Chrysler Neon 1995-1999 Repair Guide

Power Sunroof

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REMOVAL & INSTALLATION



See Figure 1

Sunroof Drive Motor

WARNING
Do NOT cycle the new motor before installation. The motor is shipped in the closed position. The sunroof vent position is programmed into the motor and is dependent on the closed position of the motor. If the drive motor and sunroof mechanism are not both in the closed position, the sunroof vent height will not be correct.

  1. Remove the headliner until the sunroof drive motor is accessible.
  2.  
  3. If the drive motor is to be reused, cycle the sunroof to the full forward position.
  4.  
  5. Detach the wire harness connector from the motor.
  6.  
  7. Remove the three screws attaching the drive motor-to-sunroof module bracket.
  8.  
  9. Separate the drive motor from the bracket.
  10.  

To install:
  1. With the help of an assistant, hold the sunroof glass panel in the closed position and engage the drive motor into the sunroof drive cables.
  2.  
  3. Install the screws holding the drive motor to the bracket.
  4.  
  5. Connect the wire harness to the drive motor.
  6.  
  7. Install the headliner.
  8.  
  9. Connect the negative battery cable. Check for proper sunroof operation.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the sunroof glass and related components

Sunroof Glass Panel
  1. Disconnect the negative battery cable.
  2.  
  3. Place the sunroof sunshade in the fully open position.
  4.  
  5. Remove the 6 glass mounting screws.
  6.  
  7. Push the glass panel upward from the underside until the glass panel clears the roof panel.
  8.  
  9. Lift the glass the panel from the vehicle.
  10.  

To install:
  1. Position the glass panel in the opening in the roof.
  2.  
  3. Install, but do not tighten, the glass attaching screws.
  4.  
  5. With the help of an assistant, hold the glass panel in place, then tighten the 6 mounting screws.
  6.  
  7. Check the sunroof to make sure it is the proper height, as outlined later in this section.
  8.  

Sunroof glass height adjustment

Flushness Adjustment
  1. Place the sun shade in the fully open position.
  2.  
  3. To adjust the front of the glass, perform the following:
    1. Loosen the front and middle glass attachment screws.
    2.  
    3. Adjust the front of the sunroof glass panel so that the corners are flush to 1.0mm below the top surface of the roof panel.
    4.  
    5. Tighten all of the glass attachment screws.
    6.  

  4.  
  5. To adjust the rear of the glass, perform the following:
    1. Loosen the rear and middle glass attachment screws.
    2.  
    3. Adjust the rear of the sunroof glass panel so that the corners are flush to within 1.0mm of the top surface of the roof panel.
    4.  
    5. Tighten all of the glass attachment screws.
    6.  

  6.  

Vent Height Adjustment

  1. Cycle the sunroof module to the vent position using the drive motor.
  2.  
  3. Check the glass height in tilt using the proper measuring tool.
  4.  
  5. If the vent height is greater than 35mm, use the switch to slowly set to the proper height.
  6.  
  7. After setting the correct height, remove the drive motor.
  8.  
  9. With the motor removed, use the switch to set the tilt by operating the gear to the fully closed position.
  10.  
  11. Using the tilt switch only, operate the motor until it comes to a full stop at the tilt position.
  12.  
  13. Install the drive motor and verify correct operation.
  14.  

 
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