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.).