EXPERTEC TSB (91-T-17-SATURN)

EXPERTEC TSB

TECHNICAL SERVICE BULLETIN

SUNROOF OPERATES TO VENT ONLY - (REPLACE FRONT LOCATORS)

Model(s): Saturn

Bulletin No.: 91-T-17

Date: 10/03/1991

SUBJECT

Sunroof Operates to Vent Position Only (Replace Front Locators) 1991 Saturns VIN # 112757 or Before.

CONDITION

Customer comments that the sunroof will not open fully, it will open to the vent position and stop.

CAUSE

The sunroof guide front tumblers may not be disengaging from the locators.

This prohibits the sunroof from moving to the full open position.

CORRECTIVE ACTION

Replace left and right locators with new parts using the following procedures.

PROCEDURE

1. Cycle the sunroof to the vent position.
   NOTE: Do not cycle the sunroof to the fully closed position without glass being installed or damage to the guide assemblies may occur.
2. Remove six screws attaching the sunroof glass to guide assemblies.
3. To disengage lower block of front tumblers from locators, push down on front tumblers, while at the same time powering the sunroof to the full open position.
4. Remove right and left locator attaching screws using a T-20 Torx Drive Bit. To remove locator, insert a small phillips screwdriver into the locator screw opening and tilt the screwdriver towards the center of the opening, releasing the locator from the guide assembly (Item 1 in Fig 1 & 2). Slide locator forward to remove from module (Item 2 in Fig 1 & 2).
   NOTE: When removing the right locator, carefully pull on the wire harness to release attaching tape exposing the connector, then disconnect the harness and remove the locator.
5. Install the new locators.
   NOTE: Before installing the right locator, connect wire and feed into the microswitch opening. To install locators in module, position locator 9.5mm (3/8 in.) forward of installed location and slide rearward to engage into the guide. Insert screw into locator and tighten. Torque: 9 N-m (80 lbs. in.)
6. Apply lubricant at guide blocks using P/N 21485277, or equivalent.
7. Cycle the sunroof guides to the vent position and install glass onto the guide assemblies and align mounting holes.
8. Apply Loctite 222 Small Screw Threadlocker (or equivalent) to sunroof glass attaching screws and install them. Do not tighten screws until the next step.
9. Cycle sunroof to closed position and adjust front of glass to 1 mm (0.039 in.) below roof surface. Adjust rear of glass to 1 mm (0.039 in.) above roof surface. Tighten ail attaching screws. Torque: 9 N-m (80 lbs. in.)
10. Cycle sunroof to make sure of correct operation.

BULLETIN ILLUSTRATION LIST

PARTS REQUIREMENTS

21038896 1 - Locator RH Side

21038897 1 - Locator LH Side

WARRANTY 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	Replace Locator Both Sides	T9511	0.5 hrs