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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 2297 (SUNROOF SYSTEM)REPAIR INSTRUCTIONSSUNROOF FRAME 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 2010 Cadillac STS. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Sunroof Module-To-Roof Bolts
    GM776057Courtesy of GENERAL MOTORS CORP.
  1. With an assistant, position the new sunroof module assembly into the alignment pins (2) located on the roof ring.
  2. Hand start the 2 center, side to side, sunroof module assembly to roof bolts (1) in order to hold the sunroof module into place.
  3. Finger tighten the 2 center bolts.
    4. CAUTION: Refer to Fastener Caution .
  4. Install the remaining sunroof module to roof bolts.

    Tighten:  Tighten all of the bolts to 9 N.m (80 lb in).

    5. Fig 2: Drain Spout
    GM758127Courtesy of GENERAL MOTORS CORP.
  5. Connect the front and rear drain hoses to the drain spouts (1) on the sunroof module.
    6. Fig 3: Sunroof Motor/Actuator, Electrical Connector & Screws
    GM1542792Courtesy of GENERAL MOTORS CORP.
  6. Install sunroof motor/actuator to the module.
  7. Install the screws to the motor/actuator.

    Tighten:  Tighten all of the bolts to 6 N.m (53 lb in).

  8. Connect the electrical connector to the sunroof motor/actuator.
  9. Secure the harness with suitable straps.
  10. Install the air deflector. Refer to Sunroof Air Deflector Replacement .
  11. Install the sunshade. Refer to Sunroof Sunshade Replacement .
  12. Install the sunroof window and loosely install the screws. Refer to Sunroof Window Replacement .
  13. Adjust the sunroof window. Refer to Sunroof Window Height and Opening Fit Adjustment .
  14. Verify the proper operation of the sunroof before securing the headliner.
  15. Initialization/Teach the sunroof motor. Refer to Sunroof Motor/Actuator Initialization/Teach Process .
  16. Install the headliner, with an assistant. 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.