EXTERNAL TRIM 164 GROUP 75 EXTERNAL TRIM TABLE OF CONTENTS CENTER AND SIDE GRILL! Removaliinstaliation .. . 75-4 1564 FRONT COMBINATION LAMPS AND RADIATOR FINISHERS . 75-4 + Removalinstaliation .. 75-4 FRONT SIDE TRIM. 75-5 + Removal/installation .. 75-5 DOOR STRIPS .. 75-5 + Removaliinstaliation 75-5 UNDER - DOOR TRIM AND KICKPLATE 75-5 + Removal/instaliation .. 75-5 ORIP.., Removal installation FRONT GRAVEL GUARD + Removal/installation REAR GRAVEL GUARD. + Removalinstallation WINDSHIELD. Removal .. + Preparation tor instatiation ... installation REAR WINDOW .. - Removal Preparation for Installation .. Installation FRONT BUMPER, sessiccssssss Removalinstallation .. REAR BUMPER Removalinstallation .. SPOILER ("S" VERSION ONLY), Removal installation SUN ROOF .. Sun roof opening Sun root closing «+ Opening to “Quarter light” position .. + Closing from “Quarter light position Inner trim and spoiler operation Metal panel Disassembly Reassembly Adjustment .. Tle-strap guide and meta! pane! seal + Disassembly/Reassembly ‘Spoiler components. + Disassembly/Reassembly Electric motorEXTERNAL TRIM SS 868 TECHNICAL CHARACTERISTICS AND SPECIFICATION + Tightening torques. 75-28 + FIUIGS @fd LUDFICAIIS essersssseerserrrererssstee 78-28 | - Sealing compounds 75+ 28 + Products for windshield and rear 75-28 window bonding Windshield washer mixture + Disassembly/Reassemb); + TIMING sssesssereteee + Manual operation + Mobile ralt.. rs + Disassembly Reassembly + Inner trim. + Disassembly Reassembly.. > Frame. 78-29 : + Removal 75-29 + Installation 75-29 TROUBLESHOOTING PROCEDURE... Sliders and flexible racks + Disassembly Reassembly .. 75-2EXTERNAL TRIM = 183 SYN re ILLUSTRATED INDEX ‘SOLER RENOVALINSTALLATION (page 75-18) REAR WINDOW REMOVAL (ooge 75 - 12) PREPARATION FOR INSTALLATION (page 75-13) INSTALLATION (page 75-13) PANEL SEAL (page 75-21) SPOILER (page 76 -24) SPOILER COMPONENTS (page 75-28) ELECTRIC MOTOR page 75-28) MOBILE RAIL (page 78-25) ‘NNER TAIM (page 78 - 28) FRAME (page 75.29) SUDERSANO FLEXIBLE © nip MMR (mee 7-32) REMOVAL (age =} FALLATION (page 75 6) : wonosiieio = REMOVAL (ge 75-5) EN PREPARATION FOR SNSTALLATION page 78-10) WSTALLATION (page 75.13) ‘FRONT COMBINATION LAMPS AND RADIATOR FINSHERS REMOVALANSTALLATION (page 78-4) REAR GRAVEL GUARD REMOVALACSTALLATION REMOVALANSTALLATION (age 75-2) UNDER-DOOR Thum AND CENTER AND Side GRILLS. KOCKPLATE, Sa RUINETALLATION REMOVALINSTALLATION (age 75-4) a IREMOVALINSTALLATION (page 75-7) woe FRONT BUMPER AEMOVALINBTALLATION (page 75. 14) POON STRIPE sn gage . REAR BUMPER REMOVALINSTALLATION (page 78-18) 75-3CENTER AND SIDE GRILLS REMOVALINSTALLATION o 1. Disconnect negative (-) lead trom battery. 2. Remove Atfa Romeo badge. 3. 4. Unscrew and remove three nuts and washers secur- ‘Open bonnet. ing center gril Remove center grill. Unscrew and remove three nuts and washers secur- Ing each skie gril Remove side grils. Remove engine hood safety lock (see Group 56). 75-4 EXTERNALTRIM 16a For parts and/or components described in ‘other pages of same Group or in other Groups, refer to related procedures and information, FRONT COMBINATION LAMPS AND RADIATOR FINISHERS REMOVAL /INSTALLATION 1. Disconnect negative (-} lead from battery. 2, Remove radiator seal 3. remove plastic rivets securing seal to each combi- nation lamp. 4. Remove seals from both headlamp units. 5. Remove screws and washers securing radiator pip- ing cowls. 6. Remove radiator piping cowls. 7, Rettove four bolls and washers securing upper finisher to radiator. 8. Remove radiator upper finisher. Repeal procedure in reverse order tor installa- tion.EXTERNAL TRIM ss 164 FRONT SIDE TRIM 4. Remove plastic rivets, trom door inner side, which ‘secure strip to lower end of door. REMOVAL/INSTALLATION 5, Withdraw door strip rearwards and remove it. 1. Disconnect negative (-) lead from battery. 2. Remove trim cover. 