panels. 21. Disconnect the underhood lamp electrical connector, if equipped. 22. Remove the hood. 23. Remove the VCM. 24. Remove the coolant recovery tank. 25. Remove the heater hoses. 26. Disconnect the electrical connectors from the grille mounted lamps. 27. Remove the right front headlamp assembly. 28. Remove the front bumper. 29. Remove the right wheelhouse panel. 30. Disconnect the radio antenna cable. 31. Disconnect the electrical connector for the horn. 32. Remove the right fender. 33. Remove the evaporator case heat shield, if equipped. 34. Remove the blower motor resistor. 35. Remove the evaporator case bolts and screws. 36. Remove the accumulator. 37. Remove the condenser to the evaporator line fitting. 38. Remove the bolts which retain the evaporator case to the bulkhead. 39. Pull back lightly on the heater case to remove the evaporator case. 40. Remove the evaporator case retaining screws. 41. Disassemble the evaporator case sections, and remove the evaporator core. NOTE: If replacing the evaporator core, remove the expansion (orofice) tube and install it into the new core. INSTALLATION PROCEDURE 1. Install the evaporator core. 2. Assemble the evaporator case sections. 3. Install the evaporator case retaining screws. Tighten to 2.5 N.m (24 in lb) . 4. Install the evaporator core assembly to the vehicle. 5. Install the bolts which retain the evaporator case to the bulkhead. Tighten the bolts to 4.5 N.m (40 lb in) . 6. Install the condenser to the evaporator line fitting. 7. Install the accumulator. 1998 Chevy Truck S10/T10 Blazer 2WD 8. Install the evaporator case bolts and screws. Tighten to 2.5 N.m (24 In in) . 9. Install the blower motor resistor. 10. Install the evaporator case heat shield, if equipped. 11. Install the right fender. 12. Connect the electrical connector for the horn. 13. Install the radio antenna cable. 14. Install the right wheelhouse panel. 15. Install the front bumper. 16. Install the right front headlamp assembly. 17. Connect the electrical connectors to the grille mounted lamps. 18. Install the heater hoses. 19. Install the coolant recovery tank. 20. Install the VCM. 21. Install the hood. 22. Connect the underhood lamp electrical connector, if equipped. 23. Install the left and right cowl vent grille panels. 24. Install the instrument panel carrier. 25. Reposition the the steering column, and install the steering column retaining nuts. 26. Install the HVAC control assembly. 27. Install the radio. 28. Install the instrument panel cluster. 29. Connect the driver side SIR. 30. Install the BCM. 31. Install the lower left instrument panel mounting bolt. 32. Install the knee bolster. 33. Connect the park brake release cable. 34. Install the left side instrument panel sound insulator. 35. Install the center instrument panel sound insulator. 36. Install the left and right front speaker grilles. 37. Install the lower right instrument panel mounting bolt. 38. Connect the passenger side SIR. 39. Install the instrument panel storage compartment. 40. Install the right side instrument panel sound insulator. 41. Connect the negative battery cable. 42. Inspect the system for leaks.

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TOYOTA AND LEXUS HIGHLANDER HYBRID REMOVAL AND INSTALLATION MANUAL

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Filed Under (Toyota Manuals) by admin on 08-03-2012

