Chrysler Concorde/Intrepid/LHS/New Yorker/Vision 1993-1997

Power Sunroof

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REMOVAL & INSTALLATION



Module

See Figures 1, 2 and 3



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Fig. Fig. 1: Exploded view of the sunroof assembly



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Fig. Fig. 2: Sunroof assembly legend



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Fig. Fig. 3: Sunroof module location

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the left A-pillar molding.
  4.  
  5. Unplug the wire connector from the body harness at the A-pillar.
  6.  
  7. Remove the headlining.
  8.  
  9. Disengage the hose clamps and separate the drain tubes from the sunroof module.
  10.  
  11. Remove the bolts holding the sunroof module mounting brackets to the side rails. Do not loosen or remove the brackets from the module.
  12.  
  13. With the aid of an assistant, remove the bolts holding the sunroof module to the roof panel.
  14.  
  15. Separate the sunroof module from the roof panel.
  16.  
  17. Remove the sunroof module through the rear door opening.
  18.  

To install:
  1. Insert the sunroof module through the rear door opening.
  2.  
  3. Position the sunroof module to the roof panel.
  4.  
  5. With the aid of an assistant, install the bolts holding the sunroof module to the roof panel.
  6.  
  7. Install the bolts holding the sunroof module mounting brackets to the side rails.
  8.  
  9. Push the drain tubes onto the sunroof module and engage the hose clamps.
  10.  
  11. Engage the wire connector to the body harness at the A-pillar.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Test the sunroof operation and adjust as necessary.
  16.  
  17. Install the headlining.
  18.  
  19. Install the left A-pillar molding.
  20.  

Drive Motor

See Figure 1

  1. Remove the headlining as necessary to gain access to the motor.
  2.  
  3. Unplug the wire connector.
  4.  
  5. Remove the bolts holding the drive motor to the module.
  6.  
  7. Separate the drive motor from the sunroof module.
  8.  

To install:
  1. Position the drive motor to the sunroof module.
  2.  
  3. Install the bolts holding the drive motor to the module.
  4.  
  5. Engage the wire connector.
  6.  
  7. Install the headlining.
  8.  

Trough Guide Link Cover

See Figure 1

  1. Open the sunroof to the vent position.
  2.  
  3. Disengage the push-in fasteners holding the cover to the trough guide link.
  4.  
  5. Loosen the nut holding the guide link trough at the rear.
  6.  
  7. Separate the linkage cover from the sunroof.
  8.  

To install:
  1. Position the linkage cover to the sunroof.
  2.  
  3. Tighten the nut holding the guide link trough at the rear.
  4.  
  5. Engage the push-in fasteners holding the cover to the trough guide link.
  6.  
  7. Test the sunroof operation.
  8.  

Glass Panel

See Figure 1

  1. Open the sunroof to the vent position.
  2.  
  3. Remove the trough guide link cover.
  4.  
  5. Remove the nuts holding the glass panel to the guide brackets.
  6.  
  7. Separate the glass panel from the vehicle.
  8.  

To install:
  1. Make sure the sunroof mechanism is in the vent position.
  2.  
  3. Place the glass panel in position in the opening.
  4.  
  5. Install the nuts holding the glass panel to the guide brackets. Do not tighten the nuts.
  6.  
  7. Align the glass panel as necessary.
  8.  
  9. Tighten the nuts holding the glass panel to 30 inch lbs. (3 Nm).
  10.  
  11. Install the trough guide link cover.
  12.  

Sunshade

See Figure 1

  1. Remove the glass panel.
  2.  
  3. Remove the rear drain trough.
  4.  
  5. Bow the sunshade upward to release the sunshade from the channel forward of the gate slot.
  6.  
  7. Lift the sunshade upward and forward out in the left channel.
  8.  
  9. Slide the sunshade forward.
  10.  
  11. Remove the sunshade from the vehicle.
  12.  

To install:
  1. Position the sunshade to the vehicle.
  2.  
  3. Insert the sunshade into the channel on the right side of the opening.
  4.  
  5. Insert the sunshade into the gate slot in the left channel.
  6.  
  7. Slide the sunshade rearward.
  8.  
  9. Bow the sunshade upward and insert the sunshade edge into the channel forward of the gate slot.
  10.  
  11. Install the rear drain trough.
  12.  
  13. Install the glass panel.
  14.  

