Power Sunroof
Calibration & TimingNOTEThere is no adjustment available for
a normally operating sunroof. This procedure is used to set sunroof
motor/module to sunroof assembly timing.
1. Manually push the sunroof guide rail assembly to the full
forward position until it is locked into position. This is verified
by attempting to push the guide assembly rearward. NOTEThe guide
rail assembly will be raised above the U-frame assembly when in the
lock position.
Fig. View of the sunroof guide rail assembly in the lock
position, raised above the U-frame assembly 2. Remove the sunroof
glass. 3. Manually move the guide rail pivot inside the guide rail
cam slot until it is centered between the etched timing marks on
both rails.
Fig. View of sunroof guide rail pivot, guide rail, timing marks,
U-frame, and wind deflector 4. Verify that the white marking is
visible in the new motor/module timing window. If the mark is not
visible, connect a power source to the motor/module and cycle the
switch until the motor/module is in the closed position (white mark
in window).
Fig. View of sunroof motor/module, with timing window
Diagnosis & TestingMotorIf the power top is completely
inoperative, perform the following diagnostic steps:1. Check the B+
40 amp fuse in the Integrated Power Module (IPM). If OK, go to Step
No. 2. If not OK, repair the shorted circuit or component as
required and replace the inoperative fuse. 2. Check the Accessory
delay 20 amp fuse in the IPM. If OK, go to Step No. 3. If not OK,
repair the shorted circuit or component as required and replace the
inoperative fuse. 3. Partially remove the headliner to access the
sunroof motor/module. 4. Disconnect the motor/module electrical
connector. Using a voltmeter, check for Battery voltage at the B+
terminal of the harness connector. If OK, go to Step No. 5. If not
OK, repair the B+ circuit as necessary. 5. With the ignition switch
in the -RUN- position check for Battery voltage at the Accessory
Relay Output terminal of the harness connector. If OK, go to Step
No. 6. If not OK repair the Accessory Relay Output circuit as
necessary. 6. Using an ohmmeter test for continuity between the
harness connector ground circuit and a known good ground.
Continuity should be present. If OK go to Step No. 7. If not OK,
repair the open ground circuit as necessary. 7. Turn the ignition
switch to the -OFF- position. Reconnect the motor/module electrical
connector. With the ignition switch in the -RUN- position check for
battery voltage on the -VENT-, -CLOSE- and -OPEN- circuits at the
back side of the motor/module connector. If OK, go to Step No. 8.
If not OK replace the motor/module assembly. 8. Turn the ignition
switch to the -OFF- position. Disconnect the motor/module and
sunroof switch electrical connectors. Using an ohmmeter check for
continuity on the -VENT-, -CLOSE- and -OPEN- circuits between the
motor/module and sunroof switch. Continuity should be present. If
OK, diagnose the sunroof switch. If not OK, repair the control
circuits as necessary.
Switch1. Remove the overhead console. 2. Disconnect the power
sunroof switch wire harness connector. 3. With the ignition key in
the -RUN- position, check for battery voltage on the -OPEN-,
-CLOSE- and -VENT- circuits of the sunroof switch harness
connector. If OK, go to Step No. 4. If not OK, inspect the wiring
harness and connectors between the motor/module and switch for
damage and repair as necessary. 4. With the ignition key in the
-OFF- position check for continuity between the ground circuit of
the sunroof switch harness connector and a known good ground.
Continuity should be present. If OK, go to Step No. 5. If not OK,
inspect the wiring harness and connector and repair the ground
circuit as necessary. 5. Using an ohmmeter, test the continuity of
the power sunroof switch in each switch position: With sunroof
switch off, there should be no continuity between pins With sunroof
switch in the open position, continuity between 3 & 1 With
sunroof switch in the closed position, continuity between 3 & 4
With sunroof switch in the vent position, continuity between 3
& 2
6. If OK, inspect the wiring harness and connectors for damage
and repair as necessary. If not OK, replace the power sunroof
switch.
Fig. Sunroof switch pinout
Removal & Installation1. Move the glass panel to the fully
closed position. 2. Disconnect the battery negative cable. 3.
Remove the headliner. 4. Disconnect the four drain tubes from
sunroof housing. 5. Disconnect the sunroof wire connector. 6.
