SMU - Revised/Added Sunroof Specifications and Procedures

This Service Manual Update bulletin is being issued to revise and add sunroof specifications and procedures in the Roof subsection of the 2000 C/K Service Manual. Please replace the current information in the Service Manual with the following information.

Removal Procedure

1. Remove the sunroof finishing lace. Refer to the Finishing Lace Replacement procedure in the Service Manual.
2. Remove the headliner. Refer to the Headliner Replacement procedure in the Interior Trim subsection of the Service Manual.



3. Remove the drain hoses. Refer to the Sunroof Drain Hose Replacement -- Front and Sunroof Drain Hose Replacement -- Rear procedures in the Service Manual.
4. Disconnect the electrical connectors.
5. Remove the nine bolts retaining sunroof module.
6. Remove the module from vehicle.

Installation Procedure

1. Install the module to the vehicle.




Notice: Refer to the Fastener Notice in the Cautions and Notices subsection of the Service Manual.

2. Loosely install the nine bolts retaining the module to the roof.

Use a drill bit to align the two holes A and B.

Tighten
Tighten the nine bolts in the sequence shown to 9 N·m (80 lb in).

3. Connect the electrical connectors.
4. Install the drain hoses. Refer to the Sunroof Drain Hose Replacement -- Front and Sunroof Drain Hose Replacement -- Rear procedures in the Service Manual.
5. Install the headliner. Refer to the Headliner Replacement procedure in the Interior Trim subsection of the Service Manual.
6. Install the finishing lace. Refer to the Finishing Lace Replacement procedure in the Service Manual.
7. Synchronize the sunroof motor if necessary. Refer to the Sunroof Motor Synchronization procedure in the Service Manual.

1. In order to adjust the glass height, the sunroof glass must be in the zero (closed) position.

Important: Do not remove the screws from the sunroof mechanism.

2. Loosen the four adjustment screws.
3. Adjust the rear glass panel (1) so that the panel is flush with the roof panel (A), (0 to 2.0 mm (0.079 in) above A).
4. Tighten the rear screws.
5. Adjust the front glass panel (2) so that the panel is flush with the roof panel (A), (0 to 2.0 mm (0.079 in) below A).

Notice: Refer to the Fastener Notice in the Cautions and Notices subsection in the Service Manual.

6. Tighten the front screws.

Tighten
Tighten all four adjustment screws to 7 N·m (62 lb in).

Removal Procedure

1. Remove the sunroof glass panel. Refer to the Sunroof Glass Panel Replacement procedure in the Service Manual.
2. On one side of the drain channel (1), push the tab (3) rearwards and lift up the drain channel. Do the same for the other side.
3. Slide the drain channel from the guide (2).

Installation Procedure

1. Slide the drain channel into the guide tab (2).
2. Push on the drain channel (1) until the channel locks into place by the retainer (3). Do the same for the other side.
3. Ensure both sides are properly seated in the guide.
4. Install the sunroof glass panel. Refer to the Sunroof Glass Panel Replacement procedure in the Service Manual.

Removal Procedure

From inside the vehicle, grab on one end of the lace at the joint, pull gently until the lace is off the headliner and sunroof.

Installation Procedure

1. Center one end of the lace to the rear of the sunroof.
2. Push on the lace to the sunroof by working slowly around the opening.

•	Once the halfway point is reached, start the other end around the opening.

•	The headliner will overlap the lace at this point.

3. With the lace fully seated on the sunroof, start at the joint and gently pull the pull-cord away from the lace in order to wrap the flange over the headliner.

Removal Procedure

1. Remove the glass panel. Refer to the Sunroof Glass Panel Replacement procedure in the Service Manual.
2. Remove the drain channel. Refer to the Drain Channel Replacement procedure in the Service Manual.
3. With the sunshade (1) in the closed position, push the front (either side) sunshade spring (glider) (2) inward and release the glider from the track.

Gently pull same corner of the sunshade outward and wiggle the remaining gliders out of the track.

Installation Procedure

1. Install the sunshade and place both gliders on one side into track. Compress one of the other gliders inward and slide into the track.

Repeat this procedure for the last glider.

