GM Malibu/Cutlass 1997-2000

Sunroof

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REMOVAL & INSTALLATION



Glass Panel


Click image to see an enlarged view

Fig. The sunroof glass panel is secured to the assembly by these 3 screws on each side of the panel

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

To install:

  1. Position the glass panel into the opening.
  2.  
  3. Tighten the retaining screws to 35 inch lbs. (4 Nm).
  4.  
  5. Adjust the sunroof window as outlined in this section.
  6.  

Motor
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the sunroof window. Refer to procedure outlined in this section.
  4.  
  5. Remove the headliner trim panel.
  6.  
  7. Detach the electrical connector from the sunroof actuator.
  8.  



Click image to see an enlarged view

Fig. Sunroof motor timing marks


NOTE
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 with a flat-bladed prytool. 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 sunroof motor screws.
  2.  
  3. Remove the sunroof motor.
  4.  

To install:


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

  1. Installation is the reverse of removal. Tighten the motor screws to 35 inch lbs. (4 Nm).
  2.  

GLASS ADJUSTMENT



  1. Slide the sunroof shade open.
  2.  
  3. Position the sunroof glass panel in the fully closed position.
  4.  
  5. Separately 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 to 35 inch lbs. (4 Nm).
  10.  

 
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