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com ELECTRIC SUNROOF 8E- 1

ELECTRIC SUNROOF

CONTENTS

DESCRIPTION AND OPERATION:

Descriation and operation of Electric Sunroof 8E-1
DIAGNOSIS:
Electric Sunroof Diagnosis 8E-1
MAINTENANCE AND ADJUSTMENTS:
Panel Alignment - Front Left or Right ; 8E-2
Panel Alignment - Rear, Left or Right 8E-2
Ramp Alignment 8E-3
Panel Does Not Run True 8E-3
Cable Guide Alignment 8E-3
Maintenance 8E-3
MAJOR REPAIR:
Headlining Panel Removal and Installation 8E-4
Sunroof Motor Removal and Installation 8E-4
Gear Box Assembly Removal and Installation 8E-4
Sunroof Panel Removal and Installation 8E-5
Rear Slide and Cable Removal and Installation 8E-5
Drain Hose Replacement 8E-6
Weatherstrip Removal and Installation 8E-7
SPECIFICATIONS: (Not Applicable)

DESCRIPTION AND OPERATION of the windshield pillars that exhaust through the rocker
panels, and one in each rear quarter panel that exhausts
DESCRIPTION AND OPERATION OF ELECTRIC
through the rear wheel housings.
SUNROOF
In case of an electrical failure, the sunroof may be closed
The sunroof is actuated by a two-way electrical motor manually by using the following steps:
mounted near the center of the windshield header area.
See Figure 8E-1. 1. Remove plug located just in front of the sunroof open
ing (center area).
The motor drives an auxiliary unit with a gear on the
output shaft. This gear drives two flexible cables that at 2. Remove screw located behind plug.
tach to the sunroof panel and control its movement. See
CAUTION:: Observe the number ofand type of
Figure 8E-2.
washers when removing screw. The screw and
The electrical power for the sunroof is taken from the washers provide adjustment for the auxiliary
existing power window relay. From here the current is drive clutch and must be replaced exactly as
routed to two relays. Activating the switch energizes one they were removed.
of the relays, supplying current to the motor and then to 3. Using crank provided in glove box, insert threaded end
ground. Activating the switch on the opposite direction into the socket of the winding gear and crank in a clock
activates the other relay and supplies a reverse current wise direction.
flow to the motor and then to ground. (Figures 8E-17,
8E-18 and 8E-19).
DIAGNOSIS
To open, place control switch in the open position to
activate the motor. The roof panel will retract down and ELECTRIC SUNROOF TROUBLE DIAGNOSIS
rearward, moving on guide rails, from the flush roof posi Motor Runs, Panel Fails to Rise
tion back into a storage area between the headliner and
roof. 1. Panel does not run true due to mechanical resistance.
Drive cables may be broken or disconnected.
To close, place control switch in the close position to
activate the motor, the roof panel moves forward in the 2. Front slides are tilted and need alignment.
guide rails and, as it nears the end of its forward travel,
3. Check alignment of ramp and lifting elements.
the rear portion moves upward on two ramps. This posi
tions the panel flush with the roof and seals it tightly in a. Remove winding gear access plug and screw slotted
the opening. head screw. Add another washer (shim).

There are four plastic drain tubes to drain off any water b. Replace screw, check operation, tighten screw and
seepage past the weatherstrip. One tube is located in each install plug.
8E- 2 1975 BUICK SERVICE MANUAL www.TeamBuick.com
GEAR BOX

SCREWS

CONNECTOR

8E-1

Figure 8E-1 Motor and Drive Unit

Motor Fails to Run in One Direction Only

1. Reverse wiring of the two relays and activate switch.

2. If motor runs in opposite direction, a relay is defective.

3. If motor runs in same direction, switch is defective.

Motor Fails to Run

1. If power windows also fail to operate, check power

window circuit breaker.

2. With test light, check voltage at the supply terminal

of the relays.

3. Activate control switch and check voltage at the mo

DRIVE GEAR
tor. Also check motor ground wire.

4. Replace motor.

FLEXIBLE
MAINTENANCE AND ADJUSTMENTS
CABLES
PANEL ALIGNMENT - FRONT, LEFT OR RIGHT

1. To obtain a flush fit, loosen both front slide screws. See

Figure 8E-3.

2. Turn knurled nuts clockwise to raise panel and coun

terclockwise to lower panel. See Figure 8E-3.

