For 1990-2009 cars

# Sunroof Operates Slow, Binds or Becomes Inoperative

Subject: | Sunroof Operates Slow, Binds or Becomes Inoperative -- Replace the Sunroof Drive Cables and Tubes -- Due to a revision in step 6 , changing the drill bit from 1/4 inch to 1/8 inch, and adding a NOTICE just before step 11, this bulletin is being revised and supersedes bulletin 96_T_29, which should be discarded.

Models: | 1996 Saturn Sedans equipped with the sunroof option (CF5), built before and including VIN TZ291557

### Condition:

The sunroof operates slow, binds or becomes inoperative when opening or closing the sunroof.

### Cause:

The sunroof drive cables become corroded.

### Correction:

Replace the sunroof drive cables and drive cable tubes according to the procedure in this bulletin.

### Procedure

1. Remove the sunroof glass.

| Important: If the sun roof functions, cycle to the vent position before removing the sunroof glass.

1.1. | Remove the 6 screws attaching the sunroof glass to guide assemblies.

1.2. | Lift the glass from the sunroof module assembly.

2. Remove the sunshade. Refer to Sunroof Sunshade removal procedure in the Vehicle Interior Systems section of the Body/Repair Service Manual.

Important: Cycle the sunroof guides to the closed position before removing the sunroof module.

3. Remove the sunroof module. Refer to Sunroof Module removal procedure in the Vehicle Interior Systems section of the Body/Repair Service Manual.
4. Place the sunroof module on a clean workbench with the sunroof actuator, motor, facing up.
5. Remove the 3 sunroof actuator screws and remove the sunroof actuator from the sunroof module.

Notice: Make sure not to enlarge the diameter of the rivet hole in the plastic substrate of the sunroof module when drilling out the actuator mounting plate attaching rivet.

6. Using a 1/8 inch drill bit, drill out the actuator mounting plate attaching rivet and remove the actuator mounting plate.
7. Turn the sunroof module over, and remove the 2 locator block screws and remove the locator block. Repeat the procedure for the opposite side of the sunroof module.
8. Use a pair of needle nose pliers to lift the drive cable end out of the guide assembly. Repeat the procedure for the opposite side of the sunroof module.

Important: If the sunroof was locked in the open position, it will be necessary to partially remove the copper cable tubing and use it to pull the guide forward to expose the cable end.

9. Disengage the flared end of the copper cable tubing, however, Do Not discard the black plastic tubing, it will be reused.
10. Use 3M® General Purpose Adhesive Remover P/N 08984 or equivalent to clean all sealer and rust stains from around the sunroof module cable tubing pass through holes, cable locator blocks and actuator mounting area. Also, to provide a clean sealing surface, clean any cable grease from the new copper cable tubing

Notice: Make sure not to crush the plastic tubing when installing wire ties. If the wire ties are installed too tightly, the drive cable cannot move freely inside the plastic tubing, causing the sunroof to become inoperative.

11. Install a new sunroof drive cable into the end of the new left side copper cable tubing, longer tube, and then through the flared end of the shorter black plastic tube. Repeat the procedure for the right side, using the remaining tubes. Use wire ties P/N 21020792, to hold the tubes together as shown.
12. Use 3m® Strip Caulk P/N 08610 or equivalent, to seal the cable tubing pass through hole in the sunroof module. Wrap a 305 mm (12 inch) length of strip caulk around the copper tubing, 25.4 mm (1 inch) back from the flared end of the copper tubing, and mold it into a cone shape as shown. Repeat the procedure on the opposite side of the sunroof module.

Important: The cam sides of the cable ends must be positioned as shown in the illustration or the cable ends will not enter the sunroof module's cable guide channels. In the correct orientation, the lobes of the cam on the cable are aligned diagonally from the inboard top, to the outboard bottom of the square shaped guide slot, on both sides.

13. Route the cable assemblies into the pass through holes of the sunroof module, and install the drive cable ends into the notches in the guide assembly.

Important: It may be necessary to pull several inches of cable through the tubing assembly to rotate the cam on the cable to the correct orientation.

14. Using the installed cable, push the guide rearward to verify the proper orientation of the cam on the cable. If the orientation is correct, the cam will slide into the guide channel. If the orientation is incorrect, the cam will stop at the guide slot.
15. After the correct cable end orientation has been verified on both sides of the sunroof module, using the cables, pull both guides to the forward most, closed, position.

Important: Remove any sealer that penetrates the pass through holes to the inside of the sunroof module. Sealer on the inboard side of the module will restrict the water drainage system of the sunroof module.