3. Remove two screws Securing side trim screw 4. Disjoint front side trim from plastic clips and remove eM coven Repeat procedure in reverse order for installa. tion. DOOR STRIPS REMOVAL/INSTALLATION 1. Disconnect negative (-) lead trom battery 2. Remove screw protective cap on inner side of door 3. Remove strip securing screw trom inner side of oor. YQ PROTECTIVE CAP Ne Repeat procedure in reverse order for installa- tion. UNDER - DOOR TRIM AND KICK- PLATE REMOVAL/NSTALLATION 1. Disconnect negative (-) lead trom battery 75-5EXTERNALTRIM 8 $$$ _ 4 2. Remove front side trim. Remove sctews securing trim on the lower end. 4. Remove plastic rivets, which secure trim on lower side. 5. Unlock the plastic catches. 6. Raise door seats. 7. Remove plastic rivets, which secure trim on upper side 8. Remove under-door trim and kickplate. ‘TRIM AND KICKPLATE SCREW: \ For parts andior components described in other pagesot same Group or in ather Groups, refer to related procedures and informations. NOTE: The above procedure for under-door trim and kickplate removal and installation, is also appli- cable to “5” version. DRIP REMOVAL 1. 2 Disconnect negative (-) kaad from batiery Remove plastic rivets which secure drip in area ot rear door. Rlemove drip (the dripis bounded in area of reardoor and is tongued in area of front door). INSTALLATION 1 Replace plastic catches securing drip in area of front oor, if damaged. Insert drip front edge in its seat on wing. Bond drip rear section (self-adhesive) in area of rear door. ‘Secure drip rear section with plastic rivets in area of rear door. insert drip rear edge between rear pillarand roof. The edge must be inserted under rear window channels. Position drip center section so as drip holes mate with holes for roof rack/sky holder installation. Position wire under drip lower edge. 75-6EXTERNAL TRIM 164 8. Engage drip on plastic catches by tapping lightly on while pulling wire; insert drip lower edge on metal fim. 9. Connect negative (-) lead to battery. Re REAR EDGE (BETWEEN REAR PILLAR ‘DAUP FRONT EDGE (BEAT Cn WING) FRONT GRAVEL GUARD REMOVALINSTALLATION 1 2. Remove frontwheelby removing five attaching bots, Remove two tront-hal gravel guard securing screws (side and lower) and screw connecting gravel guard front-hal to rear-half. Remove bolt and nut connecting gravel guard front- half to rear-halt. Remove front-halt grave! guard. Remove three rearhalt gravel guard securing ‘screws (side and lower). . Remove rear-halt gravel guard, SECURING) Repeat procedure in reverse order for installa: tion. 75-7REAR GRAVEL GUARD REMOVALANSTALLATION 1. Remove rearwheel by removing five attaching bots 2. On right-hand gravel guard, remove tank filler pipe (see Group 04). 3. Remove four side seouring screws. Remove aff securing screw with related washer. 5. Using a suitable punch, push inwards the nails of ex- pansion blocks on forward side of gravel guard. 6. Retrove expansion blocks. 7. Remove rear gravel guard. REAR ‘GRAVEL GUARD mais, EXTERNALTRIM 164 For parts and/or components described in other pages of same Group or in other Groups, refer to related procedures and informations. WINDSHIELD REMOVAL x 2gean 12. 13. Disconnect negative (-} lead from battery Remove front pillar trims (see Group 66) Rlemove sun visors, rearview mirror and courtesy lamp (see Group 66) CAUTION: Protect adequately roof trim to avold dam- age or soiling. Disconnect and lower forward edge of roof trim (see Group 66) Remove engine hood (see Group 66) Remove protective caps from windshield wipers nuts. Remove windshield wipers nuts, Remove windshield wipers arms. Remove windshield lower finisher. . Remove drips (refer to relevant paragraph). Remove windshield side housing panels, complete with plastic rim. Cut bonding fine round the whole edge of windshield using electric cutters and blades as depicted in figure. Remove windshield. 75-8EXTERNAL TRIM 8195PREPARATION FOR INSTALLATION 1. Install seal, observing positioning measures as de- pkcted in figure. 