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Sunroof: Removal & Installation Mazda RX-8 I

Sun Roof/t-Top/convertible Top 12 illustrations ~1095 words

FRONT DRAIN HOSE INSTALLATION

CAUTIONIf the front drain hose is pinched or bent at any point, the water in the hose may not drain and could leak inside the vehicle. During and after installation of the trims and headliner, always make sure there is no interference with the front drain hose. Correct any abnormality if found.
  1. Apply soapy water to the part of the sunroof frame where the front drain hose is inserted.
  2. Insert the front drain hose end into the sunroof frame.
  3. Install the front drain hose to the clips parallel to the pillar and free of looseness.
  4. Insert the front drain hose grommet into the hole of the inner hinge pillar.
  5. Install the following parts: Headliner (See «HEADLINER REMOVAL/INSTALLATION»(ref-178403-S19009629372005061500000) .) Assist handle (See «ASSIST HANDLE REMOVAL/INSTALLATION»(ref-178403-S23122633592005061500000) .) Sunvisor (See «SUNVISOR REMOVAL/INSTALLATION»(ref-178403-S21013632222005061500000) .) Interior light (See «INTERIOR LIGHT REMOVAL/INSTALLATION»(ref-178404-S41164716852005061500000) .) Map light (See «MAP LIGHT REMOVAL/INSTALLATION»(ref-178404-S16618549752005061500000) .) Rear pillar trim (See «REAR PILLAR TRIM REMOVAL/INSTALLATION»(ref-178403-S00720306752005061500000) .) Tire house trim (See «TIRE HOUSE TRIM REMOVAL/INSTALLATION»(ref-178403-S34208887982005061500000) .) Inner scuff plate (See «INNER SCUFF PLATE REMOVAL/INSTALLATION»(ref-178403-S10793838542005061500000) .) Rear seat (See «REAR SEAT REMOVAL/INSTALLATION»(ref-178399-S03461608852005061500000) .) A-pillar trim (See «A-PILLAR TRIM REMOVAL/INSTALLATION»(ref-178403-S21109983142005061500000) .) Roof side trim (See «ROOF SIDE TRIM REMOVAL/INSTALLATION»(ref-178403-S32499072472005061500000) .)

Scheme 7

Scheme 7: REAR DRAIN HOSE REMOVAL
Scheme 7: REAR DRAIN HOSE REMOVAL
  1. Remove the following parts: Roof side trim (See «ROOF SIDE TRIM REMOVAL/INSTALLATION»(ref-178403-S32499072472005061500000) .) A-pillar trim (See «A-PILLAR TRIM REMOVAL/INSTALLATION»(ref-178403-S21109983142005061500000) .) Rear seat (See «REAR SEAT REMOVAL/INSTALLATION»(ref-178399-S03461608852005061500000) .) Inner scuff plate (See «INNER SCUFF PLATE REMOVAL/INSTALLATION»(ref-178403-S10793838542005061500000) .) Tire house trim (See «TIRE HOUSE TRIM REMOVAL/INSTALLATION»(ref-178403-S34208887982005061500000) .) Rear pillar trim (See «REAR PILLAR TRIM REMOVAL/INSTALLATION»(ref-178403-S00720306752005061500000) .) Map light (See «MAP LIGHT REMOVAL/INSTALLATION»(ref-178404-S16618549752005061500000) .) Interior light (See «INTERIOR LIGHT REMOVAL/INSTALLATION»(ref-178404-S41164716852005061500000) .) Sunvisor (See «SUNVISOR REMOVAL/INSTALLATION»(ref-178403-S21013632222005061500000) .) Assist handle (See «ASSIST HANDLE REMOVAL/INSTALLATION»(ref-178403-S23122633592005061500000) .) Headliner (See «HEADLINER REMOVAL/INSTALLATION»(ref-178403-S19009629372005061500000) .) Trunk end trim (See «TRUNK END TRIM REMOVAL/INSTALLATION»(ref-178403-S06885816182005061500000) .) Trunk side trim (See «TRUNK SIDE TRIM REMOVAL/INSTALLATION»(ref-178403-S23608374622005061500000) .)
  2. Remove the sunroof frame from the rear drain hose.
  3. Remove the rear drain hose from the clips.
  4. Pull the rear drain hose into the vehicle interior and remove the rear drain hose.

