Body - Sunroof Wind Noise/Auto Express Feature Inop.
NUMBER: 23-003-10GROUP: Body
DATE: February 27, 2010
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-013-08 REV. B, DATED DECEMBER 18, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED.
THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs.
HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW.
THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER TO PERFORM THIS PROCEDURE.
THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET.
StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.03 OR HIGHER FOR THIS BULLETIN.
StarMOBILE STANDALONE MODE OR StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE.
SUBJECT:
Flash: Sky Slider Wind Noise or Sky Slider Wind Noise and Loss of Auto (Express) Mode
OVERVIEW:
This bulletin involves lubricating the Sky Slider front drive cables and flashing the Sky Slider sunroof if previous Service Bulletins have not been performed, replacing the Front Header Bow and initializing the sunroof module, to correct wind noise or wind noise and a loss of auto-open or auto-close (express) mode(s).
MODELS:
2008 - 2009 (KK) Liberty
NOTE:
This bulletin applies to vehicles equipped with a Sky Slider sunroof (sales code GWH) built before September 27, 2008 (MDH 0927XX).
NOTE:
If more detailed removal and installation procedures are required refer to the KK Sky Slider Wind Noise Repair V8 E4ile located at DealerCONNECT > Efiles > Service > STAR Center > Misc Documents >.
SYMPTOM/CONDITION:
The vehicle operator may experience excessive wind noise with the sunroof in the closed position or excessive wind noise with the sunroof in the closed position and loss of "Auto Mode when operating Sky Slider sunroof. On vehicles built prior to January 16, 2008 Wind noise can be caused by closing roof at speeds above 60 MPH (96 KMH).
NOTE:
Export vehicles will not auto-close or auto-open while the ignition key is in the accessory position.
DIAGNOSIS:
If the vehicle operator experiences the Symptom/Condition, perform the Repair Procedure.
PARTS REQUIRED:
SPECIAL TOOLS/EQUIPMENT REQUIRED:
REPAIR PROCEDURE:
1. Has Service Bulletin 23-013-08 been performed before?
a. Yes >>> proceed to Step # 10
b. No >>> proceed to Step # 2
CAUTION:
Care should be taken not to over-torque drive gears when opening or closing sunroof manually or damage will result.
2. Remove the cargo lamp, Refer To 08 - Electrical / 8L - Lamps and Lighting / Lamps/Lighting - Interior/Lamp, Cargo - Removal.
3. Locate the REAR motor (1) drive axle hole and using a 6 mm hex socket or equivalent (4), manually open the rear drive assembly (7 turns counter clockwise) with a extension and driver used as a hand crank (Fig. 1).
4. Cut a section of 1/8 in ID tubing approximately 4 in long to be used as dispenser on the end of the grease tube.
5. Have an assistant operate the front "auto-open" function while applying 1/8 of a tube of grease per side to front drive cables until front of roof travels 1/2 way open. Press nozzle of grease application tubing against the slot of the corresponding drive cable channel (Fig. 2).
NOTE:
Rear header will move forward an additional 1.5" after the front header starts moving.
NOTE:
Be sure to stop top Front Header at the half way point.
NOTE:
If grease falls into slider track make sure to clean it out with alcohol.
6. Check front of both tracks to ensure they are clear of debris or obstructions.
7. Close front of sunroof and repeat lubrication procedure for the other side cable.
NOTE:
After lubrication of the other side cable, leave the front edge of sunroof open so it is located over the rear seat area. Approximately 762 cm (30 in).
NOTE:
Clean any excess lubricant that spills into sunroof slider channel with alcohol.
CAUTION:
Care should be taken not to over-torque drive gears when opening and closing sunroof manually or damage will result.
8. Manually close the rear section of the sunroof using hand crank.
9. Install cargo lamp.
10. Open front of Sky Slider sunroof half way. It may be necessary to push and hold the open button to get the top to open half way.
11. Pull front edge of the headliner down to separate the headliner hook and loop strip and the expose fasteners on the front of the movable roof header.
12. Carefully remove the plastic push pin holding the headliner at each end of the bow.
NOTE:
If pin broke during removal, make sure all pieces are removed to prevent rattle.
13. Remove the 5 Torx screws, (130) from the bow (Fig 4).
14. Flip the loose header bow over so the bottom side is facing up.
15. Remove and discard the push nuts on both ends (Fig. 5).
16. Carefully peel off the listing strip sticking to the edge of the header (Fig. 5).
17. Remove headliner strap from header bow on both ends (Fig. 5).
18. Carefully remove the clear tape from the mastic patch on the passenger side only.
19. Disengage top cover J-clip from header bow flange (Fig. 5).
20. Carefully remove Top Cover Tension Cables from header bow on both ends.
CAUTION:
Care should be taken to insure cables do not slide back into top cover pockets when disengaged.
21. Header should now be free from assembly, slide header back out of top cover.
22. Slide new header from kit p/n 68057092AA up into position in top cover pocket until die cast pins show through the holes in plastic.