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Engine and Vehicle Identification Chart………………………………………..4-2 General Engine Specifications………4-2 Engine Tune-Up Specifications……..4-2 Capacities ………………………………….4-3 Valve Specifications …………………….4-3 Crankshaft and Connecting Rod Specifications……………………..4-3 Camshaft and Bearing Specifications ……………………………4-4 Piston and Ring Specifications……..4-4 Torque Specifications………………….4-4 Wheel Alignment ………………………..4-5 Tire, Wheel and Ball Joint Specifications ……………………………4-5 Brake Specifications ……………………4-5 Scheduled Maintenance Intervals……………………………………4-6 STEERING AND SUSPENSION ………………4-28 A Air Bag…………………………………….4-28 Disarming ……………………………4-28 Precautions ………………………….4-28 Alternator …………………………………..4-7 B Brake Caliper ……………………………4-30 Removal And Installation……….4-30 C Camshaft and Valve Lifters…………4-14 Inspection ……………………………4-16 Removal & Installation…………..4-14 CV-Joints………………………………… 4-24 Overhaul ……………………………..4-24 Cylinder Head …………………………..4-10 Removal & Installation…………..4-10 D Disc Brake Pads………………………..4-32 Removal And Installation……….4-32 E Engine Assembly ………………………..4-7 Removal & Installation…………….4-7 Exhaust Manifold ………………………4-12 Removal & Installation…………..4-12 F Front Crankshaft Seal………………..4-14 Removal & Installation…………..4-14 Front Halfshaft………………………….4-23 Removal & Installation…………..4-23 Front Strut ……………………………….4-28 Removal & Installation…………..4-28 Front Wheel Bearing………………….4-29 Fuel Filter ………………………………..4-21 Fuel Injector……………………………..4-22 Removal & Installation…………..4-22 Fuel Pump ……………………………….4-21 Removal & Installation…………..4-21 Fuel System Pressure………………..4-21 Relieving ……………………………..4-21 H Heater Core………………………………..4-7 Removal & Installation…………….4-7 Hybrid Transaxle Assembly…………4-22 Removal & Installation…………..4-22 I Ignition Timing ………………………….. 4-7 Adjustment…………………………….4-7 Intake Manifold …………………………4-11 Removal & Installation…………..4-11 L Lower Ball Joint………………………..4-29 Removal & Installation…………..4-29 Lower Control Arm……………………4-29 Removal & Installation…………..4-29 O Oil Pan…………………………………….4-18 Removal & Installation…………..4-18 Oil Pump …………………………………4-18 Removal & Installation…………..4-18 P Pinion Seal ………………………………4-27 Removal & Installation…………..4-27 Piston and Ring………………………..4-21 Positioning ………………………….4-21 Power Rack And Pinion Steering Gear…………………………..4-28 Removal & Installation…………..4-28 R Rear Halfshaft………………………….. 4-24 Removal And Installation……….4-24 Rear Main Seal…………………………4-19 Removal & Installation…………..4-19 Rear Strut…………………………………4-28 Conventional Strut Overhaul…..4-28 Removal And Installation……….4-28 Rear Traction Motor…………………..4-22 Removal & Installation…………..4-22 Rear Wheel Bearing…………………..4-29 Removal And Installation……….4-29 T Timing Belt ………………………………4-19 Removal & Installation…………..4-19 V Valve Lash ……………………………….4-17 Adjustment…………………………..4-17 W Water Pump ……………………………..4-10 Removal & Installation………..

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2000 Ford Windstar Intake Manifold-Lower Removal And installation manual

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Filed Under (Ford Manuals) by admin on 25-06-2012

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Intake Manifold—Lower Removal 1. Partially drain the cooling system. For additional information, refer to Section 303-03 . 2. Remove the upper intake manifold (9424). For additional information, refer to Intake Manifold—Upper in this section. 3. Remove the fuel supply manifold (9F792). For additional information, refer to Section 303-04B . 4. Disconnect the EGR vacuum tube (9E498). 5. Disconnect the EGR-to-exhaust manifold tube (9D477). * Loosen the nut. 6. Disconnect the upper radiator hose (8260). * Reposition the clamp. * Disconnect the hose. 7. Disconnect the heater hose (18472). * Compress the fitting * Disconnect the hose. 8. Disconnect the intake manifold runner control (IMRC). 9. Position the water bypass tube (8555) aside. 1. Remove the bolts. 2. Position the tube aside. 10. NOTE: Note the location of the six long bolts. Remove the lower intake manifold (9J447). 1. Remove the bolts. 2. Remove the intake manifold. 11. Remove the intake manifold runner control (IMRC) if necessary. For additional information, refer to Section 303-14 . 12. Remove and discard the lower intake manifold sealing components. Installation 1. Refer to the illustration for intake manifold sealing component locations. 2. Install the lower intake manifold front and rear end seals. 1. Apply a bead of sealant to the intake manifold front and rear end seal mounting points as indicated. * Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4. 3. Install the lower intake manifold front and rear end seals. 3. Install the intake manifold gaskets (9439). 4. Install the intake manifold runner control (IMRC) if required. For additional information, refer to Section 303-14 . 5. NOTE: The lower intake manifold must be installed within four minutes of applying sealant. Position the lower intake manifold. 1. Apply a bead of sealant to the lower intake manifold mounting at the points indicated. * Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4. 3. Position the lower intake manifold.

