Sunroof / Moonroof: Service and Repair

Sun roof

Special tools:
998 6006 SCISSORS 998 6006 Scissors
115 8957 HOSE PLIERS 115 8957 Hose Pliers

Checking the seal

Checking the seal




If work has been carried out on the sun roof mechanism that could affect the seal, it must be tested. This is best carried out with the headlining removed. Check the seal by pouring water into the sun roof base plate. During the test the drain hoses from the sun roof must be sealed.
The rear drain hoses are inside the side panels in the cargo compartment and can be sealed by clamping using a hose clip 115 8957 HOSE PLIERS 115 8957 Hose Pliers.
The front drain hoses are difficult to access. They can be sealed by applying sealant to the front drain on the sun roof base plate.

Note! Do not forget to remove the sealant after completing the test.

After work involving the removal of the sun roof base plate, carry out the following test.
1. Test the front and rear edge gutter sealing on the sun roof base plate by pouring water in before installing it in the car.
2. Install the sun roof base plate in the car and connect the drain hoses.
3. Check that all seals are intact. Install other components so that the sun roof is complete.
4. Seal the drains as above.
5. Pour water into the sunroof base plate. Check for leaks.
6. Remove the drain hose seals.
7. Check that the drains function correctly.

Sun roof, replacing

Apron molding




Remove the apron molding on both sides.
Open the sun roof to its maximum tilt position.
Slide the inner cover plate back and lift out.

Mounting screws




Remove the two screws (A) on each side.

Handling the sun roof




Lift up the front of the sun roof so that it is horizontal.
Slide the sun roof backwards.
Lift out the sun roof.

Installation
Adjust the sun roof height at the front and rear. See Adjustment.
Test the function by moving the sun roof to its limit positions.

Weatherstrip sun roof replacing

Removing the weatherstrip
Adjusting the glass sun roof weatherstrip when replacing it. The seal lip on the weatherstrip must be removed from the rear edge and sides of the sun roof when the weatherstrip is replaced. The seal lip must only be left between the rails at the front of the sun roof. The lip is to prevent the sun roof from "lifting" when driving at high speed.

Note! Do not scratch the sun roof when it is removed from the car.




Remove the sun roof (see Sun roof, replacing) and place it upside down on a soft and clean surface.
Remove the old weatherstrip
Position the end of the new weatherstrip in the middle of the rear edge of the sun roof and press it into place on the sun roof frame up to the front corner. Continue as follows.

Installing the weatherstrip guide
Install a plastic weatherstrip guide (D) on the weatherstrip at one front corner on the inside of the sun roof as illustrated.
Press the weatherstrip and guide into place on the metal frame of the glass sun roof.
Press the weatherstrip into place up to the next corner and install another weatherstrip guide in the same way as the first.
Press the weatherstrip into place around the entire sun roof.
Note: Seat the weatherstrip guide against the outer edge of channel (E) in the sun roof frame as indicated by the arrows.

Cutting the weatherstrip




Position the weatherstrip joint in the middle of the rear edge of the sun roof. Cut off excess weatherstrip using scissors (P/N 998 6006 SCISSORS 998 6006 Scissors ).

Caution! Use sharp scissors of the correct type so that the cut is smooth and straight. This will provide good adhesion for the bonded joint. See the illustration.

Bonding the weatherstrip




Bond both ends of the weatherstrip together tightly using adhesive (P/N 1161095-3) .

Removing the seal lip from the weatherstrip




- Place the sun roof loosely on top of the frame as illustrated
- Cut the front edge (A) of the seal lip by both rails as illustrated
- Pull the seal lip (A) (lower illustration) from the cut back to the weatherstrip joint at the rear edge of the sun roof. There is a groove along the seal lip to make it easy to pull off the weatherstrip.

Installing sun roof
Install glass sun roof. See Sun roof, replacing.