14 rum 0.71 in) WEASURE 0 FR jou] MEASURED FROM WINDSHIELD CENTER, WINDSHIELD EOCE. 7:1 2002 000) NOTE: I windshield was previously Installed, re- move old seal and any trace of adhesive from glass edge. CAUTION: + Use only Alfa Romeo adhesive kit (P/N 162.00.76.001.99). + Open container just before application; observe manufactures Instructions on adhesive container. NO Ee EXTERNALTRIM 184 ‘Apply adhesive strip to upper and side edges of windshield, Install upper and side channels. Install lower channel. Clean windshield edges and channels with degreas- ing compound contained in ki. ‘Allow to dry. Apply adhesive primer on windshield edges and on channels. Allow primer to dry. |. Just before installation of windshield, apply adhesive between seal and channels. The width of adhesive ‘bead ("a” or “b" dimension) could be as depicted in figure. 75-10EXTEANAL TRIM 164 INSTALLATION CAUTION: A + Use only Alfa Romeo adhesive kit (P/N 162.00.76.001.99). + Open container just before application; observe manufactures Instructions on adhesive container. 1. Smooth any trace of adhesive (referto step Sof topic “Preparation for installation”) and wipe otf withdry: oth or compressed air any residual of works; apply primer and allow it 10 dry. 2. Reinstall side housing panels using rivets. 3. Reinstall plastic edges. 75-14 a= Using sucker pads, position windshield in ts seat ‘Adjust two positioning spacers. as necessary until windshield is property positioned. 6. Apply light, uniform pressure all around windshiels oa edge. 7. Allow adhesive to cure thoroughly. 8. Reinstall windshield lower tinisher. 9. Reinstall all components removed. 10. Correct negative (-) lead to battery. For parts and/or components described in ‘other pages of same Group or in other Groups, refer to related procedures and informations.EXTERNALTRIM Bes REAR WINDOW REMOVAL 1. 2. 3. Disconnect negative (-) lead from battery. Remove rear pillars trims (see Group 68) Remove rear seats (vehicles equipped with spilt seat) or complete rear seat (vehicles equipped with standard - type seat) (see Group 66). Remove rearstop (S version excluded) and rearwin- dow parcel shett (see Group 66). Remove trunk lid (see Group 56). Raise forward section of trunk seal. Remove three plastic rivets securing roof trim rear edge. 164 CAUTION: Protect adequately roof trim to avoid dam- ‘age or solling. Lower root trim rear edge. Disconnect heated rear window wiring. Remove rear window lower finisher. Gut bonding line round the whale edge of rear win- dow using electric cutters and blades as depicted in figure, REARSEAT HEATED REAR WINDOW Win ‘TYPES OF CUTTER: ‘A: WITH LONG BLADE (ANGULAR AREA IB: WITH SHORT BLADE (STRAIGHT AREA) 75-12EXTERNAL TRIM 166 — ic PREPARATION FOR INSTALLATION 1. Install seal, observing positioning measures as de- pected in figure. LAs AND CHANNEL SIE UPPER AND: ‘SIDE CHANNELS. NOTE: If reat window was previously installed, re- move old seal and any trace of adhesive from glass edge. CAUTION: + Use only Alfa Romeo adhesive kit (P/N 162.00.76.001.99). + Open container just betore application; observe manufactures Instructions on adhesive container. install upper and side channels on rear window. {install lower channel. Clean glass edges and channels with degreasing ‘ompound contained in kit sen 75-13 5. Allow to dry. 6. Apply adhesive primer on glass edges and on chan- nels. 7. Allow primer to dry. INSTALLATION CAUTION: + Use only Alfa Romeo adhesive kit (P/N 162.00.76.001.99). + Open container just before application; observe manutactures instructions on adhesive container. 1. dust before installation of rear window, apply adhe- sive between seal and channels. 2. Smooth any trace of adhesive and wipe off with dry Cioth or compressed air any residual of works; apply Primer and allow it to dry. 3. Using sucker pads, position rear window on its seat 4. Adjust two positioning spacers as necessary unti ear window is property positioned. 5. Apply light, uniform pressure all around rear window edge. Allow adhesive to cure thoroughly. Reinstall rear window lower finisher. Reinstall all components. removed. Connect negative (-) lead to battery PoreEXTERNALTRIM == 164 NOTE: - For parts and/or components described in sions lights; disconnect wirings then remove traspar- other pages of same Group or in other ents. Groups, refer to related procedures and | 9. Remove seven upper screws and washers. informations. 10, Move the bumper aside and disconnect the piping of - Check that wires are correctly secured to the telescopic headlamp washer. connectors before connecting wiring. 