Freelander Body Repair Manual — part 51
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BODY
SUNROOF
1
SUN ROOF ASSEMBLY - 3 DOOR
Service repair no - 76.83.01
Remove
WARNING: Wear protective gloves when
handling solvents and primers.
WARNING: Wear suitable eye protection
when cutting out sun roof.
1. Remove headlining.
See Interior trim
components.
2. Disconnect drain tubes from sun roof.
3. Remove and discard cable ties.
4. Loosen 4 Torx screws securing clamping
plates and remove plates.
5. Remove glass panels and ’T’ bar.
6. Remove 8 screws securing wind deflectors.
7. Remove wind deflectors.
![](/vehicles/onond/veyondd/mowous/ckin.png)
BODY
2
SUNROOF
8. Remove sun roof tray seal.
See this section.
9. Mask up roof and sun roof aperture.
10. Cover interior trim with protective sheet.
11. Make a cut through the sealer at the back of
the sun roof, a 90
°
bend in the cutting tool will
help.
CAUTION: Take care not to damage paint
or roof aperture flange when cutting out
sunroof.
12. Using suitable cutting wire, cut through PU
sealer securing sunroof to roof.
NOTE: Multi-strand cutting wire is advised,
as a sawing action may be required on the
corners. Single strand wire may overheat
and break during sawing action.
13. Remove section of sunroof.
Refit
1. Clean surrounding area with solvent.
2. Use a vacuum cleaner to clear away dust and
debris.
3. Cut sealer on roof flange down to a smooth
even finish.
4. Etch prime and paint any damaged areas.
5. Apply primer over etch primer on flange.
6. Apply activator over old sealer on flange.
7. Allow activator to cure.
8. Fit pre-cut nozzle to sealer cartridge, remove
lid and shake out crystals, install in applicator
gun.
NOTE: Modify nozzle as required.
9. Apply a continuous bead of sealer around roof
flange as shown. Make bead slightly thicker at
the corners.
NOTE: Sealer bead should be 8 mm by 8
mm.
10. Check for breaks and air bubbles in the sealer.
11. With assistance position sunroof and align to
roof aperture.
12. Fit sun roof tray seal.
See this section.
13. Position sunroof clamping plates, fit and tighten
screws.
14. Connect drain tubes and secure with NEW
cable ties.
15. Remove body and trim protection.
16. Position wind deflectors, fit and tighten screws.
17. Fit ’T’ bar and glass panels.
18. Fit headlining.
See Interior trim components.
![](/vehicles/onond/veyondd/mowous/nove.png)
BODY
SUNROOF
3
WIND DEFLECTOR - GLASS SUN ROOF - 3
DOOR
Service repair no - 76.83.28
Remove
1. Release and remove sun roof glass panel.
2. Remove 4 screws securing hinges, and
remove wind deflector.
3. Collect hinges.
NOTE: Hinges are handed.
Refit
1. Locate hinges to wind deflector, position wind
deflector, fit and tighten screws.
2. Position glass panel and secure catch.
![](/vehicles/onond/veyondd/mowous/rothat.png)
BODY
4
SUNROOF
SEAL - SUN ROOF TRAY
Service repair no - 76.83.61
Remove
1. Remove side rail front end covers.
2. Unscrew 4 Torx bolts securing front of side
rails and side rails.
3. Remove front and rear roof finishers.
4. Remove roof glass.
5. Remove ’T’ bar.
6. Release seal from inner part of tray.
7. Release seal from corners of tray and ease
from between roof and tray.
8. Remove tray seal.
Refit
1. Position seal to roof.
CAUTION: Do not use sharp tools to
locate seal
2. Locate seal to corners of tray and fit between
roof and tray.
3. Fit seal to inner part of tray.
4. Fit ’T’ bar.
5. Fit roof glass.
6. Fit roof finishers.
7. Ensure gaskets are in position on side rails.
Tighten Torx bolts to 22 Nm. to secure side
rails.
8. Fit side rail end covers.
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