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Old 10-24-2010, 12:37 PM   #1
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Default Sunroof stuck open!

Hey Guys...

I know someone out there has had their sunroof get stuck open. Well my wife'* '03 Grand Am is stuck open (about 3/4" from completely closing). The sunroof will open and retract yet, when it gets to this point it does not close fully (sunroof motor stops). Greased all the slides and checked for any blockage on the track.

I know GM put out a TSB for this sometime ago. At my shop we really dont work on sunroof just seeing if anyone can give me an idea other then having to re-time the actuator!

Thanks!!
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Old 10-24-2010, 01:00 PM   #2
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it is possibleit could have skipped some teeth and it thinks 3/4 closed is fully closed??
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Old 10-24-2010, 02:09 PM   #3
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This happened on my Grand Prix. I have to push it shut.
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Old 10-24-2010, 03:45 PM   #4
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Quote:
Originally Posted by Jonpro03 View Post
This happened on my Grand Prix. I have to push it shut.
Problem is I can't push the damn thing shut!! (wish it would have been a manual sunroof!!)
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Old 10-28-2010, 09:59 PM   #5
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Does anyone know how to re-time the sunroof motor acuator?

TSB: 03-08-67-009A states that it more then likely is a motor replacement.
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Old 10-28-2010, 11:59 PM   #6
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Ask and you will receive. A long read but I felt it better to give you the whole shebang.

Per GM Policy:

2000-2004 Cavalier/Sunfire/Alero/Grand Am – Inoperative Sunroof Module Retime module or replace only motor for inoperative complaints. Don’t replace entire sunroof module assembly. 03-08-67-009A



Sunroof Will Not Open or close Completely (Replace Sunroof Motor) #03-08-67-009A - (Mar 8, 2004)
Sunroof Will Not Open or Close Completely (Replace Sunroof Motor)
1998-2004 Chevrolet Cavalier

1999-2003 Oldsmobile Alero

1998-2003 Pontiac Grand Am

1998-2004 Pontiac Sunfire

This bulletin is being revised to change the part number. Please discard Corporate Bulletin Number 03-08-67-009 (Section 08 -- Body and Accessories)

Condition
Some customers may comment that the sunroof will not open or will not close completely.

Cause
This condition may be due to the sunroof motor. Follow the procedure below for diagnostics.

Sunroof Motor Diagnosis
Remove the headliner as necessary. Refer to Headliner Replacement in Interior Trim (SI Document ID #856974).



Jumper Pin #1 and Pin #8 on the sunroof express module. If more access is needed, push the module towards the motor and unlock it from the bracket. Refer to the Illustration above.

Notice
Avoid operating the sunroof glass to the full open position. Since the limit switch has a jumper across it, there will be no indication to the sunroof module to stop the glass at the full open soft stop. The glass can slide past the full open position, possibly damaging the sunroof assembly and/or the roof.


With the ignition ON, push the sunroof switch to the close position to fully seat the sunroof. If this action fully closes the sunroof, replace the sunroof motor only. Refer to the Sunroof Motor Replacement below. If this action does not fully close the sunroof, go to Diagnostic Starting Point-Roof (SI Document ID #823850).
Remove the jumper and re-lock the sunroof express module back into its bracket.
Sunroof Motor Replacement
Service Procedure

Notice
This sunroof system is timed from the factory so that the sunroof actuator automatically shuts off when the window panel reaches a certain position. Be careful not to disrupt this factory timing when removing the sunroof actuator from the sunroof module. Disrupting the factory timing may cause damage to the sunroof system. Close the window panel whenever you remove the sunroof actuator from the sunroof module assembly.


Clip the tie straps and remove the express module by sliding it towards the motor to unlock it from the slots provided in the module.
Disconnect the wire harness from the express module, power supply, and switch.
Remove the sunroof motor/actuator bolts (2) from the sunroof motor/actuator.
Remove the sunroof motor/actuator from the sunroof module.
Remove the sunroof glass.



Make sure the sunroof lift arms are aligned by inserting a pin in the front sunroof glass attachment hole to the lift arm cam. If you can insert a large paper clip through the two, it is aligned. Refer to the illustration above.



If the arms are not aligned, push the arms with a screwdriver at the location shown. Refer to the illustration above.

Important
Before you install a new sunroof motor/actuator or re-install the old actuator to the sunroof module, ensure that the actuator is timed to the closed position.


Verify that the original sunroof motor/actuator or the new sunroof motor/actuator is timed to the closed position by performing the following steps:




The hole in the large timing gear (3), the notch in the disk (2) below the drive gear and the scribe mark (1) on the drive gear should all be in line with each other. Refer to the illustration above.
If the actuator is not timed to the closed position, connect the switch, headliner harness and express module to the sunroof motor/actuator and run the actuator to the closed position. Verify that all timing marks are aligned.
Position the sunroof motor/actuator to the sunroof module.

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 fasteners. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.


Install the sunroof motor/actuator. Tighten
Tighten the sunroof motor/actuator to 3 Nm (27 lb in).

Connect the wire harness connectors to the express module. Slide the express module into the slots and lock it. Reconnect the power supply and the switch to the express module. Secure the wire harness to the drive tube and return tube with tie wraps.
Install the headliner as necessary. Refer to Headliner Replacement in Interior Trim (SI Document ID #856974).
Parts Information
Part Number
Description

89023553
Motor


Parts are currently available from GMSPO.

Warranty Information
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

N3360
Motor, Sunroof Drive-Replace
0.8 hr

Add
Diagnosis Time
0.3 hr
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