11. Loosen the screws, remove the headlamp washer and the sprayer from the bumper. FRONT BUMPER 12. Remove front bumper. REMOVAL /INSTALLATION For parts and/or components described in other pages of same Groups or in other 1. Disconnect negative (-} lead {rom battery Groups, refer to related procedures and 2. Remove two lower side sorews and washers, informations. 3. Remove two inner side sorews and washers. - Check that wires are correctly secured to 4, Remove four lower front plastic rivets. connector before connecting wiring. 5. Remove two front screws and washers. 6. Remove headlamp units (see Group 40) NOTE: As for “S" version, removal and installation 7. Remove fogiamps (see Group 40). procedures of the front bumper are identical. 8. Withdraw LH. and R.H. trasparents of overall dimen- ‘TRANSPARENT oo screw TELEsconic HEADLAMP. WASHER wining ‘TRANSPARENT (OVERALL DIMENSIONS uGkT)EXTERNAL TRIM 164 REAR BUMPER ‘9. Remove four side bolts and washers securing bumper. REMOVAL/INSTALLATION 10. Rlemove four afi nuts and washers securing bumper. 11. Draw back rear bumper and remove it. 1. Disconnect negative (-) lead from battery. 2 Removes three Screws and washers securing under- For parts andior components de in , other pages of same Group or in other a Remove wonutsand washers securing vunder-trunk Groupe, refer to related es and in 4, Remove under-trunk trim. formations: 5. Withdraw L.H. and F.H. trasparents of overall dimen- ~ Check that wires are correctly secured to sions lights; disconnect wiring then remove traspar- ‘connector before connecting wiring. ents. 6. Remove three aft screws and washers securing | NOTE: As for “S “version, removal and installation bumper. procedures of the rear bumper ara identical. 7. Remove two side forward screws and washers se- curing bumper. 8 Remove side and aff trunk trims (see Group 66), TRANSPARENT (OVERALL DIMENSIONS eH ‘em 5SEXTERNALTRIM 4 SPOILER (“S"” VERSION ONLY) REMOVAL/INSTALLATION 1. Disconnect negative (-) lead from battery. Remove trunk trim (see Group 66). 3. Remove four botts and washer securing spoiler to trunk id, 4, Lower trunk lid and remove spoiler. x Repeat procedure in reverse order for installa- tlon. ‘See Group 40 for removal and Installation Of rear stop light. REAR STOPLIOHT 184 SUN ROOF DESCRIPTION ‘The sun-roof is of the metai-type. without sunshade curtain, and can be completely opened or positioned to "quarter light" position, which allows air to escape from passenger compariment with kmited ventilation. The sun roof consists of an outer metal panel and inner trim with spoiler. “The frame of sun root, complete with guides and siders for movement, is located under root skin, in non-visible (position: shders are connected to metal panel anditoinner skin, and are actuated by flexible racks. Flexible racks are driven by motorpinion gear andactuate sliders movement, When sun roof is open, spoiler automatically moves toa position which corrects the air flow. Water that eventually drips through sealof metalpanel, is collected by four channels located on frame comers and then is drained outboard through three four drain hoses, which are routed inengine compartment (from drain ines) and in the trunk (rear drain lines) ‘The sun roof is actuated by means of two pushbutions focatadonthe centraldome. One switch controls opening of the sun root, the other controls the closure, as well as the rear edge of the sun roof. 75-16EXTERNAL TRIM 75-17EXTERNALTRIM Es 1ea OPERATION ‘SUN ROOF OPENING Position (a) : Roof closed ‘When pushbutton switch is actuated to open position - The sliding pin follows the cam, and moves trom Mto N position. - Middle slider moves to aft position. - The cam, fixed to metal panel, moves downward. Position (b): Roof lowered an aft side to avold interierence with body during opening. = 75-1816a a= + The metat panel rotates, lowering on ks rear side. + The middie slider moves rear slider rearward. ~The middie slider moves rearward and disengages | - The rear slider, connected to front slider with a rod, ratchet of notched rod ratchet gear. rags It in ks