Procedure
Complaint 1:The front panel rattles at approximately 25 MPH when both panels are opened equally.
Correction 1:
The front sliding blocks, part numbers 5412 8 120 591/592, have had flocking applied to the entire underside of the block beginning with production code 70 (approximately 2/94).
If the sliding blocks must be replaced, remove both front drive cables, Operation 54 12 245. Remove the sliding blocks (1) from the guides, taking care not to lose the checks (2). Grease the underside of the new blocks, and install with the beveled side of the checks towards the rear.
Complaint 2:
The front panel rattles while being driven over very rough surfaces and the panel is in the vent (raised) position.
Correction 2:
The first change for this complaint was the actuating mechanisms, part numbers 54 12 8 120 679/680 (1), were improved with a new riveting method beginning with production code 79 (approximately 4/94)
The second change for this complaint was the lift pin diameter of the sliding rails (1), part numbers 54 12 8 120 597/598, was increased from 4.0 to 4.2 mm beginning with production code 82 (approximately 5/94).
Cars with sunroof production codes prior to 79 will need the actuating mechanisms and sliding rails replaced. Cars with sunroof production codes from 79 to 82 only need the sliding rails replaced.
To replace the actuating mechanisms, remove the front lid, operation number 54 12 102. Remove the rear motor, operation number 54 13 012. Remove the spring retainers (1) by sliding them to the front.
Pull the actuating-mechanisms (1) forward to the openings in the track. Lift the rear drive cables (2) slightly and remove the actuating mechanisms.
Grease the undersides of the new actuating mechanisms and the spring retainers before installation.
To replace the sliding rails, the front panel must be removed. Remove the screws from both sides and remove the front brace (1).
Push down the spring (1) and push back the spring retainer (2).
Remove the circlips (1) from the retaining pins (2), and tap out the pins with a punch. Pull the sliding rail (3) away from the sliding block (4).
Install new rails and reinstall removed components.
Complaint 3:
Squeaking noises from the rubber feet resting of the top of the rear panel.
Correction 3:
The rubber feet (2) were changed from a concave profile to a convex profile beginning with production code 65 (approximately 11/93).
To correct, replace the actuating mechanisms, part numbers 54 12 8 120 679/680 as in Complaint 2.
Complaint 4:
The rear panel rattles when the front panel is in the vent position.
Correction 4:
The rear panel frame, part number 54 12 9 068 330, was improved beginning with production code 86 (approximately 6/94) with four redesigned plastic guides that have had slits (1) added.
To replace the rear panel frame, remove the rear panel, operation number 54 12 106.
Electrically crank the mechanism approximately 15 cm forward from the zero (closed) position. Remove the screws in the left and right hold down plates.
Push the frame towards the rear until the rear guides disconnect from the carriers for the rear drive cable. The frame will be in its lowest position.
Lift up on one side of the frame (1) so that it bends slightly (2) and remove the frame, being careful not to damage the sunroof seal.
Install the new frame, taking care not to deform the curvature of the panel surround.
Complaint 5:
The front headliner panel rattles when a door is slammed or when sharp bumps are encountered while the front panel is in the vent (raised) position.
Correction 5:
The sliding blocks (2), part number 54 12 8 120 565, on the front headliner frame (1) were improved with optimized dimensions beginning with production code 65 (approximately 11/93).
Remove the front headliner, operation 54 12 132. Replace all six sliding blocks with new design, and reinstall headliner.
Complaint 6:
There is a squeaking noise when the front panel is moved to the vent position.
Correction 6:
Add grease to the contact point (1) between the spring and the front headliner frame.