23. Attach Top Cover Tension Cables to end of header on both ends.
24. Attach top cover J-Clip to the header bow extrusion along flange (Fig. 5).
CAUTION:
This step is critical. J-Clip must snap into header bow and lay flat.
25. Install NEW push nuts from kit p/n 68057092AA all the way down over the die cast pins at each end (Fig. 5).
26. Pull red protective cover off two-sided tape on header and stick one side of the listing strip to the tape (Fig. 5).
NOTE:
Make sure listing strip lays flat and does not run up the header wall.
27. Attach headliner strap on both ends (Fig. 5).
28. Apply NEW clear tape patch from kit p/n 68057092AA over the top cover and burnish down with squeegee for full wet out. Reference drivers side for tape location.
29. Protect (cover) the rear seat under bow.
CAUTION:
This next step is critical. Holes must be 7.5 mm (0.295 in).
30. Drill out the five holes in the retainer bow to 7.5 mm (0.295 in)
31. Flip the new header over into position and align onto the retainer bow.
32. With the aid of an assistant, apply slight down pressure to the front of header and slight up pressure to screws as they are retightened (Fig 6). Start with the center screw and work outward. Torque all 5 screws to 20 N-m (177 In Lbs.)
NOTE:
Ensure next step is performed.
33. Verify torque of all screws to 20 N-m (177 In Lbs.).
34. Install NEW plastic push pins from kit p/n 68057092AA in headliner and Front Retainer bow at each end.
35. Reattach headliner to Velcro, starting at center and working your way outboard.
36. Remove rear seat (cover) protection and if necessary clean up carpet and seat.
NOTE:
Ensure next step is performed.
37. Check front of both tracks to ensure they are clear of debris or obstructions.
38. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash and initialization process is complete.
39. Connect the CH9410 StarSCAN(R) Ethernet cable to the StarSCAN(R) and the dealer's network drop.
NOTE:
The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center".
40. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle data link connector (DLC).
41. Turn the ignition switch to run.
42. Is the vehicle build date before January 16, 2008 (MDH 0116XX)?
a. Yes >>> proceed to Step # 43
b. No >>> proceed to Step # 56 for STAR Scan or Step # 59 for wiTech
43. Has Service Bulletin 23-013-08 been performed before?
a. Yes >>> proceed to Step # 56 for STAR Scan or Step # 59 for wiTech
b. No >>> proceed to Step # 41 for STAR Scan or Step # 57 for wiTech
44. Select "ECU View"
45. Touch the screen to highlight SUNR in the list of modules.
46. Select "More Options"
47. Select "ECU Flash".
48. Record the "Part Number", displayed on the "Flash SUNR" screen, for later reference.
49. Select "Browse for New File". Follow the on screen instructions.
50. Highlight the listed SUNR calibration.
51. Select "Download to Scantool".
52. Select "Close after the download is complete, and then select "Back".
53. Highlight the flash file and select "Update Controller". Follow the on screen instructions.
54. When the update is complete, select "OK".
55. Verify that the part number changed at the top of the "Flash SUNR" screen.
NOTE:
Due to the SUNROOF programming procedure, a DTC may be set in other modules (TCM, BCM, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.
NOTE:
The temperature must be between 5°C (41°F) to 45°C (113°F) for initialization to be performed. Outside of this temperature range, an initialization will not start and if requested by a diagnostics scan tool, the Electronic Control Unit (ECU), (sometimes referred to as the Power Top Control Module) sends the proper reject code.
NOTE:
Vehicle voltage must be maintained between 13V - 15V during initialization.
NOTE:
Clear codes before performing Initialize sequence.
56. Using the StarSCAN(R), initialize Sky Slider module.
a. Select SUNR in the list of modules on the diagnostic scan tool.
b. Select "More Options".
c. Select "System Tests".
d. Select "Sunroof Initialization".
e. Follow the on-screen prompts.
f. Disconnect and remove scan tool.
57. Using the wiTECH Diagnostic Application for flashing an SUNR ECU is made available through the wiTECH Diagnostic Application. For instructions select the "HELP tab on upper portion of the wiTECH window, then "HELP CONTENTS. This will open the Welcome to wiTECH Help screen were help topics can now selected.
58. After reprogramming clear any DTC's that may have been set in other modules due to the reprogramming. The wiTech application will automatically present all DTC's after the flash and allow the tech to clear them.
NOTE:
The temperature must be between 5°C (41°F) to 45°C (113°F) for initialization to be performed. Outside of this temperature range, an initialization will not start and if requested by a diagnostics scan tool, the Electronic Control Unit (ECU), (sometimes referred to as the Power Top Control Module) sends the proper reject code.
NOTE:
Vehicle voltage must be maintained between 13V - 15V during initialization.
NOTE:
Clear codes before performing Initialize sequence.
59. Initialize Sky Slider Module.
a. Select SUNR in the list of modules
b. Select System Test Tab.
c. Select Sunroof Initialization
d. Follow the on screen prompts
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.