movement. - The ratchet gear lowers and allows front rearsliders | - Themetalpane! moves trom position (b} to tull-travel to move. position (b’). wet. suoma PANEL Pw RATCHET GEAR ~2 \ \ — \ { Front SUDER cm ROD (CONNECTION wo super NEAR SUDER BETWEEN REAR AND FRONT ao Suber a Position (b') ; Roof open ‘SUN ROOF CLOSING | tS depressed to “quarter light" position: - The middie slider moves toward front slider. ‘The operation is the reverse of opening. = The sliding pin moves forward, following cam profile. + The cam raises, together with metal panel. OPENING TO “QUARTER LIGHT” POSITION = The metal panel opens to “quarter light" position. With sun root in closed position, when the control switch suns wea Oi om —_—, BETWEEN REAR AND. FRONT SLER) woTeHED ROO oe Position (e) : Roof open to “quarter light” position 75219EXTERNALTRIM Se CLOSING FROM “QUARTER LIGHT POSITION” The operation is the reverse of opening to “quarter light” position INNER TRIM AND SPOILER OPERATION Inner trim STRAP SLIDE ‘ne inner trim is connected to front slider by means of strap slides, which allow manual operation of inner trim. it necessary, regardless of metal panel position 75-20 164 Inner spotter Root Closed METAL PANEL, HEUCAL SPANO, NNER SPOILER Roof open to “Quarter light” position ‘The inner spoiler is connected to metal panel coupler fitings (one on each side) which maintain it in open position even if metal panelis in “quarler light” position, ‘The closed positionot inner spoiler is assured by a roller (one on each side) of middie slider sliding pin. The tie-strap, connecting middie slider sliding pin to metal panel, adjusts tension of metal helical spring in regard to its position.EXTERNAL TRIM 184 METAL PANEL 4. Slightly push downwards inner trim supports and manually refit inner trim. DISASSEMBLY 5. Close sun roof unt'l sliding pins are in position corre- sponding to maximum straps slacnen ng NOTE: Make sure that hands are ciean betore dis- | § Disconnect negave ()) lead from battery. assembly (or reassembly) the metal panel. | 7 ®y operating as shownintigure, push tle-sirap guide (€) onwards along strap sider, winning spring reac- thon. 1. Open sun roo! to “quarter ight” postion. 8. Set rap tee trom sicing pin. 5 EE en ani vere 9. Repeat steps 7 and for other tie-strap. isconnect innar spoiler from metal panel. 10. Remove screws and washers securing adjusting plates (two each side) to metal panel. - 11. Remove four adjusting plates. CAUTION: 12, Remove metal panel complete with tie-strap guide During movement of inner trim, avold inter- ference with mobile rail. and seal. 6-230. meEXTERNALTRIM REASSEMBLY NOTE: Make sure that your hands are clean before reassembly. 1. With inner trim in fullaft position, set sicies forward toa maximum “quarter light” position. 2. Position metal panel, complete with tie-strap guide and seal. ———_——— waa 75 22 164 » install four adjusting piaies with screws andwashers. Do not torque screws. Close sun root. . Perform sun root adjustment as described below. Check sun-roof proper operation. oop CAUTION: During movement of inner trim, avoid inter- ference with mobile rail, 7. Manwally refit inner trim 8. Open sun roof to “quarter light" position 9. Push upwards inner spoiler. 10. Connect inner spoiler to metal pane! by coupler fitting,EXTERNAL TRIM 184 = In order to avoid vibrations vehicle run, check felts for condition betore reassembly metal panel. Replace felts as necessary. - Check seal for condition betore reassembly ‘metal panel. Replace seal as necessary. ADJUSTMENT For coupling with the following procedures, two operators are required: one operating from vehicle outside, the ‘other working inside the vehicle. ‘The extarnal operator lines up and matches each angie of ‘metal with sun roof frame, while the internal operator set Position of adjusting plates and torque related bolts. 1. Check thatallcomers of metal panel are aligned with frame and that metal panel is centered: adjust posi- tion o plates as necessary. 