Wind Deflector

See Figure 1

  1. Open the sunroof.
  2.  
  3. Remove the screws holding the track access plugs to the sunroof housing on each side of the wind deflector.
  4.  
  5. Remove the wind deflector from the vehicle.
  6.  

To install:
  1. Position the wind deflector to the vehicle.
  2.  
  3. Install the screws holding the track access plugs to the sunroof housing on each side of the wind deflector.
  4.  
  5. Check operation of the sunroof.
  6.  

Controller

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the headlining, as necessary, to gain access to the controller. Refer to the procedure outlined in this section
  4.  
  5. Unplug the controller wire connector from the body harness at the driver's side A-pillar.
  6.  
  7. Unplug the position sensor wire connector from the controller.
  8.  
  9. Unplug the drive motor wire connector from the controller.
  10.  
  11. Remove the push-in fasteners holding the controller to the sunroof module and separate the controller from the vehicle.
  12.  

To install:
  1. Position the controller to the vehicle.
  2.  
  3. Install the push-in fasteners holding the controller to the sunroof module.
  4.  
  5. Engage the drive motor wire connector to the controller.
  6.  
  7. Engage the position sensor wire connector to the controller.
  8.  
  9. Engage the controller wire connector to the body harness at the driver's side A-pillar.
  10.  
  11. Install the headlining, if removed, as outlined in this section.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Check operation of the sunroof.
  16.  

Position Sensor

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the headlining, as necessary, to gain access to the sensor on the driver's side of the vehicle. Refer to the procedure outlined in this section
  4.  
  5. Unplug the position sensor wire connector from the controller.
  6.  
  7. Remove the tape covering the position sensor wire harness.
  8.  
  9. With the use of a suitable prying tool, pry downward on the inner lip of the sensor retaining bracket.
  10.  
  11. Slide the sensor from behind the bracket.
  12.  

To install:
  1. Slide the sensor in position behind the retaining bracket.
  2.  
  3. Crimp the inner lip of the retaining bracket around the sensor.
  4.  
  5. Engage the position sensor wire connector to the controller.
  6.  
  7. Install tape over the position sensor wire harness.
  8.  
  9. Install the headlining. Refer to the procedure outlined in this section
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Check operation of the sunroof.
  14.  

Guide and Cam

See Figure 1

  1. Remove the glass panel.
  2.  
  3. Remove the glass panel guide brackets.
  4.  
  5. Push the glass panel slides rearward and separate the slide from the link.
  6.  
  7. Actuate the sunroof switch and close the sunroof intermittently until the forward end of the cam is past the rear end of the plugs.
  8.  
  9. Remove the screws holding the plugs to the front of the tracks.
  10.  
  11. Separate the plugs from the end of the tracks.
  12.  
  13. Remove the wind deflector.
  14.  
  15. Install the track plug to the side of the sunroof that does not require service. If both sides require service do not install the plug.
  16.  
  17. Actuate the sunroof switch closed until the cam stops.
  18.  
  19. Remove the screws holding the guide link to the guide.
  20.  
  21. Separate the front guide from the sunroof module.
  22.  
  23. Actuate the sunroof switch vent intermittently until the cam slide is 0.5 in. (12 mm) past the front of the tracks.
  24.  
  25. Separate the cable end from the cable slide.
  26.  
  27. Separate the cam slide from the sunroof module.
  28.  
  29. Remove the screws holding the trough to the rear guide shoes.
  30.  
  31. Separate the trough from the sunroof module.
  32.  
  33. Slide the rear guide shoes forward and out of the sunroof module tracks.
  34.  

To install:
  1. Slide the rear guide shoes into the forward end of the sunroof module tracks.
  2.  
  3. Position the trough to the sunroof module.
  4.  
  5. Install the screws holding the trough to the rear guide shoes.
  6.  
  7. Position the cam slide to the sunroof module.
  8.  
  9. Insert the cable end to the cable slide.
  10.  
  11. Actuate the sunroof switch vent intermittently until the cam slide is in the tracks.
  12.  
  13. Position the front guide to the sunroof module.
  14.  
  15. Install the screws holding the guide link to the guide.
  16.  
  17. Actuate the sunroof switch and open the sunroof intermittently until the forward end of the cam is past the rear edge of the track plug.
  18.  
  19. Remove the track plug on the the side of the sunroof that does not require service.
  20.  
  21. Install the wind deflector.
  22.  
  23. Inspect the foam seal on the sunroof track and replace as necessary.
  24.  