3. Adjust opposite front slide the same. Tighten screws.

8E-2

PANEL ALIGHMENT - REAR, LEFT OR RIGHT

1. To obtain a flush fit, loosen 3/8" lock nut on rear slide.

Figure 8E-2 Drive Gear and Cables See Figure 8E-4.
 www.TeamBuick.com ELECTRIC SUNROOF 8E- 3

PANEL DOES NOT RUN TRUE

1. Close panel to determine which side jams.

2. Open panel, remove drive housing center cover and

pry off drive cable retaining clip. See Figure 8E-6.

CAUTION:; Clip is made ofspring steel. Cover

clip to prevent rapid spring-up.

3. To move right side of roof panel forward, lift right

cable at front of pinion and pull it one or more teeth to
Figure 8E-3 Panel Alignment - Front the left.

4. To move left side panel forward, perform same operat

2. Using a screwdriver, turn adjusting screw clockwise to ion on left cable.
raise panel and counterclockwise to lower panel.
5. Install retaining clip and cover, check operation.
3. Adjust opposite rear slide the same. Tighten lock nut.

Figure 8E-4 Panel Alignment - Rear

RAMP ALIGNMENT Figure 8E-6 Remove Drive Cable Retaining Clip

1. If roof panel does not raise into opening during closing

cycle, remove headlining panel from roof panel and open CABLE GUIDE ALIGNMENT
panel to full position.
1. If panel jams, check both front corner lower elbow
2. Examine ramps in drainage channel to determine guides for alignment with front and side guides.
proper alignment with lifting element at rear of panel. See
Figure 8E-5. Point of contact between lifting element and 2. If necessary, shim lower elbow guides to move guides
ramp can be seen on rearward slope on ramp. inboard for alignment with adjacent guides.

3. Pry ramp up and move ramp side to side until centered 3. If panel fails to raise, the joints of cable slides are out
with lifting element. of alignment (guide rail, corner and connector guides, and
cable drive housing) and are jamming cable drive.
4. Close roof panel and note lifting action of panel.
a. Loosen screws retaining the guide rails, corner and
5. If necessary, readjust ramps up or down and side to connector rails and cable drive housing.
side until proper lifting action of panel is obtained.
b. Retighten one by one, continually activating the drive
mechanism.

c. Where necessary, realign those points where resistance

is felt.

MAINTENANCE

1. During cable replacement lubricate cables with No. 70

lubriplate or equivalent.

2. Periodically clean off any dirt on guide rail covers. Do

not lubricate top surface of guide rail covers as this will
streak headlining.

3. Check drain holes at front. If plugged, clean with

Figure 8E-5 Sunroof Fully Open compressed air or flexible wire. Clean rear tubes from the
8E- 4 1975 BUICK SERVICE MANUAL www.TeamBuick.com
2. Align headlining panel with side guide rail lower
tracks and move rearward into/proper position.
bottom of tubes. If the tubes cannot be opened up, replace
3. Install reinforcement bow.
them.
4. Close roof panel all but approximately 3 inches.
MAJOR REPAIR
5. Install headlining panel and secure retaining clips.

HEADLINING PANEL 6. Install securing screws in panel.

REMOVAL AND INSTALLATION
Removal SUNROOF MOTOR REMOVAL AND
INSTALLATION Removal
1. Open roof panel approximately 3 inches.

2. Remove 2 screws securing headlining panel. 1. Opel sunroof to full open position and disconnect
negative battery cable.
3. Slide headlining panel forward and out of retaining
2. Remove all windshield garnish moldings, sunvisors
clips. See Figure 8E-7.
and brackets and carefully loosen headlining material
from front roof inner panel.

3. Disconnect electrical connector.

4. Remove cover off back of motor to expose mounting

screws and remove motor.

Installation

1. Position motor to gear box using existing guide pins.

2. Secure motor to gear box and reinstall motor cover.

3. Connect electrical connector.

4. Carefully reinstall headlining material using trim ce

ment, to front roof inner panel.

5. Install all garnish molding, sunvisor brackets and sun-

visors. Be careful not to pinch drain tubes when installing
garnish moldings.
Figure 8E-7 Headlining Panel Removal
GEAR BOX ASSEMBLY REMOVAL AND
INSTALLATION
4. Retract roof panel to full open position.
Removal
5. Remove headlining panel reinforcement bow by
removing tape from bow and sliding bow rearward and off 1. Gain access to sunroof motor and disconnect wiring
the headlining material. See Figure 8E-8.
(use motor removal procedure).
6. Close roof panel approximately 3 inches to permit
2. Remove drive cable housing cover and right and left
headlining frame to clear roof panel rear hooks.
elbow corner guides.
7. Pull headlining panel forward and out of side guide rail 3. Carefully remove drive cable retaining clip.
lower tracks.
CAUTION: : The clip is made of spring steel.
Installation Cover clip to prevent rapid spring-up. See Fig
ure 8E-6.
1. Retract roof panel to full open position.
4. Pull drive cables out of upper and lower front guides.

