GM Cavalier/Sunfire 1995-2000 Repair Guide

Sunroof

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REMOVAL & INSTALLATION



Glass Panel (Module)

See Figures 1 and 2



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Fig. Fig. 1: Sunroof exploded view



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Fig. Fig. 2: Sunroof glass mounting

  1. Disconnect the negative battery cable.
  2.  
  3. Slide the sunroof shade open.
  4.  
  5. Position the sunroof glass panel in the fully closed position.
  6.  
  7. Remove the six screws (3 on each side) retaining the sunroof glass panel.
  8.  
  9. Remove the glass panel.
  10.  

To install:
  1. Position the glass panel into the opening.
  2.  
  3. Tighten the retaining screws until fully driven and seated, but take caution not to strip.
  4.  

Motor (Power Only)

See Figures 3 and 4



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Fig. Fig. 3: Remove the windshield side upper garnish molding (A-pillar trim)



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Fig. Fig. 4: Sunroof motor timing marks

  1. Disconnect the negative battery cable.
  2.  
  3. Position the sunroof glass panel in the fully closed position.
  4.  

If the sunroof motor is inoperative, the glass can be closed by inserting the appropriate size hex head wrench into the drive gear. If there is a red retainer surrounding the screw, remove it and insert a flat tip screwdriver. Turn the hex head wrench until the glass is fully closed. It may require a significant amount of force to begin to move the motor. After the glass is fully seated, back the screw off approximately 15°.

  1. Remove the windshield side upper garnish moldings (A-pillar trim).
  2.  
  3. Remove the sunshade screws and remove the sunshade.
  4.  
  5. Remove the sunroof control switch assembly by gently prying it out from the headliner and detaching the connector.
  6.  
  7. Remove the sunroof opening trim lace.
  8.  
  9. Lower the headliner as required.
  10.  
  11. Detach the connector for the sunroof motor.
  12.  
  13. Remove the sunroof motor bracket bolts and remove the sunroof motor.
  14.  

To install:

Before installation, be sure that the motor is timed to the closed position, see graphic.

  1. Installation is the reverse of removal.
  2.  

GLASS ADJUSTMENT



  1. Slide the sunroof shade open.
  2.  
  3. Position the sunroof glass panel in the fully closed position.
  4.  
  5. Seperately loosen the six adjusting screws (3 on each side) and adjust the four corners of the glass panel.
  6.  
  7. Adjust the front of the glass panel to 1 / 32 (1.0 mm) below the top surface of the roof, and the rear of the glass panel to 1 / 32 (1.0 mm) above the top surface of the roof.
  8.  
  9. Tighten the adjusting screws until fully driven and seated, but take caution not to strip.
  10.  

 
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