Help with sunroof

Condam the damn thing, leave it closed and put PU resin in to that roof space !

Guido

 

Put the headliner back.

In the trunk at the end of the flexible cable tube it is capped off. Remove the cap. Open the sun roof all the way. It can now go a little further back than usual becoming decoupled from the cable.. Remove the chrome track guides. This exposes gaps on the track. When you manually pull the panel forward you can now lift the panel up where there are gaps in the track. Sorry to say there is one or 2 more steps that without looking at it are not coming to me but I think they will be evident. I know the headliner material on the sliding panel needs to be disconnected at the front edge. It is held in place by spring clips and pops down. I think that is to give access to the guides in the panel. Sorry I don't have more detail, it's been 25 years or so since I had one apart. Once out it gives access to the cable guide etc in the roof.

Going back in reverse the process. Push the panel ALL the way to the rear and this will recouple it to the cable. Run it forward electrically and put the cap back on the tube.

 

These things are a nightmare- if you do decide to remove the roof panel, be sure to cover the rear 2 inches of the panel with lots of masking tape. There is very little clearence to lift the front edge of the panel and get it out- as you do this the rear edge can catch under the actual roof and damage the paint work.
Rifledrivers method is correct- with the panel open you will see a chrome runner each side with screws holding it in place, (remove these runners)with the panel uncoupled from the cable using the manual shaft of the gearbox, you should see a couple of white plastic guides on the front of the panel- the panal being disconnected from the operating cable should slide forward , you should then be able to gently lift the front lip and it will come up and forward.
NB. Keep an eye of the rear of the panel to be sure you dont catch the paintwork.
Looking in the roof void you will see a guide and if you operate the electric open there should be a pin with a white nylon bush on it, travel up and down this guide.

As to what is making the noise you will have to see what you find-if you fix it, leave it shut for ever as it will drive you mad

 

There is no way it can flop around unless something is broken.

 

Does the sunroof actually open and close ?

 

Could it be that the tube the cable runs through has broken a spot weld? That would account for the top still remaining operational

 

Could be but the panel needs to be out to get to it. It screws in place at the forward end and slips into a receptacle at the rear.

 

That is the structural box that is welded into the roof to compensate for the loss of rigidity due to the sunroof's opening.

It comes out trough its own opening toward the outside by releasing it from the push-pull cable. (no cable tensioning involved)

Yes.

 

Does rattle when closed or open?
Removing and replacing takes 30 mins.

 

There is a write-up on F Chat somewhere re the procedure.

 

Remove that end cap.
Then let the push-pull cable exit an inch or so.
The roof will be released from the cable and you can manually slide it forward.

 

The cable does not come out, it just moves the panel. If i remember correctly this copper tube comes off the back of the gearbox- the end of the cable runs into this- and by removing the fitting it will allow the maximum run of the cable.
The panel should be full open using the electric motor and you should be able to disconnect the drive between the cable and the panel by taking a cap off the side of the gearbox, you will find a slot for a flat end screwdriver and you can manually retract the cable. Be sure to get a good screwdriver fit in order to avoid damaging the slot.
If you remove the cap and run the electric motor you will be able to work out the open / close directions.
The cable needs to be as far retracted as possable in order to disconnect it from the panel.
It is usefull to remove the operating switch and extend the wiring so you have the switch in your hand at the motor position in the boot, so you can see what is going on.

 

No leave it alone or you will make a lot more problems- the panel is easy to remove once you get the cable fully back- the motor is a nightmare to refit.