Loosen the fasteners attaching sunroof assembly. 7. With the aid of
a helper, support the sunroof and remove the fasteners attaching
the sunroof assembly to the roof panel. 8. Remove the sunroof from
vehicle.
To install: 1. Ensure that the U-nuts are in position in the
roof bow.
Fig. Proper position of the U-nuts in the roof bow 2. Raise
sunroof module assembly and guide it carefully into position. 3.
While supporting the sunroof assembly, start the attaching screws.
Tighten the attaching screws in sequence to 53 inch lbs. (6 Nm). 4.
Connect the sunroof wire connector. 5. Connect the drain tubes to
the sunroof. 6. Connect the battery negative cable. 7. Test sunroof
operation, adjust the position of the glass panel as necessary. 8.
Install headliner.
Motor1. Remove the sunroof assembly. 2. Remove the sunroof
motor/module retaining bolts and remove the motor/module.
To install:
NOTEThe sunroof motor/module must be timed with the sunroof
assembly. Failure to do so will result in improper sunroof
operation and possible leakage or damage to the assembly.
1. Assure proper sunroof motor/module timing calibration before
installation. 2. Position the sunroof motor/module to the sunroof
assembly and install the retaining bolts . Tighten the sunroof
motor/module retaining bolts to 40 inch lbs. (4.2 Nm). 3. Connect
the timed sunroof assembly to a power source and assure proper
operation before installing the sunroof assembly into the vehicle.
4. Install the sunroof assembly in the vehicle.
Fig. Sunroof assembly, motor/module, and motor/module retaining
bolts
Switch1. Disconnect and isolate the battery negative cable. 2.
Separate the overhead console from the headliner, by carefully
pulling down on the front portion, toward the windshield, to
release the retaining clips. 3. Release the sunroof switch
retaining tab, disconnect the electrical connector and remove the
switch from the overhead console.
To install: 1. Position the sunroof switch against the overhead
console and push the switch to properly seat in the retaining clip.
2. Install the overhead console assembly. 3. Connect the battery
negative cable.
Power Sunroof
Diagnosis & Testing3000GT1. Remove the sunroof motor
assembly. 2. Check to be sure that the motor moves as described in
the table when each terminal is connected to the battery.
Fig. Ensure the motor moves with the battery connected as
follows to these terminals-3000GT
Diamante1. Check the direction of rotation of the drive gear
when the battery is connected to the connector. 2. With Terminal 1
connected to the negative (-) battery terminal and Terminal 2
connected to the positive (+) battery terminal, the motor should
turn right. 3. With Terminal 2 connected to the negative (-)
battery terminal and Terminal 1 connected to the positive (+)
battery terminal, the motor should turn left.
Eclipse And Galant1. Remove the sunroof fuse and connect an
ammeter as shown in the illustration. 2. Press the sunroof switch
to operate the sunroof, and then measure the operation current
while the roof lid glass is moving (except when the sunroof starts
to operate, when it is fully open, when it is fully closed and when
it is fully tilted up). Ammeter should read 10 A or less. 3. If the
operation current is outside the standard value, check the
following points. A. Installation condition, warping or jamming of
sunroof assembly B. Sticking of drive cable C. Tilt of roof lid
glass
Fig. Connect an ammeter as shown to test the sunroof
operation-Eclipse
Lancer1. Using an ohmmeter, check the continuity between the
specified terminals. A. With the switch in the OPEN position, the
continuity between terminals 4 and 5 should be less than 2 ohms. B.
With the switch in the TILT UP position, the continuity between
terminals 3 and 4 should be less than 2 ohms. C. With the switch in
the SLIDE CLOSED or TILT DOWN position, the continuity between
terminals 4 and 6 should be less than 2 ohms.
Fig. Connect an ohmmeter as shown to test the sunroof
operation-Lancer
Removal & InstallationMotor3000GT1. Fully open the sunroof
and bring it in the tilted position. 2. Disconnect the negative
battery cable. 3. Remove the roof lid trim. 4. Remove the roof lid
mounting nuts, then lift off the roof lid. 5. Remove the sunroof
switch assembly. 6. Remove the sunroof link assembly. 7. Remove the
deflector. 8. Remove the headlining. 9. Remove the sunroof
motor.
