Procedures
1. Remove sunroof glass.
a. Remove six screws attaching sunroof glass to guide assemblies.
b. Lift glass from sunroof module assembly.
IMPORTANT:
If sunroof functions, cycle to vent position before removing sunroof glass.
2. Remove sunshade. (Refer to "Sunroof Sunshade" removal procedure in the "Vehicle Interior Systems" section of the "Body/Repair Service Manual.")
IMPORTANT:
Cycle sunroof guides to closed position before removing sunroof module.
3. Remove sunroof module. (Refer to "Sunroof Module" removal procedure in the "Vehicle Interior Systems" section of the "Body/Repair Service Manual.")
4. Place sunroof module on a clean work bench with the sunroof actuator (motor) facing up.
5. Remove three sunroof actuator attaching screws and remove sunroof actuator from sunroof module.
NOTICE:
Make sure not to enlarge diameter of rivet hole in plastic substrate of sunroof module when drilling out actuator mounting plate attaching rivet.
6. Using a 1/8 inch drill bit, drill out the actuator mounting plate attaching rivet and remove the actuator mounting plate.
7. Turn sunroof module over, and remove the two locator block screws and remove the locator block. Repeat procedure for the opposite side of the sunroof module.
8. Use a pair of needle nose pliers to lift the drive cable end out of the guide assembly. Repeat procedure for the opposite side of sunroof module.
IMPORTANT:
If the sunroof was locked in the open position, it will be necessary to partially remove the copper cable tubing and use it to pull the guide forward to expose the cable end.
9. Disengage the flared end of the copper cable tubing from the sunroof module and pull it through the pass through holes in the sunroof module. Discard the copper cable tubing; however, DO NOT discard the black plastic tubing, it will be reused.
10. Use 3M(R) General Purpose Adhesive Remover (P/N 08984) or equivalent to clean all sealer and rust stains from around the sunroof module cable tubing pass through holes, cable locator blocks and actuator mounting area. Also, to provide a clean sealing surface, clean any cable grease from the new copper cable tubing.
NOTICE:
Make sure not to crush plastic tubing when installing wire ties. If wire ties are installed too tightly, the drive cable cannot move freely inside plastic tubing, causing the sunroof to become inoperative.
11. Install a new sunroof drive cable into the end of the new left side copper cable tubing (longer tube) and then through the flared end of the (shorter) black plastic tube. Repeat the procedure for the right side, using the remaining tubes. Use wire ties (P/N 21020792), to hold the tubes together as shown.
12. Use 3M(R) Strip Caulk (P/N 08610) or equivalent, to seal the cable tubing pass through hole in the sunroof module. Wrap a 305 mm (12 in.) length of strip caulk around the copper tubing, 25.4 mm (1 in.) back from the flared end of the copper tubing, and mold it into a cone shape as shown. Repeat procedure on the opposite side of sunroof module.
13. Route cable assemblies into the pass through holes of the sunroof module, and install drive cable ends into notches in the guide assembly.
IMPORTANT:
The cam sides of the cable ends must be positioned as shown in the illustration or the cable ends will not enter the sunroof module's cable guide channels. In the correct orientation, the lobes of the cam on the cable are aligned diagonally from the inboard top, to outboard bottom of the square shaped guide slot (on both sides).
14. Using the installed cable, push the guide rearward to verify proper orientation of the cam on the cable. If orientation is correct, the cam will slide into the guide channel. If the orientation is incorrect, the cam will stop at the guide slot.
IMPORTANT:
It may be necessary to pull several inches of cable through the tubing assembly to rotate the cam on the cable to the correct orientation.
15. After correct cable end orientation has been verified on both sides of sunroof module, using the cables, pull both guides to the forward most (closed) position.
16. Seal cable tubing pass through holes by working strip caulk, installed on the tubing in step 12, to seal around the pass through holes.
IMPORTANT:
Remove any sealer that penetrates the pass through holes to the inside of the sunroof module. Sealer on the inboard side of the module will restrict the water drainage system of the sunroof module.