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2002 Chevrolet Impala Intake Manifold Replacement (Lower) Removal And Installation Manual

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Filed Under (Chevrolet Manuals) by admin on 30-04-2012

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Intake Manifold Replacement (Lower) Notes Intake Manifold Replacement – Lower Removal Procedure 1. Disconnect the negative bakery. 2. Remove the upper intake manifold. 3. Remove the left valve rocker arm cover. 4. Remove the right valve rocker arm cover. 5. Disconnect the Engine Coolant Temperature ( ECT ) sensor electrical connector. 6. Disconnect and remove the fuel injector and the Manifold Absolute Pressure (MAP) sensor wiring harnesses. 7. Remove the fuel pipe clip bolt. 8. Remove the fuel pipe clip. 9. Remove the fuel feed pipe from the fuel injector rail. 10. Remove the fuel return pipe from the fuel injector rail. 11. Remove the fuel injector rail. 12. Remove the power steering pump from the front engine cover and reposition. 13. Remove the heater inlet pipe with heater hose from the lower intake manifold and reposition. 14. Remove the radiator inlet hose from the engine. 16. Remove the lower intake manifold bolts. 17. Remove the lower intake manifold. 18. Remove the valve rocker arms and pushrods. 19. Remove the lower intake manifold gaskets and seals. 20. Clean the lower intake manifold gasket mating surfaces. 21. Remove and clean all the RTV sealant from the lower intake manifold and the engine block (1).

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1996 Nissan Altima GLE TIMING CHAIN REMOVAL AND INSTALLATION MANUAL

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Filed Under (Nissan Manuals) by admin on 24-02-2011

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Removal 1. Release fuel pressure. See FUEL PRESSURE RELEASE . Drain coolant from radiator and cylinder block. Drain engine oil. Disconnect all necessary coolant hoses, electrical connectors, vacuum hoses, fuel lines and control cables. 2. Remove front exhaust tube. Remove intake manifold collector supports, and intake manifold. Remove exhaust manifold with catalytic converter. Remove air injection valve pipe. Remove intake air duct. Remove radiator fan and shroud. Remove injectors and fuel rail as an assembly. Remove distributor cap and spark plugs. 3. Set cylinder No. 1 at TDC of compression stroke, ensuring marks on crankshaft pulley and front cover align, and distributor rotor points to spark plug wire No. 1 on cap. Remove cylinder head cover. Remove distributor. 4. Prevent camshafts from turning, and remove camshaft sprocket bolts. Remove camshaft sprocket. See Fig. 13 . Mark and remove camshaft bearing caps in reverse order of installation. See Fig. 16 . Remove camshafts. 5. Loosen cylinder head bolts in 2 or 3 steps, in reverse order of tightening sequence. See Fig. 11 . Remove camshaft sprocket cover. Remove outer (upper) chain tensioner and guide. Remove outer timing chain. Remove idler sprocket bolt. Remove cylinder head. 6. Remove oil pan and oil strainer. See OIL PAN. Remove accessory drive belts. Remove A/C compressor idler pulley (if equipped). Remove crankshaft pulley. Remove front cover. Remove chain tensioner, tensioner arm and chain guides. Remove inner (lower) timing chain and idler sprocket. Remove oil pump drive spacer and crankshaft sprocket. Inspection 1. Inspect chain roller links. Replace chain if roller links are cracked or worn. Inspect cylinder head and cylinder block mating surfaces for warpage. If warpage exceeds specification, machine cylinder head. See CYLINDER HEAD under ENGINE SPECIFICATIONS. 2. If machining reduces cylinder head height to less than specification, replace cylinder head. After machining, rotate camshaft by hand. Replace cylinder head if camshaft does not rotate freely.

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1997 Ford Explorer/ Mountaineer Intake Manifold Upper Repair Manual

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Filed Under (Ford Manuals) by admin on 09-05-2012

