Saturn Coupes/Sedans/Wagons 1991-1998 Repair Guide

Power Sunroof

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REMOVAL & INSTALLATION



See Figure 1

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

Glass

See Figure 2

  1. Turn the ignition ON and set the sunroof to the VENT position, then turn the ignition OFF .
  2.  
  3. Remove the retaining screws that attach the sunroof glass to the guide assemblies, then carefully lift the glass from the roof opening.
  4.  


WARNING
Once the glass has been removed from the sunroof, DO NOT cycle the roof to the full closed position or the guide assemblies will be damaged.

To install:
  1. With the guide assemblies still in the VENT position, lower the glass onto the guides and align the mounting holes.
  2.  
  3. Apply Loctite® 222 or an equivalent small screw threadlocker to the attaching screws, then loosely install the screws.
  4.  
  5. Turn the ignition ON and close the sunroof, then adjust the glass to 0.04 in. (1mm) below the roof surface at the front and rear of the glass, then tighten the glass attaching screws to 35-44 inch lbs. (4-5 Nm).
  6.  



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Fig. Fig. 2: Remove the glass retaining screws while the sunroof is in the vent position

Motor

See Figures 3 and 4

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the headliner from the vehicle. Refer to the procedure later in this section.
  4.  
  5. Remove the Connector Position Assurance (CPA) device from the motor harness wire connector, then unplug the harness from the motor.
  6.  
  7. Remove the 3 retaining screws, then remove the sunroof motor, spacers and guide block.
  8.  

To install:
  1. Install the motor spacers onto the motor, then slide the guide assembly to the full rearward position in order to time the cables.
  2.  
  3. Position the guide block onto the motor, aligning it to the locator pins on the motor housing.
  4.  
  5. Install the sunroof motor using the 3 screws, then tighten the screws to 27-35 inch lbs. (3-4 Nm).
  6.  
  7. Install the wiring harness connector to the motor terminals, then install the CPA device.
  8.  
  9. Install the headliner to the vehicle.
  10.  
  11. Connect the negative battery cable.
  12.  



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Fig. Fig. 3: Exploded view of the sunroof motor mounting



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Fig. Fig. 4: Remove the spacers and guide block from the motor

Switch

See Figures 5 and 6

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the map lamp lens and bezel assembly from the roof console assembly.
  4.  
  5. Disengage the sunroof opening windlace at the switch area.
  6.  
  7. Remove the sun visor inboard anchor clips.
  8.  
  9. Remove the 2 retaining screws, then lower the switch and roof console assembly.
  10.  
  11. Unplug the wiring harness connector from the switch, then depress the switch tabs at the console to remove the switch.
  12.  

To install:
  1. Push the switch into the roof console until the tabs engage, then install the wiring harness to the switch terminals.
  2.  
  3. Install the switch and console assembly using the retaining screws.
  4.  
  5. Install the sun visor inboard anchor clips and the sunroof opening windlace.
  6.  
  7. Install the map lens and bezel assembly to the roof console, then connect the negative battery cable.
  8.  



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Fig. Fig. 5: Remove the lamp lens and bezel assembly



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Fig. Fig. 6: Remove the retaining screws, then lower the switch and roof console assembly

Guide Assembly

See Figures 7 and 8

  1. Position the sunroof glass in the VENT position, then remove the glass according to the procedure earlier in this section.
  2.  
  3. If equipped, remove the wind deflector by pushing the spring ends down and forward, then slide the deflector rearward and out of the vehicle.
  4.  
  5. Remove the screw from each locator. Remove the locator from the right side, then remove the locator and microswitch from the left side. Each locator can be removed by inserting a screwdriver into the screw hole, tilting the screwdriver toward the center of the vehicle and then sliding it forward.
  6.  
  7. Remove the sunshade from the vehicle. Refer to the procedure later in this section.
  8.  
  9. Lift the drive cable end out of the guide assembly.
  10.  
  11. Remove the guide assembly screws, then remove the rear screw and spacer.
  12.  
  13. Slide the rear of the guide assembly towards the center of the vehicle and remove the guide assembly.
  14.  

