Sunroof - Diagnostics/Component Replacement
BULLETIN NO.: 01-T-43ISSUE DATE: September 2001
CATEGORY TYPE: Body-09
CATEGORY: Sunroof
CORPORATION NO.: 01-08-67-006
SUBJECT:
Service Information Regarding Sunroof Service Procedures and Serviceable Sunroof Components
MODELS AFFECTED:
^ 1996-2001 Saturn 5-Series sedans equipped With power sunroofs (RPO CF5)
^ 1997-2001 Saturn S-Series coupes equipped with power sunroofs (RPO CF5)
PURPOSE:
The purpose of this bulletin is to:
^ Provide sunroof diagnostics with VIN breakpoints.
^ Summarize the sunroof components that can be serviced by following the service procedures in this bulletin and in the S-Series service manual.
^ Provide new "Sunroof Drive Cable Guide Channel Inspection" and "Sunroof Actuator Mounting Bracket Replacement" procedures.
SUNROOF DIAGNOSTIC INFORMATION
Sunroof Actuator (Motor) Diagnostics
This section of the bulletin is intended to aid in sunroof actuator (motor) diagnostics. This information is in addition to the service information available in the S-Series service manual.
Sunroof Actuator Mounting Bracket Diagnostics
This section of the bulletin is intended to aid in sunroof actuator mounting bracket diagnostics. Refer to the service procedures in this bulletin for sunroof actuator mounting bracket diagnostics and replacement.
Sunroof Module Diagnostics
This section of the bulletin is intended to aid in sunroof module diagnostics. This information is in addition to the service information available in the appropriate S-Series service manual.
SERVICEABLE SUNROOF COMPONENTS
This section of the bulletin is intended to summarize the sunroof components that can be serviced by lowing the service procedures in this bulletin and in the S-Series service manual Based on recent sunroof warranty information, it has been found that sunroof modules/sunshades have been replaced when they could have been serviced with a component.
The following sunroof components are serviceable:
IMPORTANT:
Sunroof glass seal is no longer serviceable.
^ sunroof glass
^ sunroof sunshade
IMPORTANT:
Do not replace sunshade due to broken slide blocks. Replace slide blocks using sunshade kit.
^ sunroof sunshade slide blocks
^ sunroof actuator (motor)
^ sunroof cable locator blocks
^ sunroof drive cables
^ sunroof actuator mounting bracket
SUNROOF DRIVE CABLE GUIDE CHANNEL INSPECTION
1. Remove cable locator blocks.
1.1 Open sunroof.
1.2 Remove locator block fastening screws.
1.3 Remove locator block using needle nose pliers.
IMPORTANT:
If guide channel is fractured/broken, the cable end will most likely be separated from the guide channel
2. Lift sunroof drive cable from guide channel.
3. Inspect guide channel for damage.
If guide channel is broken or fractured, replace sunroof. Refer to the appropriate S-Series service manual for procedure.
If guide channel is not broken or fractured, proceed to step 4 and replace cable locator blocks. Then, refer to the "Sunroof Module Diagnostics" chart in this bulletin for additional diagnostics.
4. Apply Permatex(R) medium strength threadlocker (or equivalent) to locator block fastening screws. Make sure to cover the last few threads.
5. Install locator blocks.
6. Install locator block fastening screws.
Torque:
Locator Block Fastening
Screws: 2 N.m (17.5 in-lbs)
SUNROOF ACTUATOR MOUNTING BRACKET REPLACEMENT
1. Remove sunroof from vehicle. (Refer to "Sunroof Module Assembly Removal" procedure in the appropriate S-Series service manual.)
2. Place a straight edge across sunroof actuator mounting bracket as shown in illustration and inspect bracket for warpage.
^ If actuator mounting bracket is warped, proceed to step 3.
^ If actuator mounting bracket is not warped, refer to "Sunroof Actuator Mounting Bracket Diagnostics" chart in this bulletin for additional diagnostics.
IMPORTANT:
Prior to removing sunroof/sunroof actuator, make sure sunroof glass is in full closed position. This will result in proper actuator to module timing provided actuator is not operated after it is removed.
3. Remove sunroof actuator. (Refer to "Sunroof Actuator [Motor] Removal" procedure in the appropriate S-Series service manual.)
4. Using a 3 mm (.012 in.) drill bit, remove rivet that holds sunroof actuator mounting bracket to module front beam.
5. Obtain tube assembly/actuator mounting bracket kit (P/N 21059928).
IMPORTANT:
Make sure sunroof actuator mounting bracket stays tight against drive tube during rivet installation.
6. Place new actuator mounting bracket over drive tubes, making sure insert (included with tube assembly/actuator mounting bracket kit [P/N 21059928]) is mounted on bracket in correct position, and secure with replacement 3 mm x 12.3 mm rivet.
7. Install sunroof actuator. (Refer to "Sunroof Actuator [Motor] Installation" procedure in the appropriate S-Series service manual.)
8. Operate sunroof to insure repair has resolved customer complaint.
^ If repair has resolved complaint, proceed to step 9.
^ If repair has not resolved customer complaint, refer to "Sunroof Actuator Mounting Bracket Diagnostics" chart in this bulletin for additional diagnostics.
9. Install sunroof. (Refer to "Sunroof Module Assembly Installation" procedure in the appropriate S-Series service manual.)
PARTS REQUIREMENTS:
CLAIM INFORMATION:
To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for B2780 (Housing Assembly, Sunroof (Module) - Replace) or B2752 (Cap, Track Cover, Right - Replace) or B2753 (Cap, Track Cover, Left - Replace) or N3360 (Motor, Sunroof - Replace). If another procedure is performed, refer to the appropriate Electronic Labor Time Guide for the correct Labor Operation Code and Time.
IMPORTANT:
An Add Time has been added to N3360 for replacement of the motor (actuator) mounting bracket.
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