REAR DRAIN HOSE INSTALLATION

CAUTIONIf the rear drain hose is pinched or bent at any point, the water in the hose may not drain and could leak inside the vehicle. During and after installation of the trims and headliner, always make sure there is no interference with the rear drain hose. Correct any abnormality if found.
  1. Apply soapy water to the part of the sunroof frame where the rear drain hose is inserted.
  2. Insert the rear drain hose end into the sunroof frame.
  3. Install the rear drain hose to the clips parallel to the pillar and free of looseness.
  4. Insert the rear drain hose grommet into the hole of the inner rear pillar.
  5. Install the following parts: Trunk side trim (See «TRUNK SIDE TRIM REMOVAL/INSTALLATION»(ref-178403-S23608374622005061500000) .) Trunk end trim (See «TRUNK END TRIM REMOVAL/INSTALLATION»(ref-178403-S06885816182005061500000) .) Headliner (See «HEADLINER REMOVAL/INSTALLATION»(ref-178403-S19009629372005061500000) .) Assist handle (See «ASSIST HANDLE REMOVAL/INSTALLATION»(ref-178403-S23122633592005061500000) .) Sunvisor (See «SUNVISOR REMOVAL/INSTALLATION»(ref-178403-S21013632222005061500000) .) Interior light (See «INTERIOR LIGHT REMOVAL/INSTALLATION»(ref-178404-S41164716852005061500000) .) Map light (See «MAP LIGHT REMOVAL/INSTALLATION»(ref-178404-S16618549752005061500000) .) Rear pillar trim (See «REAR PILLAR TRIM REMOVAL/INSTALLATION»(ref-178403-S00720306752005061500000) .) Tire house trim (See «TIRE HOUSE TRIM REMOVAL/INSTALLATION»(ref-178403-S34208887982005061500000) .) Inner scuff plate (See «INNER SCUFF PLATE REMOVAL/INSTALLATION»(ref-178403-S10793838542005061500000) .) Rear seat (See «REAR SEAT REMOVAL/INSTALLATION»(ref-178399-S03461608852005061500000) .) A-pillar trim (See «A-PILLAR TRIM REMOVAL/INSTALLATION»(ref-178403-S21109983142005061500000) .) Roof side trim (See «ROOF SIDE TRIM REMOVAL/INSTALLATION»(ref-178403-S32499072472005061500000) .)

Scheme 8

Scheme 8: SUNROOF UNIT REMOVAL/INSTALLATION
Scheme 8: SUNROOF UNIT REMOVAL/INSTALLATION

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11
  1. Disconnect the negative battery cable.
  2. Remove the following parts: Roof side trim (See «ROOF SIDE TRIM REMOVAL/INSTALLATION»(ref-178403-S32499072472005061500000) .) A-pillar trim (See «A-PILLAR TRIM REMOVAL/INSTALLATION»(ref-178403-S21109983142005061500000) .) Rear seat (See «REAR SEAT REMOVAL/INSTALLATION»(ref-178399-S03461608852005061500000) .) Inner scuff plate (See «INNER SCUFF PLATE REMOVAL/INSTALLATION»(ref-178403-S10793838542005061500000) .) Tire house trim (See «TIRE HOUSE TRIM REMOVAL/INSTALLATION»(ref-178403-S34208887982005061500000) .) Rear pillar trim (See «REAR PILLAR TRIM REMOVAL/INSTALLATION»(ref-178403-S00720306752005061500000) .) Map light (See «MAP LIGHT REMOVAL/INSTALLATION»(ref-178404-S16618549752005061500000) .) Interior light (See «INTERIOR LIGHT REMOVAL/INSTALLATION»(ref-178404-S41164716852005061500000) .) Sunvisor (See «SUNVISOR REMOVAL/INSTALLATION»(ref-178403-S21013632222005061500000) .) Assist handle (See «ASSIST HANDLE REMOVAL/INSTALLATION»(ref-178403-S23122633592005061500000) .) Headliner (See «HEADLINER REMOVAL/INSTALLATION»(ref-178403-S19009629372005061500000) .) Head impact pad (See «HEAD IMPACT PAD REMOVAL/INSTALLATION»(ref-178403-S35168581012005061500000) .) Glass panel (See «GLASS PANEL REMOVAL/INSTALLATION»(ref-178401-S26440844072005061500000) .)
  3. Disconnect the front and rear drain hoses from the sunroof frame.
  4. Remove the bolts from curtain air bag module points A.
  5. Remove the bolt, then remove the bracket.
  6. Remove the rear door striker (upper).
  7. Remove the rear set bracket.
  8. Remove the nuts and screws, then remove the sunroof unit.
  9. Install in the reverse order of removal.
  10. Adjust the glass panel. (See «GLASS PANEL ADJUSTMENT»(ref-178401-S12784341942005061500000) .)

