Sunroof Motor

This procedure covers the removal and replacement of the sunroof motor assembly on a 2019-2024 Toyota RAV4 with 2.5L I4 engine, requiring removal of the overhead console and headliner panel.

Warnings

Tools required

Parts

• Sunroof motor assembly × 1 — Use OEM specification
• Interior trim clips (assorted) × 1 — OEM replacement clips as needed

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn ignition off and remove key from vehicle
3. Open sunroof to the tilt position to verify current motor operation before beginning work
4. Gather all tools and new parts before starting
5. Place protective covering over front seats to prevent damage during overhead work

Procedure

1. 1

   Disconnect battery negative terminal
   Open the hood and locate the battery in the engine compartment. Using a 10mm socket, loosen the negative terminal bolt and remove the negative cable from the battery. Secure the cable away from the battery terminal. Wait at least 3 minutes for airbag system capacitors to discharge before proceeding.
   ⚠Always disconnect negative terminal first to prevent electrical shorts.
   Torque spec

   Battery Terminal Bolts6 Nm (4 lb-ft)
2. 2

   Remove overhead console assembly
   Using trim removal tools, carefully pry down the front edge of the overhead console near the dome lights. Release the retaining clips along the sides and front. Disconnect the electrical connectors for dome lights, sunroof switch, and any other sensors or switches. Lower the console carefully and set aside.
3. 3

   Remove sunroof switch assembly
   If not already disconnected with the overhead console, locate the sunroof switch connector. Press the locking tab and disconnect the electrical connector. Remove any Phillips screws securing the switch assembly housing and set aside.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
4. 4

   Remove A-pillar trim panels
   Starting at the top, carefully pull the A-pillar trim covers on both driver and passenger sides away from the body. These are typically held by clips. Work from top to bottom, releasing each clip carefully. Set trim panels aside in a protected area.
5. 5

   Lower headliner panel at front
   With assistance, carefully pull down the front portion of the headliner panel approximately 6-8 inches to access the sunroof motor area. Support the headliner with one hand or have an assistant hold it. Do not crease or bend the headliner material sharply.
   ⚠Headliner material is fragile and can be permanently creased if bent too sharply.
6. 6

   Locate and access sunroof motor
   With the headliner lowered, locate the sunroof motor assembly mounted to the sunroof track mechanism near the front of the sunroof opening. Use a work light to illuminate the area. The motor will be a black rectangular assembly with an electrical connector and mounting bolts.
7. 7

   Disconnect sunroof motor electrical connector
   Locate the electrical connector on the sunroof motor. Press the locking tab and carefully pull the connector away from the motor. Ensure the wiring harness is free and will not be damaged during motor removal.
8. 8

   Remove sunroof motor mounting bolts
   Using a 10mm socket, remove the mounting bolts securing the sunroof motor to the sunroof track assembly. There are typically 2-3 bolts. Support the motor with one hand while removing the final bolt to prevent it from falling.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
9. 9

   Remove sunroof motor from track
   Carefully disengage the motor drive gear from the sunroof track cable mechanism. Note the orientation and position of the motor for installation of the new unit. Remove the motor from the vehicle through the headliner opening.
10. 10

    Install new sunroof motor
    Position the new sunroof motor in the same orientation as the removed unit. Engage the motor drive gear with the sunroof track cable mechanism, ensuring proper alignment. Hold the motor in position while installing mounting bolts.
    ⚠Ensure motor gear teeth properly mesh with track cable to prevent binding.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
11. 11

    Reconnect electrical connector
    Connect the electrical connector to the new sunroof motor, ensuring the locking tab clicks into place securely. Verify the connection is firm and the wiring harness has adequate slack.
12. 12

    Reinstall headliner and A-pillar trim
    Carefully push the headliner panel back into its original position, ensuring all edges are properly seated. Reinstall the A-pillar trim panels on both sides by aligning the clips and pressing firmly until each clip engages. Work from top to bottom.
13. 13

    Reinstall overhead console
    Reconnect all electrical connectors for dome lights, sunroof switch, and sensors. Position the overhead console and press upward firmly to engage all retaining clips. Verify all edges are flush and properly seated.
14. 14

    Reconnect battery and initialize sunroof
    Reconnect the negative battery terminal and tighten to specification. Close the sunroof completely if it is not already closed. Turn the ignition to ON position without starting the engine. Press and hold the sunroof close button for at least 10 seconds after the sunroof is fully closed to complete the initialization procedure. This resets the sunroof position sensor.
    ℹ️Sunroof initialization is critical for proper auto-close and pinch protection functions.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Ensure all trim panels are properly seated and clips are fully engaged
2. Verify all electrical connectors are securely attached with locking tabs engaged
3. Check that headliner is smooth without creases or sagging areas
4. Confirm overhead console functions including dome lights operate correctly

Verification

• Test sunroof tilt function by pressing tilt button and verifying smooth operation
• Test sunroof slide open function to verify motor operates smoothly without binding or unusual noise
• Test sunroof slide close function and verify auto-close safety feature activates properly
• Verify sunroof stops at fully open and fully closed positions without overtravel
• Check for any unusual motor noise or vibration during operation
• Confirm sunroof switch illumination and all overhead console lights function properly

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