Body - Rear of Sunroof Not Flush With Roof
NUMBER: 23-028-05 REV. AGROUP: Body
DATE: August 27, 2005
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-028-05, DATED
MAY 5, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISIONS TO THE
DIAGNOSIS.
THE StarSCAN FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE
INTERNET.
THE FLASH FILE WILL BE AVAILABLE ON THE NEXT StarSCAN� UPDATE CD
RECEIVED AFTER CD 6.02.
SUBJECT:
Rear Of Sunroof Glass Is Not Flush To Roof
OVERVIEW:
This bulletin involves flash reprogramming the sunroof motor and possibly replacing the sunroof drain channel.
MODELS:
2005 (LX) 300/Magnum
NOTE:
This bulletin applies to vehicles built prior to September 1, 2004 (MDH 0901XX) and equipped with a Sunroof (sales code GWA).
SYMPTOM/CONDITION:
Sunroof does not fully close (fit flush to roof) and/or fully vent and/or is noisy at the end of full open travel.
DIAGNOSIS:
1. Verify the rear of the sunroof glass to roof flushness concern.
2. **UNCALIBRATE THE SUNROOF.
a. Insure the battery is at least 12 Volts.
b. Place the ignition switch in RUN position.
c. Locate the sunroof fuse (Fuse 44 in the Power Distribution Center located in the trunk).
d. While the sunroof is still in motion, have an assistant remove the sunroof fuse.
e. Reinstall the sunroof fuse.
3. RECALIBRATE THE SUNROOF
a. Press and hold the sunroof vent switch until it stops at the full vent position.
b. Verify sunroof operation by opening, closing, and venting the sunroof.
c. If the uncalibrate/recalibrate procedure corrected the sunroof glass to roof fit, perform the Repair Procedure.
4. If the uncalibrate/recalibrate procedure did not eliminate the sunroof glass to roof fit, use the procedures outlined in TechCONNECT(R) BODY/SUNROOF/GLASS PANEL/ADJUSTMENTS to adjust the glass panel. If the sunroof glass is now flush, perform the Repair Procedure.**
PARTS REQUIRED:
NOTE:
There are two methods to download flash files to StarSCAN(R). The first method (preferred) is to download the flash files to the StarSCAN(R) from the internet. The second method is to download the flash files from the latest StarSCAN(R) Software Update CD.
SPECIAL TOOLS/EQUIPMENT REQUIRED:
REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE:
NOTE:
The StarSCAN(R) must be at version 5.02 or higher before the "Using The Internet To Retrieve The Flash File" repair procedure can be performed.
NOTE:
The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center".
NOTE:
Make sure the StarSCAN(R) is configured to the dealership's network before proceeding.
NOTE:
If this flash process is interrupted/aborted, the flash should be restarted.
1. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop (optional).
2. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle.
3. Power ON the StarSCAN(R).
4. Retrieve the old Sunroof Motor (SUNR) part number. Using the StarSCAN(R) at the "Home" screen:
a. Select "ECU View"
b. Touch the screen to highlight SUNR in the list of modules.
c. Record the "Part Number", displayed on the "ECU Overview" screen, for later reference.
5. Connect the CH9410 StarSCAN� ethernet cable to the StarSCAN(R) and the dealer's network drop (if not already connected).
6. Download the flash file from the internet to the StarSCAN(R). Using the StarSCAN(R) at the "Home" screen:
a. Select "Flash Download"
b. Select "Use connected vehicle" (StarSCAN(R) must be connected to the vehicle) or "Enter information manually" (connection to the vehicle is not necessary). Press the "Next" button and follow the on screen instructions.
c. Select the appropriate calibration.
d. Select "Download to Scantool".
e. Select "Close" after the download is complete.
7. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle (if not already connected).
8. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts.
9. Download the file from StarSCAN(R) to the vehicle. Using StarSCAN(R) at the "Home" screen:
a. Select "ECU View".
b. Browse the list of ECUs using the scroll arrows. Highlight the SUNR.
c. Select "More Options".
d. Select "ECU Flash".
e. Highlight the appropriate SUNR "Calibration" from the list.
f. Select "Update Controller".
g. When update is completed, select "OK".
NOTE:
Due to the SUNR programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.
10. With the sunroof in the full open vent position, inspect the outboard attachments of the sunroof drain channel for breakage. If the drain channel is broken use the procedures outlined in TechCONNECT(R) BODY/SUNROOF/WATER CHANNEL to replace the drain channel, p/n 05137559AC.