WARNING
The rear edge of the track plug and screw heads must not be higher than the sunroof track or damage to the sunroof mechanism can result.

  1. Position the plugs to the end of the tracks.
  2.  
  3. Install the screws holding the plugs to the front of the tracks.
  4.  
  5. Install the glass panel guide brackets.
  6.  
  7. Install the glass panel.
  8.  
  9. Synchronize the cables as outlined in this section.
  10.  


WARNING
Any time cables, cams or guides have been replaced, the sunroof cables must be synchronized. If the cables are not synchronized, the sunroof linkage will bind and could break the mechanism.

  1. Check operation of the sunroof.
  2.  

Cable

See Figure 1

  1. Remove the sunroof guides and cams.
  2.  
  3. Pull the cables forward from the tracks and separate the cables from the vehicle.
  4.  
  5. Remove the wind deflector from the vehicle.
  6.  

To install:
  1. Lubricate the cables with Lubriplate ® white grease, or equivalent.
  2.  
  3. Push the cables rearward into the tracks and casings.
  4.  
  5. Install the sunroof guides and cams.
  6.  
  7. Synchronize the cables as outlined in this section.
  8.  


WARNING
Any time cables, cams or guides have been replaced, the sunroof cables must be synchronized. If the cables are not synchronized, the sunroof linkage will bind and could break the mechanism.

  1. Check operation of the sunroof.
  2.  

ADJUSTMENTS



Cable Synchronization

See Figure 1


WARNING
Any time cables, cams or guides have been replaced, the sunroof cables must be synchronized. If the cables are not synchronized, the sunroof linkage will bind and could break the mechanism.

  1. With the sunroof drive motor, glass panel and glass panel slides removed, push the cam slides rearward until the cams contact but do not release the rear shoes.
  2.  
  3. Slowly pull the cam slides forward until the rear edges of the cam slides are in line with the front of the notches in the tracks.
  4.  
  5. Install the sunroof drive motor, glass panel and glass panel slides.
  6.  
  7. Check alignment and operation of the sunroof.
  8.  

Glass Panel Alignment

The sunroof glass panel should be aligned parallel to the sides of the sunroof opening with slight weatherstrip compression. A 0.003 in. (0.13 mm) thick paper card can be used as a gauge to measure the fit around the roof opening to the glass panel. The front edge of the glass panel should be flush to 0.004 in. (1.0 mm) lower than the forward roof panel. The rear edge of the glass panel should be flush to 0.004 in. (1.0 mm) higher than the rearward roof panel.

Glass Panel Side Clearance
  1. Open the sunroof to the vent position.
  2.  
  3. Remove the trough guide link covers.
  4.  
  5. Loosen the nuts holding the holding the glass panel to the mounting brackets.
  6.  
  7. Close the sunroof glass panel.
  8.  
  9. Shift the glass panel on the mounting brackets to achieve the proper alignment.
  10.  
  11. Tighten the nuts holding the glass panel to the mounting brackets to 30 in. lbs. (3 Nm).
  12.  
  13. Open the sunroof to the half vent position.
  14.  
  15. Verify the glass fit and operation.
  16.  
  17. Install the trough guide link covers.
  18.  

Glass Panel Front Height

  1. Close the sunroof glass panel.
  2.  
  3. Remove the trough guide link covers.
  4.  
  5. Loosen the screws holding the holding the glass panel mounting bracket to the forward guide plate.
  6.  
  7. Reposition the mounting bracket up or down and secure the screws.
  8.  
  9. Verify the sunroof operation.
  10.  
  11. Install the trough guide link covers.
  12.  

Glass Panel Rear Height

  1. Close the sunroof glass panel.
  2.  
  3. Remove the trough guide link covers.
  4.  
  5. Loosen the screws holding the holding the glass panel mounting bracket to the slides.
  6.  
  7. Reposition the glass panel up or down and secure the screws.
  8.  
  9. Verify the sunroof operation.
  10.  
  11. Install the trough guide link covers.
  12.  

 
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