How to: remove and repair your sunroof

[Aitch]

Well last week after I opened my sunroof I couldn't get it to close properly. One side was lagging behind the other, I had to push that side to get it mostly closed, and it wouldn't seal up properly with the roof. I found out that one of the two cables had come loose and wasn't pulling its weight (pun intended, laugh now before you start the job - it can be a long one).

I forgot to take pics while ripping out the interior, but here's the Coles notes:

1) remove all the upper interior pillars. For the fronts (A-pillars) just pull at the top towards the middle of the car, then lift out. The middle pillars (B-pillars) work the same way, but first you have to remove the covers on the upper seatbelt mounts (they unclip with a good tug) and then remove the seatbelt bolt.

2) for the rear window surrounds, you also have to remove the seatbelt ring on the driver's side. These surrounds require you to pull back some of the lower trim to get them out properly

3) Now to take out the headliner. Start at the back, and remove the three interior fasteners near the rear hatch. At the rear seats, unscrew the HS (holy-shit) grab handles above each door (repeat for front passenger side). The clear plastic of the dome light needs to be pried out, then you can see the two screws holding it in to the roof. Undo these and then unclip the wires on the back of the light

4) At the front seats, remove the sunvisors and clips. The maplights/sunroof control will pop down as it is only held up with spring clips. Unclip the two wiring harnesses behind this.

5) The headliner should now be hitting your head. Remove through the back hatch. Sedans, I have no idea of the best way to wedge it out, be creative but don't crease it.

On to things I have pictures of....

[Aitch]

6) Now you have to start unbolting things. First remove the attachment for the sunroof controller
http://img239.echo.cx/img239/2753/10007608as.th.jpg (http://img239.echo.cx/my.php?image=10007608as.jpg)

7) Next, unhook the air hoses (two each, front and back) going to the sunroof assembly. I can only assume these are to control pressure differentials underneath the headliner while cruising.
http://img239.echo.cx/img239/5316/10007591uh.th.jpg (http://img239.echo.cx/my.php?image=10007591uh.jpg)

8) Unclip the wire going across to the dome light. These clips are persistent bastards, pry them out and they'll go back in ok.
http://img239.echo.cx/img239/7613/10007580yg.th.jpg (http://img239.echo.cx/my.php?image=10007580yg.jpg)

Oh and wiseasses can shut up about the pink suede. IT'S LIGHTISH RED!!! lol

9) Start undoing bolts holding the sunroof assembly in. There are three on each side (red circles), and two across the front. Get someone to help hold up the assembly while you do this, or start from the front and back and leave the middle bolts for last
http://img239.echo.cx/img239/4508/10007565vy.th.jpg (http://img239.echo.cx/my.php?image=10007565vy.jpg)

DO NOT let the weight rest on the brackets at the back, they're light aluminum and bendy!

10) Take the assembly out the back of the car. Again, sedan owners use your imagination. Now your interior should have that stripped down, race-ready look
http://img129.echo.cx/img129/1069/10007533rw.th.jpg (http://img129.echo.cx/my.php?image=10007533rw.jpg)

11) Take those bendy brackets off so you don't screw them if you turn over the sunroof while it's out. (It's easier to take them out now instead of in the car)
http://img129.echo.cx/img129/2097/10007518ty.th.jpg (http://img129.echo.cx/my.php?image=10007518ty.jpg)

[Aitch]

12) I can't remember if it's absolutely necessary to remove the sunshade. I find it easier to get it out of the way, and then no greasy hands on suede. This tab (bottom of sunshade):
http://img298.echo.cx/img298/7779/10007487lo.th.jpg (http://img298.echo.cx/my.php?image=10007487lo.jpg)
has to get over this tab (under sunroof):
http://img298.echo.cx/img298/6052/10007503wa.th.jpg (http://img298.echo.cx/my.php?image=10007503wa.jpg)
and then the sunshade slides right out the back.

