GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 S10 Pickup - 4WD 🢒 Body and Accessories 🢒 Roof 🢒 Sunroof Opening Position Switch Replacement

Removal Procedure

    Important: 

       • Remove the headliner. Refer to Headlining Trim Panel Replacement in Interior Trim.
       • The sunroof open position (SOP) switch is aligned to the drive cables. The SOP switch comes from the factory set to the sunroof glass panel CLOSED position. A position lock pin has been installed by the factory on the top of the SOP switch. This pin must remain until after the installation of the sunroof actuator and of the SOP switch. This lock pin locks the drive gears in place and must be removed before the complete sunroof module is installed to the vehicle.
       • If the SOP switch is removed for inspection, the sunroof must be in the CLOSED position. A position lock pin must be inserted. If a position lock pin is not available, place 2 wires, such as the ends of a paper clip, in the holes.

  1. Move the sunroof to the closed position.
  2. Remove the sunroof window. Refer to Sunroof Window Replacement .
  3. Remove the sunroof control module. Refer to Sunroof Control Module Replacement .

    4. Object Number: 594490 Size: SH
  4. If you reuse the SOP switch, insert the position lock pin (1) in order to lock the SOP switch in the closed position.
  5. Remove the sunroof motor/actuator. Refer to Sunroof Motor/Actuator Replacement .
  6. Disconnect the electrical connector from the SOP switch (3).
  7. Remove the screw (2) which secures the SOP switch to the sunroof module.
  8. Hold down on both of the drive cables. Lift up on the SOP switch in order to remove the switch from the sunroof module.

Installation Procedure

    Object Number: 594499 Size: SH

    Important: The cable mechanisms and/or the cam mechanisms, on both sides of the glass, contain a set of timing holes. These holes are aligned in the CLOSED position of the sunroof glass panel . These holes are located on the side opposite the rear screw hole, which is used in order to mount the sunroof glass panel. When installing a new sunroof open position (SOP) switch, set the sunroof glass panel to the CLOSED position.

  1. Use a flat-bladed tool if you adjust the cable mechanism and/or the cam mechanism in order to align the cable and/or the cam timing holes.

    2. When the timing holes are aligned, insert a pin with diameter 0.0317 mm (1/8 in) or a drill bit (1) into each set of the timing holes. Use tape in order to hold each pin in place.

    Important: The SOP switch comes from the factory with a position lock pin that is installed on top of the switch. This locks the timing gears in place. Do not remove the position lock pin until after the SOP switch and the actuator are installed.

  2. Keeping the position lock pin on the new SOP switch, align the switch over the drive cables.

    3. Object Number: 594501 Size: SH
  3. Apply pressure to the SOP switch until the switch is completely seated.

    4. If the switch does not slide into position, the ridges on the drive cable housings will not go into the grooves on the back of the SOP switch. Lift each cable into the switch, and press down on the assembly until the assembly is completely seated.


    Object Number: 594490 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  4. Install the screw which secures the SOP switch to the sunroof module.

    5. Tighten
    Tighten the screw to 3.4 N·m (30 lb in).

  5. Connect the electrical connector to the SOP switch.
  6. Install the sunroof motor/actuator. Refer to Sunroof Motor/Actuator Replacement .
  7. Remove the position lock pin (1).
  8. Remove the 2 alignment pins from the cable mechanisms and/or from the cam mechanisms.
  9. Install the sunroof control module, but do not install the headliner until after the sunroof operation has been verified. Refer to Sunroof Control Module Replacement .
  10. Verify the operation of the sunroof module.
  11. Install the sunroof window. Refer to Sunroof Window Replacement .
  12. Install the headliner. Refer to Headlining Trim Panel Replacement in Interior Trim.