Repairing a sunroof

To begin with we need to make up our mind on what type of a sunroof we are going to disassemble and up to what condition. The procedure of disassembling a mechanical sunroof is pretty simple and is described here by a set of points that would be almost the same for an automated sunroof. That’s why we are going to base on a power sunroof, and for other roofing needs like eavestrough installation is better to get services from for this purpose.

The process is similar for any of the 190-124 models. The complete and detailed process of disassembling a sunroof is described below. The sunroof itself should be movable, i.e. it should be able to move at least halfway inside – in other case the device should be removed completely to avoid any further damage. Also it’s a good idea to move the sunroof by a button rather then mechanically. So, let’s start.

Power sunroof
1. Move the sunroof inside at least halfway. If it’s not operational, open the trunk and remove the left part of the booster coverage. The gear motor assembly work can be seen there. You can move the sunroof in off-normal mode by twisting the neb with a 6-mm spanner. Keep in mind that the screw-nut located deeper inside is the tension regulator and you don’t need to touch it. It is being regulated only when the cable spin-out takes place. The screw-nut is often covered with some paint and the paint continuity is a good sign. The small white wheel is the position regulator and its usage will be described below.

2. After moving the sunroof, unbutton the inner clip coverage either by a screwdriver or by hands – be sure not to bend it.

3. First pull the coverage all the way out and then push it all the way in, or move the sunroof itself, bend it upwards and remove it. Pulling the coverage out is needed to protect the stringers from damage and not to break the mechanism used to lift the sunroof. The fact is that these parts tend to break.

4. Now remove the sunroof itself. It should be in the aftermost position. Use a screwdriver to unscrew these:

…and do the following:

In such a way we release the roof and prevent those tender shiny parts from damage. Now close the sunroof leaving an opening of an inch or two – you’ll find the shiny screw-nuts with bold heads – four 8-mm screw-nuts in total. Mark their current positions and unscrew them. Then lift the cover.

5. Now we need to disassemble the passenger compartment. Remove the inner mirror by pulling it down and unscrew its holder (three cross screws).

Remove the shields (two screws fix each of them on the sides). Lift the square cap located on the shield bracket in the middle by an awl. You’ll see a screw inside – unscrew it as well.

Remove the interior lamp – lift it from one side and detach from the wires. Unscrew the small screws in the aluminum plate in the front of the sunroof and remove the plate.

Remove the velvet seals from the front doors and remove the front pillars coverage either by pulling them down or by lifting them with a screwdriver towards the center of the dashboard. Remove the plate and detach take off the handles.

Click off the holding lock and unbend the cover – there’s an 8-mm screw. Remove the center pillars coverage – move the seats all the way to the front, unscrew the two screws on the bottom and move the plastic part to the bottom. Remove the velvet seals from the back doors. Release the center pillars coverage from the upper click – pull the top of the coverage inside of the passenger compartment and let it hand on a belt. Then remove the back pillars coverage. The best way to do this is to remove the “seating” part first, then the “back” part and release the front edge by slightly pushing the coverage. The main thing is not to break the front clicks – the back ones are metal. Pull out another interior lamp and detach the wires.

6. Now release the ceiling from the pin-tucks located on the sides of the roof. The hardtop has additional interior lamps on the sides and no partitions. The soft top can’t be removed – it’s attached to the rubber on the rear screen, so just release it till that point.

7. Unscrew the flexible cable holder attached to the cross-arm – two 8-mm screws hold it.

Use a flat screwdriver to unbend the side plates. Caution: they are very tender, so only unbend them enough to remove – and not a single millimeter more. They won’t hold more than 4-5 bends.

8. Unscrew the cable guide holder located at the back of the sunroof base.

9. Remove the drainage tubes from the basis – lift carefully and be sure not to damage them – they may be glued there.

10. Unscrew the 10-mm screws all round leaving one in front and one behind diagonally for the sunroof not to hit your head.

11. Hold the basis in the middle with one hand and unscrew the remaining screws – the sunroof falls down on the headrests hanging on the cable guide.

12. Lower down the front squabs and pull out the cable guide after moving the base to the front.

13. Now try to get the sunroof base out of the car. You can simply open the passenger door and remove the door check strap to open it wider. To remove the check strap pull the fixing disc and knock it slightly with a hammer from the bottom. After that insert flat pliers under the head and knock them upwards. Now the door can be opened wide enough for you to get the sunroof base out of the car without scratching the dashboard.

14. Now, as you’ve got the whole mechanism on your table, you can clean and overhaul it.

15. First of all remove the drain. To do this you’ll have to lift it and pull out the first and then the second guide pin.

16. Unscrew the six 8-mm screws and remove the cross-arm.

17. Now you can release the flexible parts of the sunroof.

18. Remove the side guides. They are fixed either by screws (in the old models) or simply by clicks (the news ones). Slightly lift the clicks and remove the detail by bending it inside the sunroof a little bit.

19. Now pull out the flexible sunroof guide and remove it.

20. The plate. Unbutton the levers holding the base and the plate…

Remove it by pulling it aside, but the slot is closed there…

21. Release the plate from the hook ends…

Lift the click in order to do this.

Now unscrew the plate. Release one of the edges first and then the second one and then take the plate out.

22. Now you’ve got an empty base and a lot of spare parts.

Everyone who has done this should ask himself: “My God, how much many did I save?!”

23. Wash the basis. All the wear surfaces should be lubricated by non-oily Castrol LMX or by special silicon grease.

24. Assemble the base in the reverse order, fasten the cover and regulate the screw-bolts on the cross-arm until you reach the most flexible sliding along the guides.

25. Install the sunroof in the reverse order (you could install it after assembling but it’s somewhat uncomfortable – you’d better remove the cover).

26. After installing the cover and fixing the cable you can adjust the cover for it to get into the opening without the rubber first. To remove the rubber unscrew the screws all round in front and on sides; clean the rubber and grease it with silicon lubricant. After that place the rubber back and fix it with the screws. You can adjust the mechanism with the 8-mm screws (those ones with wide heads).

27. If you didn’t remove the cable, you can start assembling the ceiling. Otherwise, insert the cable into the cable holder and let it pass under the cross-arm by spinning the motor rod with a key. When done, fix the cable.

28. Travel adjustment is required. Unclick the motor adjusting wheel and press the sunroof open/close button. By controlling the sunroof position you can make sure it performs correct disregarding the old settings. When the sunroof is closed – set the adjusting wheel in the corresponding position.

29. Now we can get back to the ceiling. The procedure is the opposite of what we have done above, the only problem is that holders…

…should connect with the levers.

When moved backwards, they are parallel to the basis and you can place them back with a huge metal ruler, though it won’t be that easy.

The cable holder should be placed over the cable guide and only then the front clips can be locked.

Mechanical sunroof
30. If you have a common mechanical sunroof the procedure is as follows.

31. Unscrew the screw under the handle.

32. Unlock the front clips.

33. Insert the cup into the hole located in the sunroof cover.

34. Remove the cover and see the following.

35. Disassemble the whole mechanism, clean it, correct defects, and grease with a lubricant.

36. The full mechanism removal is identical to the one with a power sunroof. The assembled mechanism can be replaced locally. The weaknesses are: the rollers on the pins and the clamping plates.

Provided by den

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1 Response

  1. Jim says:

    Wow! Thanks!

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