11. Insure the battery is at least 12 Volts.
12. Place the ignition switch in RUN position.
13. Close all of the doors.
14. Press and release the vent switch (sunroof should move to vent position).
15. Once the sunroof has stopped motion at the vent position, press and hold the vent switch for at least 5 seconds to recalibrate the sunroof position.
16. If the sunroof did not reach the full vent open position, press and hold the vent switch until that position is reach then release the vent switch and repeat step 5.
17. Cycle the sunroof from the full vent open position to the full slide open position and back to the full vent open position at least 7 complete times. The sunroof is now in customer mode with the obstacle detection thresholds updated.
REPAIR PROCEDURE - USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH
FILE:
NOTE:
Before flashing this module, make sure the StarSCAN(R) is operating at 5.02 or later. The flash file will be available on the NEXT StarSCAN(R) update CD received AFTER CD 5.04.
NOTE:
If this flash process is interrupted/aborted, the flash should be restarted.
NOTE:
For detailed information on the operation of the StarSCAN(R), refer to the Quick Reference documentation provided in the StarSCAN(R) documentation kit. In addition, more recent information may also be available at the website. Look under "Training Aids" and also under "Download Center > Frequently Asked Questions" for more help.
1. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle.
2. Power ON the StarSCAN(R).
3. Retrieve the old Sunroof Motor (SUNR) part number. Using the StarSCAN(R) at the "Home" screen:
a. Select "ECU View"
b. Touch the screen to highlight SUNR in the list of modules.
c. Record the "Part Number", displayed on the "ECU Overview" screen, for later reference.
4. Insert the USB Key, into the USB port on the TechCONNECT or equivalent PC, (Fig. 1).
5. Insert the StarSCAN(R) Software Update CD into the TechCONNECT or equivalent PC.
The StarSCAN(R) Software Update CD will start automatically.
a. Select "Controller Flash".
b. Follow the on screen instructions.
6. At the "Select the type of information you wish to enter." screen:
a. If the old "Part Number" was recorded in Step # 3, proceed to Step # 7.
b. If the old "Part Number" is not known, proceed to Step # 8.
7. Select "Enter part number".
a. Follow the on screen instructions. Enter the "Part Number" (use capital letters) recorded in Step # 3 when prompted to do so. Follow the on screen instructions.
Select "Next" after each step . Select "Finish" after completing the last step.
b. Proceed to Step # 9.
8. Select "Enter YME Information".
a. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step.
b. Proceed to Step # 9.
9. Using the mouse highlight the appropriate "Calibration".
a. Select "Save to USB".
b. Follow the on screen instructions. Select "Next" after each step . Select "Finish" after completing the last step.
10. With the StarSCAN(R) powered OFF, connect the USB Key and Gender Changer to the StarSCAN(R) USB port, (Fig. 2).
11. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts.
12. Connect the StarSCAN(R) to the vehicle (if not already connected).
13. Power ON the StarSCAN(R).
14. Download the file from the USB key to the StarSCAN(R). Using the StarSCAN(R) at the "Home" screen:
a. Select "Flash Download".
b. Select "Use USB device".
c. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step.
d. At the "Flash File List" screen, highlight the SUNR "Calibration".
e. Select "Download to Scantool".
f. When the download is complete, select "Close".
15. Download the file from the StarSCAN� to the vehicle. Using the StarSCAN(R) at the "Home" screen:
a. Select "ECU View".
b. Browse the list of ECUs using the scroll arrows. Highlight the SUNR.
c. Select "More Options".
d. Select "ECU Flash".
e. Highlight the SUNR "Calibration" from the list.
f. Select "Update Controller".
g. When update is completed, select "OK",
NOTE:
Due to the SUNR programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.
16. With the sunroof in the full open vent position, inspect the outboard attachments of the sunroof drain channel for breakage. If the drain channel is broken use the procedures outlined in TechCONNECT(R) BODY/SUNROOF/WATER CHANNEL to replace the drain channel, p/n 05137559AC.
17. Insure the battery is at least 12 Volts.
18. Place the ignition switch in RUN position.
19. Close all of the doors.
20. Press and release the vent switch (sunroof should move to vent position).
21. Once the sunroof has stopped motion at the vent position, press and hold the vent switch for at least 5 seconds to recalibrate the sunroof position.
22. If the sunroof did not reach the full vent open position, press and hold the vent switch until that position is reach then release the vent switch and repeat step 5.
23. Cycle the sunroof from the full vent open position to the full slide open position and back to the full vent open position at least 7 complete times. The sunroof is now in customer mode with the obstacle detection thresholds updated.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.