2. Engage tie-straps on sliding pins. 3. Open and close sun root several times to check ” proper operation 4, Repeat agjusiment check 5. Torque adjusting plates bolts to prescribed values. METAL PANEL SECURING outs: 75-23 TIE-STRAP GUIDE AND METAL PANEL SEAL DISASSEMBLY/REASSEMBLY NOTE: Make surethat yourhands are clean before disassembly/reassembly. Disassembly metal panel. Disconnect retum springs from both tie strap guide. Orit rivet strap uice to metal pane. Remove strap guides. H necessary, remove seal from metal panel. o_ me eee ‘TesTRAP | mut | LP Lo SS & ST seaNOTE: XTERNALTRIM Check condition of anti-triction tans; replace aS necessary. Apply sealant, as indicated in figure, onto seal groove before installation. Aiter seal installation, its junction should be Positioned halt-way on the front side. The replacement seals are factory: coated with sealant. fa replacement seal Is installed, cut the ‘exceeding part. + For parts and/or components described in other pages of same Group or in other Groups, refer to related procedures and in- formations. 164 SPOILER DISASSEMBLY/REASSEMBLY 1. Open sun root. 2. Disconnect negative (-) lead trom battery 3. Remove front root-lamp. 4. Remove tworearscrews securing sun-root actuating motor. NOTE: Screws instep 4above, in lower posttion, 78-28EXTERNAL TRIM 16a 5. Remove two upper screws securing spoiler. = =< anes F DRT rR 6 Using a drift, disengage side arms trom sliding guides. 7. Remove spoiler. =@= | [ag Repeat procedure in reverse order tor reas- sembly. 75-25SPOILER COMPONENTS DISASSEMBLY/REASSEMBLY 1. Disassembly spoiler (refer to previous paragraph). 2, Remove retaining rings from pins connecting mobile part to fixed part. 3. Removal pins and “o" rings that connect mobile part to fixed part 4, Remove mobile part trom fixed part. Remove retaining rings from pins securing side arms. 6. Remove pins that secure side arms. 7. Withdraw side arms, complete with return springs, from side of mobile part 8. Remove retum springs from side arms. a Repeat procedure in reverse order for reas- sembly. *—synee RETURN nN ne N HOE AR N ™ SS “1 > Pin {SDE ARM (ATTACHMENT) ——_og™ IETAINING RING FIKED PART EXTERNALTRIM 164 ELECTRIC MOTOR DISASSEMBLY/REASSEMBLY NOTE: ff electric motor falls to operate, it is pos- een sible to move sun roo! to any required po- sition by manually turing electric motor, ‘as described in paragraph “Manual Opera- tion”. Remove metal panel. Remove two rear screw securing electric motor. Remove front nut securing electric motor. Remove bot that connects ground wire to chassis. Disconnect wiring and ground wires from electric motor. Remove electric motor. @ROUND wiRE. SECURING BOLT 4 / 75-26EXTERNAL TRIM 164 [ag - Perform timing of system before reassem MANUAL OPERATION bly of electric motor. ~ For parts and/or components described in | 1. Pushcenter hub (a) of electric motor to allow manual other pages of same Group or in other ‘operation. Groups, referto related procedures andin | 2. Manually rotate gear of electric moter to set metal formations. panal to desired position. + Check that wires are correctly secured to ‘connector before connecting wiring. TIMING 1. Connect electric motorto a 12V DC source (battery) and check that is at long full-trave! (corresponding to close travel) 2. Manually set both sliding pins to M posilion as shown, in figure. 3. Reassembly electric motor. NOTE: Afterelectric motor has been reassembied, check sun root for proper operation before reinstalling metal panel. 75-27EXTERNALTRIM MOBILE RAIL DISASSEMBLY/REASSEMBLY 4. Remove metal panel. 2. Remove two screws and washers securing mobile 3. Renove mobile rail \ sonew \ WASHER X@ MOBILE Ral ze == L For parts andior components described in other pages of same Group or in other Groups, ‘eter to related procedures and informations. 75 - 28 INNER TRIM DISASSEMBLY/REASSEMBLY 1. Remove metal panel. 2. Manually set inner trim tully forward 3. Remove four trim sliding springs by means of a punch. ae 4, Remove inner trim. + Check that felt "F* installed on spring is in good conditions: otherwise replace it to avoid vibrations during vehicle 's run. - Lubricate sliding spring after reassembly with grease as indicated in figure. For parls and/or components described in other pages of same Group or in other Groups, referto related procedures and in- formations.EXTERNAL TRIM: {ea =e FRAME 5. Remove forward bol that secures electric motor; re- move also ground wire nut and disconnect wiring REMOVAL from motor. 