5. Remove drive cable housing.

6. Remove gear box assembly along with motor.

7. Gently clamp gear box in a padded vise and remove

cover. Then, using an Allen wrench, disengage motor
from gear box.

REINFORCEMENT J| Installation
BOW
1. With gear box gently clamped in a padded vise, using
guide pins, position motor to gear box and secure, then
install cover.

2. Install motor and gear box assembly to drive cable

Figure 8E-8 Removing Bow housing, then install drive cable housing.
 www.TeamBuick.com
3. Insert ends of cables in guides, then lubricate cables
and drive gear (No. 70 grade lubriplate, or equivalent).
ELECTRIC SUNROOF 8E- 5

4. Install elbow corner guides. Alignment of lower elbow

corner guide is of utmost importance.

5. Connect wiring and check operation of system.

6. Install foam insulation padding, headlining material,

1 FRONT SLIDE ASSEMBLY
garnish modlings and sunvisors and brackets. Be careful
not to pinch drain tubes when installing garnish moldings.

SUNROOF PANEL REMOVAL AND INSTALLATION

Removal

1. Open sunroof approximately three inches.

2. Remove screws from front of headlining panel that

secures it to roof panel.

3. Slide panel forward and out of retaining clips on panel

front edge. Close roof and push headlining panel to full
rearward position. See Figure 8E-7.

4. Remove outboard screws from each front slide assem Figure 8E-1O Front Slide Assembly Clear of Guide Rail
bly. See Figure 8E-9.

5. Loosen inboard slide screw, rotate each front slide

assembly inboard to clear guide rail. See Figure 8E-10.

6. Pull each rear slide and cable assembly inboard and

out of slide retainer hole in roof panel. See Figure 8E-11.

7. Lift roof panel at front edge and pull forward and out
of opening.

Figure 8E-11 Removing Rear Slide Cable Assemble

From Retainer

3. Install outboard screws and tighten both on each side.

See Figure 8E-3.

4. Push roof panel to full forward position.

5. Lift rear of panel upward and activate switch to posi

tion. Rear slides into alignment with holes on slide retain-
. ers on roof panel. See Figure 8E-11.

6. Engage each rear slide pin into retainer hole and install
Figure 8E-9 Remove Outboard Screw From Front
Slide Assembly retainer spring plate on slide pin.

7. Actuate switch, check operation of roof panel and note

Installation
fit. Adjust if necessary.
1. With headlining panel in full rearward position, install 8. Install headlining on roof panel.
roof panel into roof opening.

CAUTION: Hold panel in horizontal position REAR SLIDE AND CABLE REMOVAL AND
when placing panel into roofopening to assure INSTALLATION
that stop on center, rear edge ofroofpanel does Removal
not damage passenger compartment headlin
ing. If only one cable is defective, replace both to assure paral
lel travel on roof panel.
2. Move each front slide assembly outboard and install
slides on guide rail tipper tracks. L Remove drive cable housing cover,
8E- 6 1975 BUICK SERVICE MANUAL
www.TeamBuick.com
housing and into lower track on left side. See Figure 8E-
16.
2. Remove both front upper elbow guides.
Make sure right side is centered with fifth screw from
3. Using screwdriver, pry off drive cable retaining clip. right guide rail. Do not engage cable in drive pinion teeth.
See Figure 8E-6.
4. Check both front corner lower elbow guides for align
4. Pull free end of one cable out of guide rail and housing, ment with front and side guides. If necessary, shim lower
pull cable and rear slide forward to front corner. See elbow guide to move inboard for alignment with adjacent
Figure 8E-12. guides.

5. Remove slide from guide track, pull cable out of front 5. Lube cables at elbow areas with No. 70 grade lubri-
guide. See Figure 8E-13. plate, or equivalent. Install both front corner upper elbow
guides.
6. Remove opposite cable in same manner.
6. Recheck position of rear slides (fifth screw from front
on side guide rail). See Figure 8E-14. With slides in this
position, engage cables in drive pinion teeth. This operat
ion is critical to assure roof panel alignment and prevent
cable breakage.

7. Lubricate cables and pinion teeth with No. 70 grade

lubriplate, or equivalent, install drive cable retaining clip.
Position narrow (notched) edge of clips toward front of
vehicle.

