Chrysler Front Wheel Drive Cars 4-CYL 1981-1995 Repair Information

Power Sunroof

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REMOVAL & INSTALLATION



Glass Panel
  1. Remove the wind deflector mechanism covers.
  2.  
  3. Position the glass to the vent position.
  4.  
  5. Position the sunshade full rearward.
  6.  
  7. Loosen the nuts holding the glass panel to the side adjustment brackets.
  8.  
  9. Slide the glass panel rearward 0.05 in. (1.3mm) and separate the glass from the sunroof unit.
  10.  

To install:
  1. Position the glass panel in the opening with the logo rearward and slide the panel forward 0.05 in. (1.3mm).
  2.  
  3. Verify that the attaching nuts are below the top surface of the glass adjustment brackets.
  4.  
  5. Close the sunroof to the center glass panel in roof opening. Tighten the center screws to hold adjustment.
  6.  
  7. Open the glass to vent position and tighten the nuts 70 inch lbs. (8 Nm). Close the glass and check the alignment.
  8.  
  9. Install the mechanism covers. Adjust the wind deflector, if necessary.
  10.  

Motor and Drive Gears

See Figure 1

Click image to see an enlarged view

Fig. Fig. 1: The motor and drive gear and related components

  1. Open the sunroof to the vent position.
  2.  
  3. Remove the headlining.
  4.  
  5. Remove the bolts holding the sunroof motor to the motor bracket.
  6.  
  7. Unplug the wire connector.
  8.  
  9. Separate he motor and drive gear from the drive cables.
  10.  

To install:
  1. Verify that the sunroof is in the vent position. Push the mechanism forward on both sides to align the drive cables.
  2.  
  3. Engage the driven gears onto the drive cables.
  4.  
  5. Install the motor and drive gear screws to 44 inch lbs. (5 Nm).
  6.  
  7. Install the headlining.
  8.  

Guide Assembly
  1. Remove the wind deflector, mechanism covers, glass panels, drain channel, sunshade and drive cable locator as necessary.
  2.  
  3. Move the glass carriage to the vent position.
  4.  
  5. Remove the front slide from the guide assembly.
  6.  
  7. Remove the screws holding the front and center guide track to the unit.
  8.  
  9. Pull the cable out of the groove for the cable end.
  10.  
  11. Pull the guide outward to release it from the housing. Separate the rear end of the guide from the clips. Slide the guide out of the unit.
  12.  

To install:
  1. Install the guide cable into the rear of the guide assembly.
  2.  
  3. Install the guide assembly at an angle so the rear portion slips under the finger clips at the rear of the module housing.
  4.  
  5. Place the cable in the groove of the cable holder.
  6.  
  7. Install the screws in the track assembly.
  8.  
  9. Install the cable locators.
  10.  
  11. Install the sunshade, the drain channel, glass panel, mechanism covers and wind deflector.
  12.  

ADJUSTMENT



Glass Vertical Height

See Figure 2

Click image to see an enlarged view

Fig. Fig. 2: Tighten or loosen the adjusting bolts to raise and lower the glass panel

  1. Open the glass to the vent position.
  2.  
  3. Slide the upper half of the mechanism covers rearward until the clips disengage and separate the covers from the vehicle.
  4.  

  1. Close the glass panel, separately loosen the adjusting bolts and individually adjust the corners of the glass.
  2.  
  3. Adjust the front of the glass panel to 0.040 in. (1mm) below the top surface of the roof panel.
  4.  
  5. Adjust the rear of the glass panel to 0.040 in. (1mm) above the top surface of the roof panel.
  6.  
  7. Secure the adjustment bolts and install the mechanism covers.
  8.  

Wind Deflector

See Figure 3

Click image to see an enlarged view

Fig. Fig. 3: Adjust the wind deflector until it is positioned as shown

  1. Open the sunroof.
  2.  
  3. Position the wind deflector so that it is 0.75 in. (19mm) above the top surface of the roof panel and 0.040 in. (1mm) rearward of the roof panel forward edge.
  4.  
  5. Secure the wind deflector to the sunroof unit.
  6.  

 
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