17. With the flared ends of the copper tube seated in the notches of the sunroof module, install locator blocks.
Torque: 3 N.m (27 in-lbs)
18. Remove old spring plate from the actuator (motor) mounting plate, clean mounting plate, and install new spring plate from cable kit (P/N 21056010).
19. Place the flared ends of the copper and black plastic cable tubing into the notches at the sunroof actuator.
IMPORTANT:
Make sure cables and tubing are installed as shown, or unit will operate backwards.
20. Using a Snap-on(R) Rivet Tool (HP200A) or equivalent, install 1/8 x 1/4 inch aluminum button-head rivet to attach actuator mounting plate to the sunroof module. Make sure to install rivet from bottom of sunroof module.
21. Time sunroof actuator according to the following steps.
^ Motor with two terminal connectors:
a. With an ohmmeter, backprobe the white and yellow wires located at the gear housing part of the sunroof actuator.
b. Insert a large flat bladed screwdriver into the sunroof actuator gear drive slot. Turn the screwdriver clockwise until the ohmmeter indicates an open circuit. (This may require approximately 11 turns.)
c. From this position, turn screwdriver 1-1/2 turns clockwise. This times the sunroof actuator to the fully closed position.
^ Motors with three terminal wire connectors:
a. Connect sunroof actuator to wiring harness in vehicle.
b. Run motor using the sunroof switch in the vent position until the motor stops.
c. Insert a large flat bladed screwdriver into the motor gear drive slot. Turn the screwdriver 1-1/2 turns clockwise. This times the sunroof actuator to the fully closed position.
d. Disconnect sunroof actuator from wiring harness.
22. With the sunroof guides in the fully closed position, install the sunroof actuator onto the sunroof module. If required, use a screwdriver in the actuator to rotate the actuator gear to align the actuator gear with the drive cables before installing the three actuator attaching screws.
NOTICE:
Do not use the screws to run the actuator up to the sunroof module. This may cause damage to the drive cables, if the actuator gear and the drive cables are not aligned.
23. Install actuator screws.
Torque: 4 N.m (35 in-lbs)
NOTICE:
Make sure sunroof module drain hoses are not kinked or blocked.
24. Install sunroof assembly into the vehicle, leaving the sunroof module fasteners loose for the sunroof alignment procedure in step 26 of this bulletin. Do not install the headliner until the sunroof module and sunroof glass has been aligned, according to procedures in this bulletin. (Refer to "Sunroof Module" installation procedure in the "Vehicle Interior Systems" section of the "Body/Repair Service Manual.")
25. Install sunroof glass:
a. Position sunroof module to full vent position.
b. Set sunroof glass on the sunroof module guide assembly.
c. Apply Loctite(R) 222 Small Screw Threadlocker or equivalent to attaching screws.
d. Install sunroof glass attaching screws.
Torque: 3 N.m (26 in-lbs)
IMPORTANT:
The sunroof glass must be installed and sunroof screws tightened in order to correctly align sunroof module to roof.
26. With sunroof glass in position and sunroof module fasteners loose, align sunroof module to roof:
a. Cycle sunroof to fully open position, then cycle sunroof to the fully closed position.
b. Tighten sunroof module fasteners.
Torque: 14 N.m (124 in-lbs)
27. Align sunroof glass:
^ Front of sunroof glass should be 1 mm (0.040 in.) below surface of the roof.
^ Rear of sunroof glass should be 1 mm (0.040 in.) above surface of the roof.
If sunroof glass is adjusted to above specifications, proceed to next step. If sunroof glass is not adjusted correctly:
a. Loosen the sunroof glass attaching screws.
b. Adjust front and rear of sunroof glass according to above specifications.
c. Tighten sunroof glass attaching screws.
Torque: 3 N.m (26 in-lbs)
28. Cycle sunroof into vent, full open and full closed positions to verify proper operation.
29. Install sunroof sunshade. (Refer to "Sunroof Sunshade" installation procedure in the "Vehicle Interior Systems" section of the "1996 Body/Repair Service Manual.")
30. Install headliner and trim. (Refer to "Headliner" installation procedure in the "Vehicle Interior Systems" section of the "1996 Body/Repair Service Manual.")