Sunroof Operation, Troubleshooting, and Repair

Overview

This guide covers the operation, troubleshooting, and repair of the sunroof on the Porsche 944 with its 16v engine. The sunroof is an electric system that tilts open or closes using lifting arms driven by a motor and flexible cable. Proper operation and maintenance are key to avoiding issues like gear stripping or motor failure. Whether you’re opening the sunroof for ventilation, removing it for an open-air drive, or fixing a malfunction, this guide will walk you through the process step-by-step.

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Tools Required

• Phillips screwdriver
• 21mm (13/16 inch) socket or spark plug socket
• Torque wrench
• 10mm (3/8 inch) wrench
• Ammeter
• Loctite 270 (high-strength threadlocker)

Parts Required

• Sunroof motor fuse (25A) – 944 615 111 00
• Plastic sunroof gears (if damaged) – 944 564 113 00

Required Additional Procedures

Steps in these procedures are required to complete this process:

• Sunroof Component Testing
• Plastic Sunroof Gear Replacement

Step-by-Step Procedure

Step 1: Operating the Sunroof Normally

1. Turn the ignition switch to the “ON” position (position 2).
2. Push the sunroof console switch back (up arrow) to open the sunroof fully.
3. Push the switch forward (down arrow) to close the sunroof until it locks in place.

Step 2: Removing the Sunroof

4. Turn the ignition switch to the “ACCESSORY” position (position 1).
5. Press the sunroof switch back (up arrow) to retract the lifting arms fully.
6. Unlatch the two front sunroof latches by hand.

7. From inside the car, push up on the back of the sunroof and slide it off the wind deflector and front guides.

Step 3: Installing the Sunroof

8. Slide the sunroof onto the wind deflector guides until it seats at the front of the opening.

9. Lower the back of the sunroof into the opening—it should sit flush with the roof.
10. Engage the two front latches securely.
11. Turn the ignition switch to the “ACCESSORY” position (position 1).
12. Press the sunroof switch forward (down arrow) to raise the lifting arms to the locked position.

Step 4: Operating the Sunroof Manually

13. Unclip the carpet on the driver’s side of the rear hatch area to access the sunroof motor assembly.
14. Remove the plastic cover (if present) by unscrewing six Phillips head screws.
15. Locate the slip clutch adjusting screw cap below and to the right of the motor, then remove it.

16. Use a 21mm (13/16 inch) socket to turn the large nut behind the lock nut—clockwise to close, counterclockwise to open.

Step 5: Adjusting the Sunroof Motor Slip Clutch

17. Open the sunroof halfway to avoid stressing the plastic gears during testing.
18. Use a 21mm (13/16 inch) socket and torque wrench to turn the hexagonal nut on the slip clutch. Check the torque—it should slip at 6 Nm (4.4 ft-lbs) ± 0.5 Nm (0.4 ft-lbs).
19. Rotate the nut 60 degrees and test the torque again. Repeat this six times (one full rotation) to ensure consistency.
20. If adjustment is needed, loosen the lock nut with a 10mm (3/8 inch) wrench.
21. Turn the adjusting nut—tighten to increase torque, loosen to decrease—until it slips at 5.5–6 Nm (4–4.4 ft-lbs).
22. Apply a small amount of Loctite 270 to the adjusting screw threads.
23. Tighten the lock nut to 15 Nm (11 ft-lbs) ± 2 Nm (1.5 ft-lbs).

Step 6: Troubleshooting Sunroof Issues

24. If the motor doesn’t run, check fuses: Fuse 1 (motor) and Fuse 8 (relay) in the main fuse panel. Replace with a 25A fuse (944 615 111 00) if blown.
25. Test the console switch, limit switches, and micro-switch between the sun visors. Follow this link to ensure this step—Sunroof Component Testing—is followed accurately.
26. If the lifting arms won’t lock, test Limit Switch 2 and the console switch using the Sunroof Component Testing procedure.
27. If the sunroof moves but won’t retract, inspect Limit Switch 1 and the main relay with the same testing procedure.
28. If the motor runs but nothing moves, check the slip clutch torque (Step 5) and inspect the plastic gears. Replace if stripped (944 564 113 00) using the –Plastic Sunroof Gear Replacement – procedure.

Post Procedure Checklist

• Verify the sunroof opens and closes smoothly without grinding noises.
• Check that the lifting arms lock securely when closed.
• Ensure the sunroof sits flush with the roof and latches engage fully.
• Test manual operation to confirm the slip clutch stops the motor appropriately.

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manual, Volume 1
• Youtube