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Date Posted: 17:02:44 07/04/02 Thu
Author: nn_bob
Subject: Re: swap manual for power sunroof - got parts, how hard?
In reply to: Chris318is 's message, "swap manual for power sunroof - got parts, how hard?" on 23:10:10 07/03/02 Wed

I didn't write this - thanks to Zach:
(Start Quote)
TOOLS REQUIRED:
#1 Phillips driver
Long flat-blade driver
9mm Nut driver
10mm ¼? Socket driver
Good, SHARP Tin snips
½? drill bit, drill(Installation)
Sheetmetal file

PARTS LIST:
Power sunroof overhead panel, emergency cover Sunroof motor, relay, lighted switch (lighted switch found on any 87?on-up E28, E30) Wiring harness from fuse box, ground Black metal motor mounting bracket 2? machine screws, with locknuts(3 needed) 30-Amp Blade-type fuse(Green)
Two small wire zip ties
INSTALLATION:
1) Open sunroof ¾ way open
2) Pop wind deflector arms upwards and out.
3) Remove 12 screws to detach wind deflector
4) From inside, pull-out door weather stripping from A-pillar bend, to ½ past grab handles
5) with CLEAN HANDS- gently peel-apart white headliner fabric away from panel material
6) Remove sunvisors
7) Unplug Active Check-Control module
8) Slide rearview mirror post rubber grommet down to mirror
9) Retract sunroof crank handle and remove screw
10) Pop-out plastic revolving plate, and remove remaining two screws to detach crank assembly and SLOWLY remove panel from rearview mirror
11) Drill-through two rivets to mounting plate. File-down metal burrs, and any remaining rivets **WARNING** Place 1? wooden backing, to prevent drill-through to body sheetmetal! (cont.)
11)From forward sunroof opening, gently pull-back foam strip insert, covering 3 9mm nuts. Remove 12)Remove remaining two 9mmm nuts above windshield 13)Cut a triangular piece off the THICK copper sunroof cable housing, to permit flush motor mounting. Be PATIENT- this requires muscle! (See Diagram Below)
Cable Housing Plate(THICK Copper):
| |
| (Sunroof cables) |
| x |
|____________x__________x___|

Cut at ?x? marks ONLY. Test-fit motor clearance.
14)Install new motor bracket against copper plate, with the five 9mm body nuts.
15)Motor mounts to three holes, on housing plate. Insert motor by joining motor gear to exposed metal worm-roller cable first. Tightly bolt-down motor with self-locking nuts, torque to 20lbs/in 16)Screw-in relay to hole in center of bracket (Be sure lock-clip is there!)
17)Bolt brown ground wire to body w/ 10mm drive
18)Zip-tie wire bundle to mounting plate, tightly
19)Run Green/Blue wire from motor through upper windshield, to A-pillar
20)Unclip A-pillar post trim by placing left hand above trim piece. Press-in and push DOWN firmly
21) Continue to run green/blue wire LIVE wire down A-pillar, and past dashboard column.
22) Remove four plastic screws to lower driver-side kick panel, under steering column. Remove panel, and continue routing wire to pedals
23) Find matching green/blue wire plugged into the white or orange fuse/power panel block below the dash and splice connector to it. Replug
24)Reinstall steering column kick panel
25)Do final check of mounting, wire connections
26) Run sunroof switch harness through opening in overhead panel first. Insert rubber mirror grommet to center of panel and secure to roof by screws at the end of the outside sunroof opening
27) Return sunvisors/check-control module/sunroof wind deflector to car
28) Plug-in new power sunroof switch. Test for proper operation*;
a) First, push button ONCE going BACKWARDS then once again to fully open sunroof.
b) To close, quickly push button forward ONCE, to engage motor- then hold forward button until roof closes.
c) Press and hold forward button to open vent-quickly press BACK once to close fully. Repeat cycle to ensure sunroof is properly aligned

The BMW power sunroof is designed as a multi-step operation, to properly confirm direction of roof movement, engaging the motor gear to the appropriate drive(1-forward/1backwards) cable. If the motor suddenly skips, or ?buzzes? loudly- the alignment of the sunroof is uneven and should be corrected immediately. Perform adjustment by loosening the large brass nut with the provided spark plug wrench, and manually cranking the roof, with the provided allen ?S? crank, to fully OPEN position and loosen motor at the three mounting points. Properly re-engage the motor gear to the cable opening and perform the open/close operation. If skipping of gears persist- then the motor was not tight and flush to the mounting bracket. If motor does not operate at all- the RELAY is dead, and should be replaced with one of your car?s model year, ideally. Otherwise, the motor unit and drive mechanism is virtually bulletproof, lasting the entire the life of the vehicle.

Zach
BMW/NA Certified Master Technician (BMW E21/E30/E28/E32/E34/E1)
But no longer turns wrenches....

That help?
(End Quote)

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