Panoramic sunroof

There are several conditions that pertain to this sunroof as illustrated in a published bulletin. One of a possible 11 different conditions can be present. There is only one however, that states a pop/creak while driving. Here is the info.

Body - Panoramic Sunroof Noise Issues Diagnostic/Repair

INFORMATION

Bulletin No: 05-08-67-014M

Date: August 28, 2009

Subject: General Guide to Panoramic Sunroof Noise Issues

Models:
2005-2007 Pontiac G6
2007 Saturn Aura

Supercede:
This bulletin is being revised to clarify the Parts information. Please discard Corporate Bulletin Number 05-08-67-014L (Section 08 - Body and Accessories).

Important
The intent of this bulletin is to identify the appropriate issue(s) and apply the appropriate correction(s) pertaining to the customer's comments. To determine the final service labor operation time, use the initial base time and then apply the appropriate add times, depending on the issue correction(s) performed. Please note - only the items performed on the vehicle being serviced should be used as the final repair time and the Repair Order must indicate the Bulletin Number and the Condition Number(s) used.

Important
Do not replace an entire sunroof module for creak/pop type noise or wind noise-type complaints. A new sunroof module does not come as a complete assembly and will require many components - including all of the glass panels - to be swapped over from the old module to the new module being installed. Correctly following the bulletin should correct these concerns.

Important
U.S. Dealer Technicians - Please review Tech Assist video 50250.17T1 at the GM Training web site prior to any repair of the panoramic sunroof system.

PLEASE VERIFY CUSTOMER CONCERN BEFORE SERVICE.

Important
If the sunroof motor/actuator assembly has been replaced, or has lost battery positive voltage or ground for any other reason, it will be necessary to initialize the motor/actuator when service has been completed. Refer to Sunroof Control Module Programming and Setup in Programming and Setup.

This bulletin covers the following issues:

- Creak/snap/pop type noise coming from the sunroof module - Install mylar washers and lubricate all module fasteners (Refer to Condition #1)
- Windnoise coming from sunroof glass panels and/or HVAC blower whistle type noise that changes with fan speed - Install glass panel cross car foam (Refer to Condition #2)
- Windnoise coming from the sunroof module seal to roof - Install updated module seal (Refer to Condition #3)
- Glass panel loose/rattling - (Refer to Condition #4)
- Plastic/metal rattle type noise coming from the rear area of the sunroof module - (Refer to Condition #5)
- Sunshade will not cycle (open or close) - (Refer to Condition #6)
- Seal itch between glass panels - (Refer to Condition #7)
- Intermittently the sunroof closes while opening - (Refer to Condition #8)
- Light coming through at the rear corner of the glass panels - (Refer to Condition #9)
- Headliner itch type noise at the front area, over the driver's and/or front passenger's head area - (Refer to Condition #10)
- Headliner squeak or itch noise at the rear of the sunroof - (Refer to Condition #11)

Condition #1

Some customers may comment on creak/snap/pop type noise from the sunroof module that occurs while driving over bumps.

Cause

This condition may be caused by the module mounting bolts/fasteners (roof interaction with the fasteners).

Correction

For vehicles built before January 1st, 2006, perform steps 1-8 below (Install mylar washers and lubricate all fasteners). For vehicles built after January 1st 2006, ensure mylar washers are present and not damaged (cut through). If they are present and NOT damaged, lubricate all fasteners (perform Steps 5-8 only). If the mylar washers are damaged, perform Steps 1-8 below.

Important
Use hand tools only, power tools will not allow the compensator to seat properly.

Figure 1

1. Install 28 Mylar washers to the mounting bolts/fasteners. Drop the headliner enough to access these attachments, being careful not to bend or damage the headliner while performing the following procedure. Loosen all four front module mounting bolts (refer to figure 1). Verify that the screws are not engaged into the roof.
Figure 2

2. Install 8 of 28 Mylar washers, two on each of the front four compensators (refer to figure 1 & 2). Figure 3A

Always retract the barrel (down) to begin reinstallation process. Figure 3B

Approximate compensator barrel location after tightening during reinstallation process. 3. Reinstall the front four compensators per the following procedure. Spin all front four compensator barrels all the way down (refer to figure 3 A, B). Figure 4A

Figure 4B

Important
To achieve proper seal to body compression, have one person push firmly upward on the black rail of the module between the two front center compensators as another person tightens the center two compensators (refer to figure 4A). This will improve the seal contact along the front edge of the module to body. Then reinstall the two outboard tolerance compensators to the roof. (Torque specification 10 Nm/89 lb in) (refer to figure 4B)

Figure 5

Figure 6

4. Install 20 of 28 Mylar washers - four to A, C, A1, C1 (refer to figure 5 & 6). Install two washers to B and B1 between the compensator and the roof (refer to figure 2 & 6). Follow the procedure below.