16. Seal the cable tubing pass through holes by working strip caulk, installed on the tubing in step 12, to seal around the pass through holes.
17. With the flared ends of the copper tube seated in the notches of the sunroof module, install the locator blocks. Tighten to 3 N·m (27 lb in)
18. Remove the old spring plate from the actuator, motor, mounting plate, clean the mounting plate, and install the new spring plate from the cable kit P/N 21056010.

Important: Make sure the cables and tubing are installed as shown, or the unit will operate backwards.

19. Place the flared ends of the copper and plastic cable tubing into the notches at the sunroof actuator.
20. Using a Snap-on® Rivet Tool HP200A or equivalent, install a 1/8 x 1/4 inch aluminum button head rivet to attach the actuator mounting plate to the sunroof module. Make sure to install the rivet from the bottom of the sunroof module.
21. Time the sunroof actuator according to the following steps:

• | Motor with 2 terminal connectors:

1. | With an ohmmeter, backprobe the white and yellow wires located at the gear housing part of the sunroof actuator.

2. | Insert a large flat bladed screwdriver into the sunroof actuator gear drive slot. Turn the screwdriver clockwise until the ohmmeter indicates an open circuit. This may require approximately 11 turns.

3. | From this position, turn the screwdriver 1½ turns clockwise. This times the sunroof actuator to the fully closed position.

• | Motors with 3 terminal wire connectors:

1. | Connect the sunroof actuator to the wiring harness in the vehicle.

2. | Run the motor using the sunroof switch in the vent position until the motor stops.

3. | Insert a large flat bladed screwdriver into the motor gear drive slot. Turn the screwdriver 1½ turns clockwise. This times the sunroof actuator to the fully closed position.

4. | Disconnect the sunroof actuator from the wiring harness.

22. With the sunroof guides in the fully closed position, install the sunroof actuator onto the sunroof module. If required, use a screwdriver in the actuator gear with the drive cables before installing the 3 actuator attaching screws.

Notice: Do not use the screws to run the actuator up to the sunroof module. This may cause damage to the drive cables, if the actuator gear and the drive cables are not aligned.

23. Install the actuator screws.

Tighten
Tighten to 4 N·m (35 lb in).

Notice: Make sure the sunroof module drain hoses are not kinked or blocked.

24. Install the sunroof assembly into the vehicle, leaving the sunroof module fasteners loose for the sunroof alignment procedure in step 26 of this bulletin. Do Not install the headliner until the sunroof module and sunroof glass have been aligned, according to the procedures in this bulletin. Refer to Sunroof Module installation procedure in the Vehicle Interior systems section of the Body/Repair Service Manual.
25. Install the sunroof glass:

25.1. | Position the sunroof module to the full vent position.

25.2. | Set the sunroof glass on the sunroof module guide assembly.

25.3. | Apply Loctite® 222 Small Screw Threadlocker or equivalent to the attaching screws.

25.4. | Install the sunroof attaching screws.

Tighten
Tighten to 3 N·m (26 lb in).

26. With the sunroof glass in position and the sunroof module fasteners loose, align the sunroof module to the roof:

26.1. | Cycle the sunroof to the fully open position, then cycle the sunroof to the fully closed position.

26.2. | Tighten the sunroof module fasteners.

Tighten
Tighten to 14 N·m(124 lb in).

27. Align the sunroof glass:

• | The front sunroof glass should be 1 mm (0.040 in) below the surface of the roof .

• | The rear sunroof glass should be 1 mm (0.040 in) above the surface of the roof.

• | If the sunroof glass is adjusted to the above specifications, proceed to the next step. If the sunroof glass is not adjusted correctly:

1. | Loosen the sunroof glass attaching screws.

2. | Adjust the front and rear of the sunroof glass according to the above specifications.

3. | Tighten the sunroof glass attaching screws.

Tighten
Tighten to 3 N·m (26 lb in).

28. Cycle the sunroof into the vent, full open and full closed positions to verify proper operation.
29. Install the sunroof sunshade. Refer to the Sunroof Sunshade installation procedure in the Vehicle Interior Systems section of the 1996 Body/Repair Service Manual.
30. Install the headliner and trim. Refer to Headliner installation procedure in the Vehicle Interior Systems section of the 1996 Body/Repair Service Manual.

### Parts Requirements

Part Number | Description
--- | ---
21056011 | Cable Assy--Sunroof
21056010 | Cable Kit--Sunroof
21020792 | Wire Ties
08984 | General Purpose Adhesive Remover (3M®)
08610 | Strip Caulk (3M®)

CLAIM INFORMATION | To receive credit for this repair, submit a claim through the Saturn Dealer System as follows:
--- | ---
-- | Case Type | Description | Labor Operation Code | Time
-- | VW | Remove Sunroof Drive Cables and Tubes | T9719 | 2.90 hrs