Today was an unusually bright, clear, pleasant day for lately, so I thought I’d finish the sunroof fixing.
A bargain from ebay got me a complete sunroof assembly: glass, motor, rails and trim. While the manual suggests removing the glass to change the assembly, I elected not to, as the adjustment’s a bit tedious, with fiddly trim pieces and awkward screws. This means a bit more weight to lift in and out. First though, out with the aforementioned expensive grease, so expensive it can only be made from the semen of virgin unicorns. This goes on the plastic slides, and I suspect it’s nothing flasher than a non-sticky silicone grease, designed to avoid picking up muck.
Removal is shockingly easy: disconnect the motor cables, and undo the bolts, leaving one in at the front to take the weight. This stage nearly went wrong- someone had been here before, and one bolt had a half-stripped torx head. I put it back in a more accessible place, in case it ever needs grinding out, but also leaving it a little looser than the others. It would have been nice to get a new one:
but it would be a special order part.
Once the bolts were out, with an assistant helping, the whole assembly comes forward, down, and is free to come out through the tailgate. The new unit goes back in the same way.
With the drain tubes and electrical connections reconnected, 2 tests: first, does it leak, and second, does it work. A pass on both items means it’s time to refit the headlining.
First step is to clean your hands: it’s an irritatingly light grey colour. Rescue any of the clips that came adrift and replace them onto the (scrubbed clean) headlining:
Then revove the rear headrests, and pass the headlining back in via the tailgate. You have to bend it into place into the recess a little. make sure the interior lamp cable and sunroof switch cable drop through the hole, then Refit the grab handles- note they are handed, and the back ones are different- and the sun visors. If, like me, you broke or scratched the little sunvisor hooks getting the impossibly tight covers off, part numbers 380 857 563, and 380 857 561A are what you need :-/ .
Apply some contact adhesive to the headlining and the plastic supports where the original glue was (bonus point if you can name the CD in-shot on the parcel shelf):
Let it dry for a few minutes, push the lining against the supports, and refit the C-pillar trims.
Finally, refit the sunroof switch and interior lamp, squeeze the clips shown in the second photo on to the sunroof frame, and bask in the joy of a clean refitted headlining and working, non-leaking sunroof, pausing only to order the damned hooks.
Result- a fixed sunroof for less than £100, even with the unicorn-bollocks-depleting grease.