Fig. Exploded view of the sunroof assembly-3000GT
To install: 1. Remove the sunroof motor cover. 2. Align the main
gear tooth with the square hole in the transmission gear. 3. While
keeping this gear position, turn the drive gear in the direction
given by the arrow to rotate the transmission gear 180. 4. Then,
check to ensure that the alignment mark on the transmission gear is
on the vertical line. 5. Press the roof lid against the front
holder while keeping it in the tilted-up position. 6. Install the
sunroof motor. 7. The remainder of the installation is the reverse
order of removal.
Diamante1. Remove the sunroof switch assembly. 2. Remove the
headliner as follows: A. Remove the sun visor assembly. B. Remove
the sun visor clips. C. Remove the dome light. D. Remove the assist
grips. E. While bending the headliner slightly, pull it through the
front door opening to remove.
3. Remove the sunroof ECU. 4. Remove the headliner bracket. 5.
Remove the sunroof motor assembly. CAUTIONWhen removing the sunroof
motor, always be sure to fully close the roof lid glass. If the
roof lid glass and the sunroof motor are not both in the
fully-closed positions, the sunroof will not operate properly.
6. Installation is the reverse order of removal.
Eclipse1. Disconnect the negative battery cable. 2. Remove the
headliner as follows: A. Remove the sun visor assembly. B. Remove
the sun visor bracket. C. Remove the sunroof switch cover. D.
Remove the headliner trim. E. Remove the headliner. CAUTIONAlways
close the roof lid glass fully before removing the sunroof motor.
If the fully-closed positions of the roof lid glass and the sunroof
motor are not the same, the sunroof will not operate properly.
3. Disconnect the electrical harness and remove the sunroof
motor assembly.
To install: 1. If the sunroof motor assembly is out of its fully
closed position, adjust the motor position by the following steps
before installation: A. Remove the sunroof motor assembly without
disconnecting the sunroof motor assembly connector. B. Close the
sunroof lid glass fully. C. Push the sunroof close switch until the
sunroof motor assembly stops turning. Repeat this operation until
the motor does not turn at all. Then install the motor assembly to
the roof.
2. Install the sunroof motor assembly. 3. The remainder of the
installation is the reverse order of assembly.
Galant1. Disconnect the negative battery cable. 2. Remove the
headliner as follows: A. Remove the sun visor assembly. B. Remove
the sun visor bracket. C. Remove the dome light assembly. D. Remove
the sunroof switch cover. E. Remove the coat hanger. F. Remove the
front and rear roof pad. G. Remove the headliner trim. H. Remove
the headliner.
3. Remove the three screws and remove the sunroof switch
bracket. CAUTIONAlways close the roof lid glass fully before
removing the sunroof motor. If the fully-closed positions of the
roof lid glass and the sunroof motor are not the same, the sunroof
will not operate properly.
4. Remove the sunroof motor assembly.
To install: 1. If the fully-closed position of the sunroof motor
is incorrect, set the motor to the fully-closed position by the
procedure given blow before installing the motor: A. Connect a
circuit analyzer between terminals (5) and (6) of the motor
connector. B. Operate the motor until the position is reached at
which continuity switches from on to off or from off to on, and
then install the motor.
2. The remainder of the installation is the reverse order of
removal.
Lancer1. Disconnect the negative battery cable. 2. Remove the
headliner as follows: A. Remove the assist grip. B. Remove the
front dome light (and sunglasses pocket, if equipped). C. Remove
the sunroof switch trim panel D. Remove the sun visor and sun visor
holder by inserting Special Tool MB990784 into sides claws of the
sun visor holder through the both sides of the sun visor holder to
remove the hinges. E. Remove the headliner by bending the headliner
through the front passenger's door.
3. Remove the sunroof motor assembly.
To install: 1. Connect the sunroof motor assembly connector and
the sunroof switch connector to the vehicle wiring harness
connector. 2. Operate the sunroof switch to slide the roof lid
glass to the fully-open position, and then tilt it up in steps of
1.18 inches (30 mm) to the fully-open position and then keep
pressing the switch for 0.5 seconds or more. 3. The remainder of
the installation is the reverse order of removal.
Switch1. Disconnect the negative battery cable. 2. Remove the
switch cover. 3. Disconnect and remove the sunroof switch panel
assembly. 4. Remove the sunroof switch. 5. Installation is the
reverse order of removal. 1. INSTALL: EVO One Touch Sunroof
Controller Installed (Pictures) Thank you JesteR for letting me
test this module out on your EVO!