8. Install drive cable housing cover.

9. Actuate switch to assure operation, then return rear

slides to fifth screw from front on side guide rails.

Figure 8E-12 Pull Cable and Slide Assembly Forward

*FIFTH SCREW
FROM FRONT
8E-14

igure 8E-14 Rear Slide in Centered Position

DRAIN HOSE REPLACEMENT

| 8E-13 | Front Drain Hose

Figure 8E-13 Slide Removed

1. Remove windshield side garnish moldings, roof side
rail garnish moldings, both sunvisor assemblies, counter
bracket and both windshield upper garnish moldings.
Installation
2. Carefully pull headlining from top of windshield area
1. Position left rear slide in guide track, move slide and
to gain access to hose.
cable back until slide is centered with the fifth side guide
rail screw from front. See Figure 8E- 14. 3. Remove hose from outlet at top. Adhesive is used to
secure hose to outlet.
2. Slide free end of cable into upper front guide, route
through the curved front center track in drive cable hous 4. Use a piece of flexible wire or cord, attach new hose
ing and into lower track on right side. Do not engage cable to lower end of old and pull new into position while
in drive pinion teeth. See Figures 8E-15 and 8E-16. removing old hose and secure with weatherstrip adhesive.

3. Install right slide and cable in same manner as left, 5. Reinstall headlining, garnish moldings, sunvisor as
except that right cable is routed in straight center track of semblies and center bracket.
 www.TeamBuick.com ELECTRIC SUNROOF 8E- 7

Figure 8E-15 Installing Cable Into Upper Front Guide

Rear Drain Hose Figure 8E-16 Drive Cables Installed

1. Pull down headlining at rear corner to gain access.

3. Remove weatherstrip from roof panel opening and
2. Remove hose at top. rear edge of roof panel.

3. Using a piece of flexible wire or cord, attach new to 4. Clean surface, using a suitable solvent, and apply wea
lower end of old and pull new into position. therstrip cement to both surfaces.

5. Position roof opening weatherstrip flush with roof and

WEATHERSTRIP REMOVAL AND INSTALLATION align one end of weatherstrip with mark on roof assembly.
1. With sunroof closed, mark joint of roof opening wea Cement weatherstrip to roof opening.
therstrip rear edge and roof panel. Weatherstrip front edge 6. Install weatherstrip on rear edge in same manner. Also
on both the panel and roof on both sides of vehicle. retained with trim nails.
2. Remove roof panel assembly. 7. Install roof panel, assembly into opening.
8E- 8 1975 BUICK SERVICE MANUAL www.TeamBuick.com

SWITCH
CONNECTOR BRACKET -
RELAY
EXISTING POWER
MOUNTING
WINDOW RELAY

INSTRUMENT
PANEL HARNESS
GROUND INSTALL IN PLACE
OF RED WIRE

screw assembly
fully driven, seated
and not stripped.

Fa] keep like color connectors

on the same relay.
[b\ existing red wire from power
window relay connector
HARNESS
(install in connector
GROUND
provided on harness).
SCREW ASSEMBLY
FULLY DRIVEN, SEATED
AND NOT STRIPPED. VIEW A 5B8E17

Figure 8E-17 Sunroof Wiring

SEELITE
LAMP SOURCE

SWITCH

ESCUTCHEON

VIEW-A
SCREW ■
FULLY DRIVEN, SEATED
AND NOT STRIPPED.

5B8E18

Figure 8E-18 Sunroof Switch

 www.TeamBuick.com ELECTRIC SUNROOF 8E- 9

[T|S WITCH -
SUN ROOF

18 PINK
IOORN/BLK-

JUNCTION
BLOCK [2]

10 RED
FROM BAT.
LOCATION TO
POWER
FT] ABOVE LEFT KICK PAD NEXT WINDOWS
•—JTO JUNCTION BLOCK
[7] ABOVE LEFT KICK PAD NEXT
■—'to power window relay FUSE BLOCK
[TllNSTRUMENT CLUSTER
•—'housing
B INSTRUMENT PAI RTIE
BAR TO LEFT OF!
COLUMN
[5]IN ROOF PANEL
5B8E19
[TJUNDER RELAY MOUNTING SCREW

Figure 8E-19 Sunroof Wiring Diagram

8E- 10 1975 BUICK SERVICE MANUALwww.TeamBuick.com

UPPER ELBOW
GUIDE

DRIVE CABLE
RETAINING CLIP

DRIVE CABLE
FRONT SLIDE HOUSING COVER
ASSEMBLY

Figure 8E-20 Sunroof Exploded View