Scheme 12

Scheme 12: SUNROOF UNIT DISASSEMBLY/ASSEMBLY
Scheme 12: SUNROOF UNIT DISASSEMBLY/ASSEMBLY
  1. Remove the glass panel. (See «GLASS PANEL REMOVAL/INSTALLATION»(ref-178401-S26440844072005061500000).)
  2. Disassemble in the order indicated in (Scheme 12).
  3. Assemble in the reverse order of disassembly.

Note. If the guide is removed, initial position setting of the sunroof motor will be required. After installing the sunroof unit, perform initial position setting using the following procedure.

  1. Press the CLOSE switch to fully close the glass panel.
  2. When the glass panel reaches the fully closed position, temporarily release the CLOSE switch and press it again for approx.13 s continuously. Continue pressing the switch until the glass panel automatically stops at the fully closed position after reaching the mechanical lock position.
  3. When the glass panel stops at the fully closed position, temporarily release the CLOSE switch, then press it again within 5 s and hold. NOTE: Press the CLOSE switch continuously until the glass panel opens to the fully open position, returns to the fully closed position and then stops.
  4. Release the CLOSE switch when the glass panel stops at the fully closed position.

Scheme 13

Scheme 13: SUNROOF MOTOR REMOVAL/INSTALLATION
Scheme 13: SUNROOF MOTOR REMOVAL/INSTALLATION
  1. Disconnect the negative battery cable.
  2. Remove the following parts: Roof side trim (See «ROOF SIDE TRIM REMOVAL/INSTALLATION»(ref-178403-S32499072472005061500000) .) A-pillar trim (See «A-PILLAR TRIM REMOVAL/INSTALLATION»(ref-178403-S21109983142005061500000) .) Rear seat (See «REAR SEAT REMOVAL/INSTALLATION»(ref-178399-S03461608852005061500000) .) Inner scuff plate (See «INNER SCUFF PLATE REMOVAL/INSTALLATION»(ref-178403-S10793838542005061500000) .) Tire house trim (See «TIRE HOUSE TRIM REMOVAL/INSTALLATION»(ref-178403-S34208887982005061500000) .) Rear pillar trim (See «REAR PILLAR TRIM REMOVAL/INSTALLATION»(ref-178403-S00720306752005061500000) .) Map light (See «MAP LIGHT REMOVAL/INSTALLATION»(ref-178404-S16618549752005061500000) .) Interior light (See «INTERIOR LIGHT REMOVAL/INSTALLATION»(ref-178404-S41164716852005061500000) .) Sunvisor (See «SUNVISOR REMOVAL/INSTALLATION»(ref-178403-S21013632222005061500000) .) Assist handle (See «ASSIST HANDLE REMOVAL/INSTALLATION»(ref-178403-S23122633592005061500000) .) Headliner (See «HEADLINER REMOVAL/INSTALLATION»(ref-178403-S19009629372005061500000) .)
  3. Disconnect the sunroof motor connector.
  4. Remove the screws, then remove the sunroof motor.
  5. Install in the reverse order of removal. NOTE: If the glass panel or the sunroof motor is moved with the sunroof motor removed, initial position setting of the sunroof motor will be required. Perform initial position setting referring to the Sunroof Motor Assembly Note. (See «SUNROOF MOTOR ASSEMBLY NOTE»(ref-178401-S00568973832005061500000) .)
  1. Measure the voltage at each terminal (other than terminal D). If not as specified, inspect the parts listed under "Inspection item" and the related wiring harnesses.
  2. Disconnect the negative battery cable.
  3. Verify that continuity at terminal D is as indicated in the Terminal Voltage Table (Reference). See «TERMINAL VOLTAGE LIST (REFERENCE)»(ref-178401-S20258592342005061500000) .
  4. If the parts and wiring harnesses are okay but the system still does not work properly, replace the sunroof relay.

Scheme 14

Scheme 14: Terminal Voltage List (Reference)
Scheme 14: Terminal Voltage List (Reference)

Scheme 15

Scheme 15
Scheme 15

Scheme 16

Scheme 16
Scheme 16

Note. The sunroof switch and the map light are a single unit.

  1. Disconnect the negative battery cable.
  2. Remove the map light from the headliner. (See «MAP LIGHT REMOVAL/INSTALLATION»(ref-178404-S16618549752005061500000) .)
  3. Install in the reverse order of removal.

Scheme 17

Scheme 17: SUNROOF SWITCH INSPECTION
Scheme 17: SUNROOF SWITCH INSPECTION

Scheme 18

Scheme 18
Scheme 18
  1. Verify that the continuity between the sunroof switch is as indicated in (Scheme 17). If not as indicated, replace the sunroof switch.

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