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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 609 (SUNROOF SYSTEM)REPAIR INSTRUCTIONSSUNROOF MODULE ASSEMBLY REPLACEMENTINSTALLATION PROCEDURE
2006 Chevrolet Cobalt SS, 4D Sedan, Standard

Installation Procedure

2006 Chevrolet Cobalt SS, 4D Sedan, StandardSECTION Installation Procedure
WARNING: This page is about a different car, the 2007 Pontiac G5 Pursuit, 2007 Pontiac G5, and 2007 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Sunroof Module To Roof Nut Tightening Sequence
    GM1610173Courtesy of GENERAL MOTORS CORP.
  1. With the aid of an assistant, position the new sunroof module assembly to the studs located on the roof ring.
  2. Install the center sunroof module to roof nuts (1, 2) and tighten by hand.
    3. NOTE: Refer to Fastener Notice .
  3. Install the remaining sunroof module (1) nuts to the module in sequence (3, 4, 5, 6, 7, 8).

    Tighten:  Tighten all of the nuts to 10 N.m (89 lb in).

    4. Fig 2: Sunroof Module Assembly
    GM1547329Courtesy of GENERAL MOTORS CORP.
  4. Connect the front and rear drain hoses (1) to the drain spouts on the sunroof module.
  5. Install the sunroof window to the new sunroof module. Refer to Sunroof Window Replacement .
  6. Install the sunshade panel to the new sunroof module. Refer to Sunroof Sunshade Replacement .
    7. Fig 3: View Of Sunroof Motor/Actuator Electrical Connector
    GM861204Courtesy of GENERAL MOTORS CORP.
  7. Connect the electrical connector to the sunroof motor/actuator.
  8. Secure the harness to the sunroof module.
  9. Verify the proper operation of the sunroof before securing the headliner.
  10. Raise and install the headliner. Refer to Headlining Trim Panel Replacement .
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.