Important
To prevent the sunroof from dropping, loosen one corner at a time following the procedure listed below. Do not over tighten the mounting bolts.

Starting with A, remove the TORX screw from the center of the 19 mm nut. Discard the small retaining spring holding the TORX screw to the 19 mm nut. Insert two Mylar washers in between the TORX screw and the 19mm nut and insert two Mylar washers above the 19 mm nut between the height adjuster and the body (refer to figure 5). Complete this procedure for B, C, A1, B1, C1 using the sequence below.

- Loosen A. (Refer to figure 6 and description above).
- Loosen B.
- Install four washers to A (refer to figure 5) and two to B (refer to figure 2).
- Tighten A. (See note # 1 below)
- Loosen C.
- Install four washers to C.
- Tighten C and B. (See note # 1 and note # 2 below).
- Repeat for A1, B1 and C1. Note # 1: Retighten TORX screw into body to 10 Nm/89 lb in.
Note # 2: Prior to fastening the two side center tolerance compensators B and B1 (refer to figure 6), turn the compensator to lower the barrel to its lowest position (refer to figure 3). Before fastening, get out of the vehicle and observe the main seal to body contact. If the seal appears to have good engagement to the roof, proceed with tightening the center two tolerance compensators screws, B and B1 (torque specification 10 Nm/89 lb in).
If the seal does not appear to have good engagement to the roof, from the inside of the vehicle, have one person push firmly upward on the center black rail of the module, while the other person tightens the two side center compensators B and B1. This will improve the seal compression to module.

Figure 7

5. Lubricate all 10 module compensators/attachments areas with GM Super lube (P/N 12346241 [in Canada use P/N 10953474]) prior to reinstallation of the headliner (refer to figure 7).

Caution
Be cautious when spraying GM super lube. To avoid any damage to the interior trim, cover all exposed areas before spraying. While spraying, use a shop towel with the other hand to catch any drips and pat the sprayed area to remove any excess lubricant.

6. If the vehicle was built before May 9th, 2007, verify that the flock tape is in place on the headliner as described in Condition #10.
7. Test drive the vehicle to confirm that all noises have been eliminated.
8. Reinstall the headliner.

Condition #5

Customers may comment on a plastic/metal rattle type noise that occurs while driving over bumps. This noise usually comes from the rear of the sunroof module.

Cause

This condition may be caused by loose mounting bolts/fasteners.

Correction
Figure 20

Important
Do not over tighten the mounting bolts.

1. Partially lower the headliner enough to access these attachments, being careful not to bend or damage the headliner while performing the following procedure. Loosen all (5) rear center mounting bolts and then re-tighten all (5) center mounting bolts at the rear of the module to 10 Nm (89 lb in). Note that the forward 3 mounting bolts are accessed by the holes in the sunshade when the sunshade is fully closed (refer to figure 20).

Important
These screws should be snug. Do not over tighten the mounting bolts.

Figure 21

2. Tighten both rear motor attachment screws (3 per motor / 6 total) to 4 Nm (35 lb in). (Refer to figure 21)
Figure 22

3. Press the reinforcement upward while tightening the rear crossmember attachment screws (3 per side / 6 total) to 4 Nm (35 lb in) (refer to figure 22).
4. Test drive the vehicle to verify condition is gone.
5. Re-install the headliner.

Condition #10

Some customers may comment on an itch type noise occurring over bumps. The noise comes from the front area of headliner at the corners where headliner meets the sunroof module, over the driver's and/or front passenger's head area.

Cause
Figure 25

The headliner may rub on a pair of plastic screw boss holes (empty/no screws in these bosses) that are part of the sunroof module on each side of the module towards the front (refer to figure 25).

Correction
Figure 26

For vehicles built before May 9, 2005, (Note: vehicles built after May 9, 2005, already has this update) partially lower the front of the headliner enough to access this area, being careful not to bend or damage the headliner while performing the following procedure. Install a 102 mm X 102 mm (4 in X 4 in) felt/flocking tape* patch to the backside of the headliner, just under the pair of plastic screw boss holes (empty/no screws in these bosses) that are part of the sunroof module on each side of the module (driver/passenger) towards the front (refer to figure 26).

VERIFY CUSTOMER COMPLAINT HAS BEEN ELIMINATED Reinstall the headliner. *The felt/flocking tape, BSR P/N KT13296, can be purchased from Kent Automotive by calling 1-800-654-6333 (in Canada, 1-800-563-1717).

Condition #11

Some customers may comment of a squeak or itch noise over bumps at the rear of the sunroof.

Cause

The metal frame of the sunroof module may be contacting the plastic portion of the sunroof module.

Correction

Loosen the metal frame and insert a piece of 3M(TM) squeak reduction tape, P/N 06356, between the plastic and metal frame.