The KPtechnologies "one touch" sunroof controller allows
opening, closing, and tilting by simply pressing the respective
button twice quickly. Once triggered, the sunroof can be instantly
stopped by pressing either of the other two buttons. Although the
EVO has one touch open from the factory we hooked up the open
wiring. It serves no real purpose, but allows you to stop the
sunroof from cloing by hitting the 'open' button. KPtechnologies
engineered this module to require two pulses to allow the sunroof
to retain all OEM funtionality. After the installation the sunroof
will continue to operate as normal, until triggered with the two
quick presses.
JesteR and I somehow made this installation much more difficult
then it needed to be, but in the end it was working, and we had a
good time, so all is good.
In true KPtechnologies style I didn't snap any pictures
disasembling the car, but there wasn't much to it. We started by
removing the dome light. This was acomplished by carefully
inserting a flat head screwdriver between the lens and the plastic.
The lens gently popped out when a little pressure was applied (this
is how you change the bulbs). With the lens removed (2) 10mm bolts
were exposed. With the bolts removed, the light fell down. We
unhooked it and stored it in a safe place.
With the dome light removed we could access the two retaining
clips holding the finisher around the sunroof switch. JesteR popped
the rear clip off and I handled the front clip. With the trim piece
out of the way two screws were exposed that held the sunroof switch
in place. Once the screws were removed I gently tugged on the (4)
wires connected to switch to create as much slack as possible,
without damaging the wires. If the wires were about 2" longer this
would have been much easier!
Now, to the wiring:
The KPtech module has 5 wires:
Power - Yellow --> EVO black/white at dome light Ground -
Black --> EVO black at sunroof switch Sunroof Open - Green
--> EVO green/blue at sunroof switch Sunroof Close - Blue -->
EVO green/yellow at sunroof switch Sunroof Tilt - Purple --> EVO
green/orange at sunroof switch
All wiring (including how NOT to solder a ground wire - notice
the wire is wrapped and soldered around the insulation, not sure
what I was thinking...):
Another shot of wiring:
And another:
Sunroof switch wiring:
Power is found at the dome light harness. All wires were ran up
through the dome light opening and then back down through the
sunroof switch opening allowing us to place the module between the
headliner and roof through the dome light opening:
Module all wired up and tested:
We wrapped the module in a piece of foam before stuffing it
between the headliner and the roof:
Module wired and stuffed behind the headliner:
We decided to wrap the module in foam before placing it between
the headliner and the roof, through the dome light opening. Once
positioned the module did not move at all. It was wedged very
tightly, with no noticable bulges in the headliner. This was
probably the hardest part, due to the small opening, and the fact
there is a piece of OEM foam blocking the way (It's a somewhat
stiff foam).
I chose to solder all wires, although in this application there
may be better methods. To protect the car we laid a protective seat
cover over the center console (drips) and for the headliner I
ripped a piece of paper to the middle, and then ran the wires
through the rip. This left the paper in between my soldering iron
and the headliner, just in case.
As you can see in the pictures, I missed the ground wiring
solering it, it slid down over the insulation and I didn't notice.
We tested the moduel before stuffing it in to the headliner and
found the mistake. Always check before putting everything back
together!
Thats about it. I would think that this can be done in 45-60
minutes tops. JesteR and I spent closer to 90 mintues on it though,
as we tested everything along the way, took pictures/movies, and
took apart a bunch of stuff that didn't need to come apart.
We made two movies, the first shows the sunroof opening and
closing, the second shows the sunroof closing and then tilting.
The sunroof can only be operated with the ignition switch in the
ON position.
1- Open2- Tilt up3- Close, Tilt downTo open, press the switch
(1).To stop the moving sunroof, press switch (2) or (3).Note The
sunroof automatically stops just before reaching the fully open
position.Press the switch again to fully open it.To close, press
the switch (3).To stop the moving sunroof, press the switch (1) or
(2).To tilt up, press the switch (2).The rear edge of the sunroof
rises for ventilation.To tilt down, press the switch (3).Warning Do
not put head, hands or anything else out of the sunroof opening
while driving the vehicle. Never leave a child (or other person who
might not be capable of safe operation of the sunroof switch) in
the vehicle alone. Before operating the sunroof, make sure that
nothing is capable of being trapped (head, hand, finger, etc.).