GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2009 🢒 Astra 🢒 Roof 🢒 Sunroof 🢒 Sunroof Housing Replacement

Removal Procedure
  1. Open the sunshade.
  2. Lower the headlining. Refer to Headlining Trim Panel Replacement.

    3. Object Number: 1937647 Size: LF
  3. Remove the front air deflector covers.

    4. Remove the cover (1) at the back (3) and remove from the front bracket (2).


    Object Number: 1937648 Size: LF
  4. Remove the front window. Refer to Sunroof Window Replacement - Front.

    5. Object Number: 1938317 Size: LF
  5. Remove the rear window. Refer to Sunroof Window Replacement - Rear.

    6. Object Number: 1937632 Size: SH
  6. Remove the rear water drain hose.
    7. 6.1. Remove the water drain hose from the sunroof.
    6.2. Remove the outer run-off in the direction of the vehicle interior.

    Object Number: 1937631 Size: SH
  7. Remove the front water drain hose actuation unit.

    8. Remove the 2 hoses.

  8. Disconnect the front wiring harness assembly.

    9. Disconnect the 2 wiring harness plugs.


    Object Number: 1937633 Size: LF
  9. Loosen the sunroof module assembly.

    10. Remove the 20 screws.

  10. Remove the sunroof module assembly.

    11. Object Number: 1938351 Size: LF
  11. Remove the wind deflector. Refer to Sunroof Air Deflector Replacement.

    12. Object Number: 1938342 Size: LH

    Note: The sunshade is blocked and cannot roll open.

  12. Lock the sunshade.
    13. 12.1. Manually roll the sunshade until the notch (1) is horizontal to the sunshade.
    12.2. Place a bolt pin (2) approximately 1 mm (0.04 in) thick on the left side in the notch in order to prevent the rolling open of the sunshade spring.

    Object Number: 1938344 Size: SH
  13. Remove the rear crossmember.

    14. Remove the 4 bolts and remove the rear crossmember.


    Object Number: 1938346 Size: SH
  14. Remove the sunshade at the rails.

    15. Remove the 2 bolts (1).


    Object Number: 1938348 Size: SH
  15. Remove the sunshade.

    16. Disconnect the sunshade (90 degree rotation) and remove.


    Object Number: 1944549 Size: SH
  16. Remove the sunshade motor.
    17. 16.1. Remove the 3 bolts.
    16.2. Disconnect the wiring harness plug.
  17. Remove the sunroof motor.
    18. 17.1. Remove the 3 bolts.
    17.2. Disconnect the wiring harness plug.
  18. Remove the outer seal.
  19. Remove the inner seal.

    20. Remove the weatherstrip from the guide.

Installation Procedure

    Object Number: 1938328 Size: LF

    Note: 

       • Place the seal with the sunroof in the front area on the markings.
       • Cut off the seal at the lower area of the front opening of the sunroof.

  1. Install the inner and outer seals.
    2. 1.1. Insert the weatherstrip into the guide.
    1.2. Cut off the extra weatherstrip and glue the end to the abutting seal (super glue).

    Caution: Refer to Fastener Caution in the Preface section.

  2. Install the sunroof motor.

    3. Connect the wiring harness plug.

    Tighten
    Tighten the 3 bolts to 4 N·m (35 lb in).

  3. Install the sunshade motor.

    4. Connect the wiring harness plug.

    Tighten
    Tighten the 3 bolts to 4 N·m (35 lb in).

    Note: Ensure that the sunshade cover is correctly placed into the guide.

  4. Insert the sunshade.

    5. Insert the sunshade into the guide and lock into position.

  5. Install the sunshade at the rails.

    6. Tighten
    Tighten the 2 bolts to 2.5 N·m (22 lb in).

  6. Install the rear crossmember.

    7. Tighten
    Tighten the 4 bolts to 5 N·m (44 lb in).

  7. Disconnect the sunshade.

    8. Remove the pin.

    Tighten
    Tighten the sunshade.

  8. Install the wind deflector swing-out arm.

    9. Tighten
    Tighten the 2 bolts to 2 N·m (18 lb in).

  9. Install the wind deflector.
    10. 9.1. Insert the wind deflector into the side guide.
    9.2. Clamp the wind deflector.
    9.3. 5 clamps.

    Tighten
    Tighten the 2 bolts to 2.5 N·m (22 lb in).

  10. Insert the sunroof module assembly.
  11. Fasten the sunroof module assembly.

    12. Tighten
    Tighten the 20 screws to 5 N·m (44 lb in).

  12. Connect the wiring harness.

    13. Connect 2 wiring harness plugs.

  13. Install the water drain hose front.

    14. Insert the 2 water drain hoses to the sunroof.

  14. Install the rear water drain hose.

    15. Insert the 2 water drain hoses to the sunroof.

  15. Insert the rear window.

    16. Note: 

       • Tighten the window cover in the upper position.
       • Install the position window pane with the curve facing down.

  16. Install the rear window.

    17. Align the window gap 1.5-2 mm (0.06-0.08 in).

  17. Insert the front window.

    18. Align and insert the window on one side.

    Note: The position disk may not rotate, since it can cause scratches in the rear window cover.

  18. Install the front window.

    19. Insert the 2 long position window panes.

    Tighten
    Tighten the 2 screws with washers to 4 N·m (35 lb in).

  19. Close the sunroof until the rear part is in the vent position.

    20. Note: The position disk may not rotate, since it can cause scratches in the rear glass cover.

  20. Install the sunroof front window rear screws.

    21. Insert the 4 long position window panes.

    Tighten
    Tighten the 4 screws with washers to 4 N·m (35 lb in).

  21. Close the sunroof.

    22. Inspect the gap 1.5-2 mm (0.06-0.08 in).

  22. Tighten the sunroof window rear screws.

    23. Press the seal lightly down and tighten the 4 screws.

    Tighten
    Tighten the 4 screws to 4 N·m (35 lb in).

  23. Open the sunroof to half open position.

    24. Tighten
    Tighten the 2 bolts at the front to 4 N·m (35 lb in).

  24. Tighten the sunroof window front screws.

    25. Tighten
    Tighten the 2 bolts to 4 N·m (35 lb in).

  25. Install the air deflector covers.
  26. Close the sunroof.
  27. Close the sunshade.
  28. Install the headlining. Refer to Headlining Trim Panel Replacement.
  29. For programming procedures, refer to Control Module References.