To install:
  1. Position the front of the guide assembly at the front mount location with the guide' rear at the opposite corner of the sunroof opening. Slide the rear of the guide under the roof panel and toward the outboard side of the opening to the rear mounting position.
  2.  
  3. Install the guide rear spacer and guide screws, then tighten the screws to 35-44 inch lbs. (4-5 Nm).
  4.  
  5. Engage the drive cable into the guide assembly.
  6.  
  7. Install the sunshade to the vehicle.
  8.  
  9. Install each locator by positioning the locator into the guide assembly slightly ahead of its installed position. Insert a screwdriver into the locator screw hole, then push rearward and down on the locator to engage it with the guide.
  10.  
  11. Install each locator screw and tighten to 35 inch lbs. (4 Nm).
  12.  
  13. If equipped, install the wind deflector by positioning the deflector front tabs under the roof flange at the front and by engaging the spring ends into the brackets.
  14.  
  15. Install the sunroof glass. Refer to the procedure earlier in this section. Be sure to properly adjust the glass before tightening the retaining screws.
  16.  



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Fig. Fig. 7: After removing the locator screw, insert a screwdriver into the screw hole, tilt the screwdriver toward the vehicle' center and slide it forward to remove the locator



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Fig. Fig. 8: Remove the retaining screws, then remove the guide assembly from the vehicle

Cables

See Figure 9

  1. Position the sunroof glass in the VENT position, then remove the glass according to the procedure earlier in this section.
  2.  
  3. Remove the sunroof motor according to the procedure earlier in this section.
  4.  
  5. Remove the screw from each locator. Remove the locator from the right side, then remove the locator and microswitch from the left side. Each locator may be removed by inserting a screwdriver into the screw hole, tilting the screwdriver toward the center of the vehicle and then sliding it forward.
  6.  
  7. Lift the drive cable ends out of the guide assembly, then pull the cables out of the sunroof cable guide tubes.
  8.  

To install:

Cables should always be replaced if they are kinked. Also, cables should always be replaced in pairs and greased before installation.

  1. Push the greased cables into the guide tubes, but be careful not to kink the cables.
  2.  
  3. Engage the cables into the guide assemblies.
  4.  
  5. Slide the guide assemblies to the full rearward position in order to time the cables.
  6.  
  7. Install each locator by positioning the locator into the guide assembly slightly ahead of its installed position. Insert a screwdriver into the locator screw hole, then push rearward and down on the locator to engage it with the guide.
  8.  
  9. Install each locator screw and tighten to 35 inch lbs. (4 Nm).
  10.  
  11. Install the sunroof motor according to the procedure earlier in this section.
  12.  
  13. Install the sunroof glass. Refer to the procedure earlier in this section. Be sure to properly adjust the glass before tightening the retaining screws.
  14.  



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Fig. Fig. 9: Lift the drive cable ends out of the guide assembly

Sunshade

See Figures 10 and 11

  1. Position the sunroof glass in the VENT position, then remove the glass according to the procedure earlier in this section.
  2.  
  3. Push the sunshade slide blocks into the sunshade in order to release them from the sunroof guide assembly, as follows:
    1. For the Sedan, both slide blocks on one side of the vehicle should be released first, then release both blocks on the other side and remove the shade through the sunroof opening.
    2.  
    3. For the Coupe, release the rear slide blocks first and remove the rear section through the sunroof opening, then repeat the procedure at the front slide blocks and remove the shade from the vehicle.To install:
    4.  

  4.  
  5. For the Coupe:
    1. Install the front half of the sunshade first by inserting the slide blocks on the right side of the sunshade in the lower slide position of the right guide assembly. Then, push the slide blocks on the left side into the sunshade to allow the front half of the shade to drop into position. When positioned, engage the blocks into the lower channel of the left guide.
    2.  
    3. Push the front half of the sunshade to the full forward position.
    4.  
    5. Position the rear half of the shade so that the stop tabs are against the bumpers on the guide assembly. Engage the right slide blocks of the shade' upper half into the upper channel on the right guide assembly.
    6.  
    7. Engage the slide blocks on the left side into the upper channel of the left guide assembly.
    8.  
    9. Slide the sunshade back and forth to assure proper and smooth operation.
    10.  

  6.  
  7. For the Sedan:
    1. Insert the slide blocks on the right side of the sunshade into the sunroof guide assembly.
    2.  
    3. Push the sunshade slide blocks on the left side into the sunshade to allow the sunshade to drop into position. Once the sunshade is positioned, engage the slide blocks into the left guide assembly.
    4.  
    5. Slide the sunshade back and forth to assure proper and smooth operation.
    6.  

  8.  
  9. Install the sunroof glass. Refer to the procedure earlier in this section. Be sure to properly adjust the glass before tightening the retaining screws.
  10.  



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Fig. Fig. 10: Push the slide blocks into the sunshade in order to engage or disengage the shade from the guides



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Fig. Fig. 11: Two slide blocks engage the guide assemblies on each side of the sunshade

 
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