6. Remove trom, side and rear screws that secure NOTE: Make sure that hands are clean before re- frame. moving frame. 1. Disconnect negative (-) lead from battery. 2. Remove inner seal. 3. Remove torward, center and aft pillars tm and roof trim (see Group 68) 4. Disconnect four drain lines from frame comers. FORWARD, CENTER AND AFT PILLARS TRI-ROOF TRIM 7 Remove trame trom vehicle. INSTALLATION NOTE: Make sure that hands are clean betore in- stalling trame. Position frame on vehicle. Install front, side and rear screws that secure frame. 3. With inner trim in aft position, reassemble metal panel, » CAUTION: + Apply pressure sensitive tape, 0.2 In (5 (mm) thick, on aft side before moving metal panel. If pressure sensitive tape interferes with body work stiffening rail during metal panel movement, Install washers (r) as required between clips (s) and frame (on rear side) and between frame and car body (in central part). The total thickness: installed In central part should be one - third of thickness installed on rear side. 75-29EXTERNALTRIM 164 4. Perform operational check. SLIDERS AND FLEXIBLE RACKS 5. Connect inner trim to metal panel. 6. Complete installation of sun root. DISASSEMBLY/REASSEMBLY Remove complete irame from vehicie. Posttion frame on tool. Remove metal panal. Remove inner trim. Remove electric motor. Remove mobile rail 1 2. 3. 4 5. 6. NOTE: The following procedure applies to one or both silders, ADHESIVE TAPE (Smm-0.2 In, thi + For parts and/or components described in other pages of same Group or in other Groups, refer to related procedures and informations. + Check that wires are correctly secured to connector before connecting wiring. 75-30EXTERNAL TRIM 164 Bes 7. Depress on ratchet gear to release it from notched | NOTE: Rear silder is connected to front sliderby a bar, fod. 8. Moved slider aftward by pulling on pin (k 9, Release ratchet gear. 13. Parllally withdraw middle slider. 10. Move slider fully rearward. 14. Remove retaining ring from sliding pin. 11. Remove att plug. 15. Remove sliding pin. 12. Withdraw rear slider. 16. Withdraw completely middle slider and flexible rack. - 19, Remove retaining ring trom pin that connects front CAUTION: slider to bracket. A The complete disassembly of sliders, as | 20. Remove clip from pin. per instruction below, should not be ac- | 21. Remove pin. complished unless strictly necessary. 22. Remove front slider from bracket. Particular care must be taken not to dam- ‘age front silderto an irrepalrabie condition, ~ Particular care must be taken during reas sembly of front slider to avoid damage. + For parts and/or components described in other pages of same Group or in other 17. Withdraw compietely front slider irom frame. Groups, refer to related procedures and 18. Disconnect at slider trom connecting rod. informations. 75-31EXTERNALTRIM 16a ews 75-32EXTERNAL TRIM 634 — TECHNICAL CHARACTERISTICS AND SPECIFICATIONS TIGHTENING TORQUES SUN ROOF Metal panel securing screws: 2.9 10 3.7 ft. Ibs 4to5Nm FLUIDS AND LUBRICANTS Application Type | Name Quantity Sliding guides of inner trim GREASE AMOCO-OPTIMOL Optimoly-PasteWhite T "SEALING COMPOUNDS Application Type ‘Metal panel seal SEALANT PRODUCTS FOR WINDSHIELD AND REAR WINDOW BONDING Name Quantity IVILSEALANT WSC6 B51 006 ‘Application Name Quantity Body work primer Kit: ALFA ROMEO _ Glass primer P/N162.00.76.001.99 ‘Sealing compound Sealing compound canridge ALFA ROMEO PYN 3521.00105.01 75-33EXTERNALTRIM ews 164 WINDSHIELD WASHER MIXTURE Windshield washer mixture @.9. WINDSHIELD WASHER SOLVENT”, Union Carbide Com., 1209 - 34 Protection up to- 40°C/-40°F Ready for use 75-34EXTERNAL TRIM TROUBLESHOOTING PROCEDURE NOTE: One of the pos le inconveniences caused by the sun roof consists in an aerodynamic rustling causing a disturbing rear noise at high speeds. For a rapid solution, referto the troubleshooting conceming noise problems, Group 66 - INTERNAL TRIM. 75-35