Sun visor, replacing

Replacing the sun visor




Remove the sun roof. See Sun roof, replacing.
Compress the sun visor springs one at a time and lift the sun visor out of the mechanism.

Replacing wind deflector

Replacing wind deflector




Open the sun roof completely.

Remove:
- the wind deflector mounting screws, one on each side
- the wind deflector.

Installation
Apply new sealing tape between the sun roof base plate and the wind deflector bracket.

Replacing the electric motor and gear housing

Electric motor

Replacing the mechanical cable

Expose the cable holder





Remove:
- the sun roof. See operation Sun roof, replacing
- the electric motor..
- the bracket, lock washer and screw (B).
Slide the mechanism forwards to access the cable holder.

Cable holder




Remove the 3 mounting screws for the cable holder.
Carefully the lift cable holder straight up.

Note! Do not bend the cable holder sideways.

Cable




Slide the mechanism forward to expose the cable.
Pull the cable out of the cable sleeve.

Installation
Lubricate the cable with petroleum jelly P/N 1161150-6 before inserting it into the cable sleeve.
Adjust the mechanism before installing the electric motor. See Adjustment.

Adjustment

Adjustment

Adjust the moving mechanism on both sides so that the mechanism is positioned as illustrated.
The illustration shows one side of the mechanism.

Adjustment (continued)




Install the electric motor.
Run the motor to the tilt position.
Install the sun roof in the mounting brackets and press it forwards until it locks.
Install a screw on each side.
Close the sun roof.
Install the front screws.

Adjustment
The sun roof weatherstrip should be 0.5 mm under the roof panel at its front edge according to (A) and 0.5 mm above it at its rear edge according to (B).

Adjust:
- the front edge front-rear / vertically
- the rear edge vertically.
Check that the sun roof is adjusted equally on both sides.
Test the sun roof function by opening and closing it to both limit positions.

Replacing the sun roof module (SRM)

Control module, sun roof, replacing




Close the sun roof.

Caution! Do not damage the headlining upholstery.

Remove:
- the roof lamp panel (lens, mounting screws, connector)
- the screw for the control module
- the control module. Carefully pry straight down and forwards. Remove the inner connector.

Installation
Turn the cog (A) until the two white markings line up as illustrated.
Check the function.

Replacing the mechanism

Mechanism





Remove:
- the sun roof. See operation Sun roof, replacing
- the sun visor. See operation Replacing the sun visor
- wind deflector. See operation Replacing wind deflector
- mechanical cables. See operation Replacing the mechanical cable
- the gutter, 2 screws on each side.
Press the mechanism outwards and pull it forwards.

Caution! Never pull the mechanism straight up.

Mechanism (continued)




The mechanism is mounted in a guide cover at the rear.

Mechanism (installing)




Check all seals before installing as follows:
- Weatherstrip (1)
- Sealing tape for screw holes (2) between the guide rail for the mechanism and the sun roof base plate
- Apply new sealant to the rear of the guide rail (3) for the mechanism before installing it in the sun roof base plate. Check for leaks. See Checking the seal
- The lead-in for the cable sleeve (4).

Note! If the guide rail has been removed it must be sealed using sealant P/N 686 275-9.

Replacing the sun roof base plate

Sun roof base plate, replacing

Remove:
- the sun roof. See operation Sun roof, replacing
- the sun visor. See operation Replacing the sun visor
- wind deflector. See operation Replacing wind deflector
- mechanical cables. See operation Replacing the mechanical cable
- the gutter. See Replacing the mechanism
- mechanism (complete). See operation Replacing the mechanism
- the seal around the sun roof opening (remove downwards)
- the headlining. See Replacing the roof lining Replacing the Roof Lining.




- the connectors for the drain hoses, 4 hose clamps (1)
- the control module for the sun roof motor (2)
- the 7 mounting screws for the sun roof base plate (3).
Lift out the sun roof base plate through the front passenger side door.

Installation
Check for leaks. See Checking the seal.