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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1242 (SUNROOF SYSTEM)REPAIR INSTRUCTIONSSUNROOF MODULE ASSEMBLY REPLACEMENTINSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Installation Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Installation Procedure
WARNING: This page is about a different car, the 2008 Chevrolet Malibu Classic. However, it is still accessible from the selected car via links, so may be relevant.
  1. If you are replacing the sunroof module assembly, install the sunroof motor/actuator. Refer to Sunroof Motor/Actuator Replacement .
    2. Fig 1: View Of Sunroof Module
    GM1222469Courtesy of GENERAL MOTORS CORP.
  2. With the aid of an assistant, position the sunroof module assembly to the roof ring.
    3. NOTE: Refer to Fastener Notice .
  3. Install the 4 bolts which secure the sunroof module assembly to the roof ring.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

    4. Fig 2: View Of Bolts Securing Sunroof Module Motor Base To Roof
    GM1224092Courtesy of GENERAL MOTORS CORP.
  4. Using the access hole in the sunroof module cross bar, install the push-pin fastener which secures the rear sunroof water gutter to the roof.
  5. Install the 2 bolts which secure the sunroof motor base to the roof.

    Tighten:  Tighten the bolts to 2 N.m (18 lb in).

    6. Fig 3: View Of Sunroof Front Drain Hose
    GM893482Courtesy of GENERAL MOTORS CORP.
  6. Connect the front and rear drain hoses to the drain spigots.
  7. Install the sunshade. Refer to Sunroof Sunshade Replacement .
    8. Fig 4: Identifying Sunroof Motor/Actuator Electrical Connector
    GM1344700Courtesy of GENERAL MOTORS CORP.
  8. Install the headliner. Refer to Headlining Trim Panel Replacement (Sedan) .

    Verify that the electrical connector is connected to the sunroof motor/actuator.

  9. Install the sunroof window. Adjust as necessary. Refer to Sunroof Window Replacement .
  10. Initialize the sunroof motor. Refer to Sunroof Motor/Actuator Initialization/Teach Process (New Motor)  or Sunroof Motor/Actuator Initialization/Teach Process (Existing Motor) .
  11. Install the sunroof finishing lace. Refer to Sunroof Opening Trim Finish Lace Replacement .
  12. Inspect the sunroof for proper operation.
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.