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Intake Manifold — Upper 1. Disconnect the battery ground cable. 2. Remove the air cleaner outlet tube; refer to Section 303-12 3. Disconnect the ignition coil electrical connector and the noise suppressor electrical connector. 4. Disconnect the idle air control (IAC) electrical connector. 5. Disconnect the EGR backpressure transducer electrical connector. 6. Disconnect the EVR solenoid electrical and vacuum connectors. 7. Disconnect the brake booster vacuum hose from the upper intake manifold. 8. Disconnect the vacuum connector from the upper intake manifold 9. Disconnect the vacuum connector from the fuel pressure regulator and remove the vacuum harness from the engine. 10. Disconnect the throttle position (TP) sensor electrical connector. 11. Disconnect the hoses from the EGR backpressure transducer ports. 12. Disconnect the six spark plug wires from the spark plugs. 13. Disconnect the spark plug wires from the seven retaining clips. 14. Remove the four ignition coil bolts and the ignition coil from the upper intake manifold. 15. Raise and support the vehicle; refer to Section 100-02 . 16. Access the LH exhaust manifold through the wheel well and disconnect the EGR inlet tube from the exhaust manifold (9430). 17. Lower the vehicle. 18. Disconnect the EGR inlet tube from the EGR valve and remove the EGR inlet tube. 19. Remove the EGR valve bolts and the EGR valve and gasket. 20. Remove the oil level indicator tube bracket nut and remove the oil level indicator tube (6754). 21. Remove the EGR outlet tube bracket stud bolt and remove the EGR outlet tube from the upper intake manifold. 22. Disconnect the accelerator cable assembly from the upper intake manifold bracket. 23. Remove the upper intake manifold nuts and remove the upper intake manifold and gasket. Installation 1. NOTE: Before installing the upper intake manifold, the EGR port must be clean and free of obstruction. Use combustion chamber cleaner and a suitable wire brush to remove carbon buildup from the EGR passages. Clean and inspect all surfaces. Install new seals and new gaskets. Use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A to clean the upper and lower intake manifold gasket surfaces. Position the upper intake manifold gasket on the fuel injection supply manifold. 2. Position the upper intake manifold and install the six nuts.

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2002 Land Rover Freelander (LN) Camshaft Timing Belt Service Repair

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Filed Under (Land Rover Manuals) by admin on 09-01-2012

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Service Repair No – 12.65.18 Remove 1. Disconnect battery earth lead. 2. Remove ancillary drive belt . 3. Remove RH front road wheel. 4. Remove 3 bolts securing RH splash shield to body and remove shield. 5. Remove 3 bolts securing camshaft timing belt LH rear cover and remove cover. 6. Rotate crankshaft in a clockwise direction and align the engine “SAFE” position, notch on crankshaft pulley aligned to the “ARROW” on front mounting plate and the timing marks aligned on the rear camshaft gears as illustrated 7. Remove bolt securing PAS pipe to engine front mounting plate. 8. Remove 3 Torx screws securing PAS pump pulley and remove pulley. Zoom Sized for Print Zoom Sized for Print Zoom Sized for Print 9. Remove 3 bolts securing PAS pump to front mounting plate and tie pump aside. 10. Release alternator battery lead terminal cover, loosen terminal nut and disconnect lead from terminal. 11. Disconnect multiplug from alternator. 12. Remove lower bolt and upper nut and bolt securing alternator to front mounting plate. 13. Remove alternator. 14. Remove Torx screw securing idler pulley to front mounting plate and remove pulley 15. Loosen bolt securing lower engine steady to front subframe. 16. Remove bolt securing lower engine steady to sump mounting, release lower engine steady from sump mounting. 17. Remove 3 bolts securing camshaft timing belt RH front cover and remove cover 18. Remove 3 bolts securing camshaft timing belt LH front cover and remove cover. 19. Assemble LRT-12-161 to LRT-12-199 and secure with clamp bolt. 20. Insert LRT-12-161 with LRT-12-199 into crankshaft pulley, loosen and remove pulley bolt. 21. Remove special tool from crankshaft pulley and remove crankshaft pulley. 22. Remove 3 bolts securing camshaft timing belt lower cover to cylinder block and remove cover. 23. Remove 2 bolts securing ancillary drive belt tensioner and remove tensioner. 24. Note fitted position of heat shield on A/C compressor and remove 3 bolts securing A/C compressor to front mounting plate and cylinder block. Release A/C compressor and heat shield and position aside. 25. Drain engine oil.

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2002 Ford Explorer Sport/ Sport Trac Cylinder Head Removal and installation manual

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Filed Under (Ford Manuals) by admin on 02-06-2012

