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2002 Cavalier Sunroof Motor

26357 Views 5 Replies 3 Participants Last post by  jfnz24
So, I get a call from my brother. He is having a problem with the power sunroof in his 2002 Cavalier (OEM installation). Says that it is not opening all the way, and sounds like the motor is giving out. If he lets it be for a little while, it goes a little more, but progresses less and less. Definitely sounds like the motor to me also.

Anyways, takes it to the garage (a Buick/Pontiac/GMC dealer) that he gets all his vehicles serviced at. They won't touch the thing, saying sunroofs are too involved. Gave him the name of a place about 25 miles away. Calls the other place, and they won't even give him the price on a worst-case scenario. Now I know they should look at it first before estimating, but being that we don't even know where the place is, we don't want to get taken by a shady operation.

So, before taking it in, he wants to take a look at the motor himself. Where is it located (Headliner?), and what would a replacement motor cost? He wants to get an idea if this is something that could be done on his own, as he already did a power window motor. Any pictures/diagrams would also be appreciated. Thanks in advance.
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ID: 778158
Sunroof Actuator Replacement
Removal 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.
  1. <LI type=1>Remove the headliner as necessary. Refer to Headlining Trim Panel Replacement in Interior Trim.

    <LI type=1>Disconnect the wire harnesses from the express module (8). <LI type=1>Remove the tie wraps securing the wire harness to the drive and return tubes (5, 6).

    Important: The sunroof actuator cannot be reused if this procedure is followed.
    <LI type=1>If the sunroof glass panel is not fully closed complete the following steps.
    4.1. Locate the allen head screw on the drive gear of the sunroof actuator (1).​
    The allen head screw is accessible with the sunroof actuator in place.
    4.2. Remove the red retainer from the allen head screw using a small flat-blade tool, if equipped.
    4.3. Turn the allen head screw until the sunroof glass panel is fully closed.​
    You may need to apply a significant amount of force to move the sunroof actuator with the allen wrench.
    4.4. Relieve the pressure on the sunroof actuator by backing off the allen screw approximately 15 degrees.​

    <LI type=1>Remove the sunroof actuator bolts (2) from the sunroof actuator. <LI type=1>Disconnect the wire harness from the connector (1) on the sunroof actuator.
  2. Remove the sunroof actuator from the sunroof module.
Installation Procedure

  1. Important: Before you install a new sunroof actuator or re-install the old actuator to the sunroof module, ensure that the actuator is timed to the closed position.
    <LI type=1>Verify that the original sunroof actuator or the new sunroof actuator is timed to the closed position by preforming the following steps.
    1.1. 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.
    1.2. If the actuator is not timed to the closed position, connect the switch, headliner harness and express module to the sunroof actuator and run the actuator to the closed position. Verify all timing marks are aligned.​

    <LI type=1>Connect the wire harness to connector (1) on the sunroof actuator. <LI type=1>Position the sunroof 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 fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
    <LI type=1>Install the sunroof actuator bolts (2) to the sunroof actuator. Tighten
    Tighten the sunroof actuator bolts to 3 N·m (27 lb in).

    <LI type=1>Connect the wire harness connectors to the express module (8), and secure the wire harness to the drive tube and return tube (5, 6) with tie wraps.
  2. Install the headliner as necessary. Refer to Headlining Trim Panel Replacement in Interior Trim.
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