2. With the sunshade in half open position, install the drain channel. Refer to the Drain Channel Replacement procedure in the Service Manual.
3. Install the glass panel. Refer to the Sunroof Glass Panel Replacement procedure in the Service Manual.

Removal Procedure

1. Pull back the sunshade.
2. Set the sunroof in the zero (closed) position.
3. From inside of the vehicle, remove the four glass panel adjustment screws.
4. From inside of the vehicle, push up on the sunroof glass panel so that the glass panel can be grabbed and lifted from the roof opening.
5. Remove the glass panel from the roof opening.

Installation Procedure

1. Ensure that the glass panel mechanism is in the zero (closed) position.
2. From outside the vehicle, carefully place the glass panel onto the mechanism.
3. Loosely install the four adjustment screws.

Important: Required position of the glass panel is when the front and rear of the sunroof glass panel is flush with the roof panel.

4. Align the glass panel. Refer to the Sunroof Glass Height and Opening Fit Adjustment procedure in the Service Manual.
5. Inspect the operation of the sunroof.

Removal Procedure

1. Remove the headliner. Refer to the Headliner Replacement procedure in Interior Trim subsection of the Service Manual.
2. Disconnect the wire harness from the sunroof motor.
3. Remove the two screws retaining the motor.
4. Pull the motor from the unit.

Some gentle back and forth rotation may be required in order to release the motor gear from drive cables.

Installation Procedure

1. Install the sunroof motor.

Notice: Refer to the Fastener Notice in the Cautions and Notices subsection of the Service Manual.

2. Install the two screws.

Tighten
Tighten the two screws to 3 N·m (27 lb in).

3. Connect the wire harness to the sunroof motor.
4. Install the headliner. Refer to the Headliner Replacement procedure in the Service Manual.
5. Inspect the operation of the sunroof.

Removal Procedure

1. The sunroof glass panel must be in the zero (closed) position.
2. Remove the headliner. Refer to the Headliner Replacement procedure in Interior Trim subsection of the Service Manual.
3. Remove the sunroof glass panel. Refer to the Sunroof Glass Replacement procedure in the Service Manual.
4. Remove the drain channel. Refer to the Drain Channel Replacement procedure in the Service Manual.
5. Remove the sunshade. Refer to the Sunshade Panel Replacement procedure in the Service Manual.



6. Remove the nine bolts retaining the module to the roof.
7. Remove the module from the vehicle.

Installation Procedure

1. Install the module to the vehicle.




Notice: Refer to the Fastener Notice in the Cautions and Notices subsection of the Service Manual.

2. Loosely install the nine bolts retaining the module to the roof.

Use a drill bit to align the two holes A and B.

Tighten
Tighten the nine bolts in the sequence shown to 9 N·m (80 lb in).

3. Install the sunshade. Refer to the Sunshade Panel Replacement procedure in the Service Manual.
4. Install the drain channel. Refer to the Drain Channel Replacement procedure in the Service Manual.
5. Install the sunroof glass panel. Refer to the Sunroof Glass Panel Replacement procedure in the Service Manual.
6. Install the headliner. Refer to the Headliner Replacement procedure in the Interior Trim subsection of the Service Manual.
7. Inspect the operation of the sunroof.

Removal Procedure

1. Remove the headliner. Refer to the Headliner Replacement procedure in the Interior Trim subsection of the Service Manual.

Important: Observe the routing of the wire harness. Failure to route the wire the same will result in the wire harness being pinched during sunroof operation.

2. Disconnect the wire harness connectors (5) and (6).
3. Remove the wire from the sunroof module.

Installation Procedure

1. Connect the wire connector (6).

Important: Do not route the wire harness on the top or the bottom of the flange as it will get pinched during sunroof operation.

2. Secure the wire harness along the outboard flange (7) and (2).
3. Secure the clip (1) and the clip (3) to the sunroof module flange.
4. Loop the wire harness around cable drive (4).
5. Connect the wire harness (5) to the sunroof motor.
6. Install the headliner. Refer to the Headliner Replacement procedure in the Interior Trim subsection of the Service Manual.
7. Inspect the operation of the sunroof.