13) Now remove the guide at the back of the sunroof. These two clips (red circles) pop back and you can wedge the black aluminum piece out.
http://img236.echo.cx/img236/1315/10007436yo.th.jpg (http://img236.echo.cx/my.php?image=10007436yo.jpg)

14) Remove two small screws underneath the assembly near the rear. These are screwed into the rear limiters which need to come out to get the sunroof all the way back.
http://img236.echo.cx/img236/2554/10007404yk.th.jpg (http://img236.echo.cx/my.php?image=10007404yk.jpg)
http://img236.echo.cx/img236/4458/10007396zl.th.jpg (http://img236.echo.cx/my.php?image=10007396zl.jpg)

15) Next, remove the motor from the front of the assembly
http://img236.echo.cx/img236/5449/10007424fe.th.jpg (http://img236.echo.cx/my.php?image=10007424fe.jpg)
Please note excellent screwing technique
http://img236.echo.cx/img236/7126/10007419kx.th.jpg (http://img236.echo.cx/my.php?image=10007419kx.jpg)
Don't worry about removing the wires, it will be fine.

[Aitch]

16) Now the sunroof will slide out the back of the assembly and FINALLY we can see what the problem is. At the rear, the cables are held through the sunroof slider bracket by a circular CRIMPED CAP!!!! No wonder on mine it simply came loose over the years and slipped off the end. Here you can see the cap properly installed on the other side. (sorry about the crappy pic)
http://img299.echo.cx/img299/2528/10007384it.th.jpg (http://img299.echo.cx/my.php?image=10007384it.jpg)

17) If this is your problem, hopefully you can find the cap and re-crimp it onto the end of the cable. If not, you may need to go to a dealer and get a new cap, or more likely, a new cable. The cap has to be the same size as the cable to be able to move through the same passage as the cable. If the cable is damaged in any other way, again you'll have to replace the cable.

18) Time to reinstall everything. Of course, it's the same as before but in reverse.

19) Reinstallation notes: First, reconnect the electric motor. Of course, unless you're EXTREMELY careful, the sunroof will not be in the same place as before and your calibration for the motor will be off. This will require some tricks in a few moments.....

20) Get all of the sunroof assembly back together in the reverse order of before. Attach those bendy brackets again. Get someone strong to help hold up the sunroof in the car while you bolt it back in place (this is a shitty one-man job, I speak from experience). Start with the middle nuts from step 9.

21) Now you're ready to set up the sunroof. Hook up the sunroof controller (it can hang from the wires). The electric motor has limiters built into it, so it must be set up properly with the position of the sunroof.

22) Use either/both the slide forward and tilt up controls to get the sunroof forward, and then aligned, with your roof so it is sealed.

23) Unbolt the electric motor so the gear is free of the cables. Note: you can only play with the slide control, or tilt control, not both at once. The tilt control is not active until the motor has reached its 'slide forward' limit, and vice versa. You need to get to this 'slide forward' limit, at which point the motor will stop, and is now in the corresponding state to the sunroof being sealed with the car's roof.

24) Now bolt the motor back into the sunroof assembly, and check that it works the sunroof properly. If not, retry this procedure. Otherwise, start putting back in the headliner and interior pillars. Alternatively, have a few beers (in last week's heat, you need more than one). This is also an excellent chance to paint interior pillars, redo your headliner, or call me and to work on both (sorry, shameless plug).

25) When putting back the interior pillars, be careful to get the bottom edges underneath the lower pieces in the car for proper fitment.

There. Hopefully your sunroof works again and you saved yourself hours of labour charges. Although now your hands may have a few unexplained small cuts in them (most of the sunroof assembly is not soft and forgiving).

[Myk]

Crap...that looks nuts!

[Logan]

Nice write-up.
Those "air tubes" are actually water drain hoses for the water that does and will get past the seal. They drain the water down into the pillars then it should spill out either in the wheel well or in the door jamb, depending on the car.

[Junior]

FAK ... that's a lot of work

[Aitch]

Thanks Doug.... makes sense.

Since my radio crapped out today, I noticed how much it's squeaking right now. I think it's the seal with the roof, maybe I didn't get it *quite* lined up when I adjusted it.

FACK!!!!

[iJay]

Bringing this one back

Does anyone know how to properly grease the track for the sunroof? or is this the exposed track we put osme grease on? Is there any internal drives/pulleys that need grease as well. Mine is a bit hesistant now-a-days

[Cocco]

^ ijay give me a call ill go thru the removal of headliner and sunroof, and give you some tips on where to grease etc. and how to take that sucker out.

Im pretty sure steve and i are the only ones who have removed all this stuff out of a P5, and its not easy and plan on it taking up your entire sunday