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Removal Both cylinder heads 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information , refer to Section 100-02 . 2. Relieve the fuel system pressure. For additional information, refer to Section 310-00 . 3. Drain the cooling system. For additional information, refer to Section 303-03 . 4. Remove the intake manifold. For additional information, refer to Intake Manifold in this section. 5. Remove the cooling fan shroud. For additional information, refer to Section 303-03 . 6. Remove the accessory drive belt. For additional information, refer to Section 303-05 7. Remove the LH valve cover. For additional information, refer to Valve Cover — LH in this section. 8. Remove the RH valve cover. For additional information, refer to Valve Cover — RH in this section. 9. Disconnect the generator electrical connections. 10. Remove the accessory drive belt tensioner. 11. Remove the bolts and the generator and generator mounting bracket as an assembly. 12. Disconnect the crankshaft position (CKP) sensor electrical connector. 13. Disconnect the wiring harness retainers. 14. Disconnect the water temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors. 15. Disconnect the exhaust gas recirculation (EGR) tube fitting. 16. Remove the upper heater coolant hose. 1. Squeeze the heater hose clamp. 2. Remove the heater coolant hose. 17. Remove the lower heater coolant hose and position aside. 1. Remove the bolt. 2. Squeeze the hose clamp. 3. Remove the heater coolant hose and position aside. 18. NOTE: The coolant hose will be removed with the thermostat housing. Move the coolant bypass hose clamp off the water pump outlet. 19. Remove the bolts, the thermostat housing and the bypass hose. 20. Remove the bolt and detach the wiring harness retainer. 21. Remove the bolts and position the accessory drive bracket aside.22. Detach the wiring harness retainer. 23. Remove the bolt and the oil level indicator tube. 24. Using the special tool, disconnect the LH spark plug wires from the spark plugs. 25. Disconnect the fuel pulse damper vacuum connector. 26. Remove the four bolts and position the fuel supply tube aside. 27. Remove the bolts and the fuel rail and injectors as an assembly.28. NOTE: Mark each of the roller followers to make sure it is installed in its original position during reassembly. Use the special tool to remove the roller followers. 29. Remove the lower radiator hose. 30. Remove the nut and position the A/C tube bracket aside. 31. Using the special tool, set the No. 1 piston at top dead center (TDC). RH cylinder head 32. Remove the RH fenderwell splash shield. 33. Remove the RH camshaft chain tensioner.

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Troubleshooting and Resolving Water Leaks for FUNSPORT Sunroofs

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Filed Under (More Manuals) by admin on 13-03-2012

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1. Opening the sunroof, just after it rains. Standing water on the glass will usually result in water dripping into the cabin. This is not a sunroof fault. Prevention is the solution! Simply drive a short distance to allow any standing water to blow off the glass prior to opening the sunroof. 2. Only after a car wash. High pressure water sprayed directly at the seal will often deflect the seal enough to enter the cabin. This is not a sunroof fault. Prevention is the solution! Don’t spray high pressure water directly on the seal. 3. During a rainstorm, water is immediately visible dripping on the rubber seal under the glass. There may be a problem with glass to seal contact. Carefully examine the seal. If it is visibly damaged or worn, it may need replacement. If dirty, it needs cleaning. An adjustment may solve the problem. Always water test to verify (see sprinkle test procedure below). a. Often dirt or debris will prevent proper contact between the glass and seal. Clean both the glass and seal with plain water (a damp cloth), or if very dirty, a mild detergent solution. Repeat water test after cleaning. If water intrusion between glass and seal continues, adjust the glass hardware. b. Adjust the glass hardware to increase clamping pressure on the seal. See procedure below. Repeat water test after adjusting. If water intrusion between glass and seal continues, replace seal. 4. Water is visible dripping through the glass hardware: Water test to verify (soak and sprinkle). You may need to slightly shift the glass hardware or change the rubber gaskets under the rectangular mounting plates. 5. After a long soaking rain the headliner gets wet. This is likely the result of water coming under the main frame or under the seal. Only a soak test will prove this. a. Under the main frame: remove the screw cover strip or pull back the headliner (of wrapped) and examine the clamping screws. Water spots or rusty screws are an indication that water is coming under the main frame. Remove the clamp frame and water spots or rust will likely be visible on the inside of the roofskin. This can be the result of an over-cut hole, a sunroof not centered on the hole (left a gap) or inadequate sealant. Solution: Remove the sunroof and re-install with new sealant. If the hole was over-cut, a larger size may be required. b. Underneath the main seal: carefully examine and verify proper seal insertion around perimeter of sunroof frame. Bottom of seal should be adhered to main frame with butyl tape. Top outer lip should be mechanically inserted into groove in frame. You may be able to manipulate the seal slightly to correct the problem. Otherwise replace the seal. c. Frame joint: typically will see water spots or rust on hinge block and handle mounting screws, particularly on the right hand side. Remove the knock-in bead and examine the channel for water or water spots. Solution: pull back the main seal at the passenger side and apply a small amount of silicone sealant across the frame joint. Allow to dry before reinserting the main seal.

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