Volkswagen Cars 2000-05

Sunroof

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Power Sunroof



The factory-installed sunroof has a frame assembly that is installed to the underside of the roof. When the sunroof is opened, the exposed frame area should be kept clean and free of debris, leaves and/or pine needles. If necessary vacuum the area periodically to keep it clean. The frame also serves as drainage channel for water as it seeps past the sunroof seals. A drainage tube is attached to each of the 4 corners of the sunroof frame, routed through the roof pillar and exits in the lower wheel well or underbody area. If the sunroof appears to be leaking, check the drains to make sure they are clear and attached.

To check the drains of a factory installed sunroof, fully open the sunroof. Fill a small cup with clean tap water and pour the contents into each of the 4 corners where the drain hose openings are visible. The water should flow from the wheel well area associated with the location of each of the drain hoses. If the water does not flow from the drain hose, locate the opening in the sunroof frame and the end of the hose and make sure both the hose and the opening are cleared of any debris.

Twice a year, with the sunroof fully opened, wipe the guide rails clean with a dry cloth, then dampen a smooth clean cloth with a light oil such as Automatic Transmission Fluid (ATF) and apply a light film of oil to the sliding surfaces of the sunroof assembly.

Emergency Closure Operation

The sunroof features an emergency closure mechanism built into the motor, should the motor fail to operate.

  1. To close the sunroof, turn the ignition key OFF and remove the key from the ignition lock, then remove the trim panel located just below the motor.
  2.  
  3. Remove the Z-shaped hex closure tool from inside the trim panel.
  4.  
  5. Insert the tool into the motor and carefully and slowly crank the sunroof closed. Some resistance will be felt while cranking the sunroof closed. If while attempting to close the sunroof, the tool cannot be cranked, the cables may have jumped time. If this occurs, remove the sunroof motor mounting fasteners and carefully lower the motor until it is clear of the cables, then reinstall the motor making sure it does not require excessive force. If necessary pivot the motor assembly side to side while attempting to mesh the drive gear with the cables until the motor engages smoothly. Reinstall the mounting fasteners with a light coating of a locking agent and tighten evenly and close the sunroof with the closure tool.
  6.  



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Fig. Should the sunroof motor fail to operate, to close the sun roof, first remove the trim panel below the sunroof motor, then . . .



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Fig. . . . remove the closure tool and . . .



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Fig. . . . insert the tool into the motor and carefully crank the sunroof closed-1.8 L Passat model shown

Removal & Installation
  1. Open the sunroof halfway and remove the steel clips at the front edge using a plastic wedge tool.
  2.  
  3. Close the sunroof and push the interior panel back all the way.
  4.  
  5. Remove both front guides from the outer panel.
  6.  
  7. Slide the springs at the rear guide in towards the center.
  8.  
  9. Remove the screws and remove the rear support plates in towards the center.
  10.  
  11. Lift the sunroof cover out.
  12.  
  13. Installation is the reverse of removal.
  14.  

  1. Slide the inside headliner back.
  2.  
  3. Open the sunroof to the tilt mode, such that the rear of the sunroof is tilted upward.
  4.  
  5. Remove the trim panel on the inside lower sides of the sunroof panel by lifting the forward edges of the trim and once the lock pin is clear of its retaining hole, slide the trim forward to release the rear pin from
  6.  
  7. Remove the 3 Torx® fasteners on each side, using a T 25 Torx® bit, and then remove the panel.
  8.  
  9. Installation is in reverse order of removal noting the following:
  10.  
    1. Install the sunroof with the fasteners lightly tightened.
    2.  
    3. Position the sunroof panel such that the front edge is level with or less than 1 / 32 inch (1mm) below the roof.
    4.  
    5. Position the rear of the sunroof panel such that the rear edge is level with or less than 1 / 32 inch (1mm) above the roof.
    6.  
    7. Tighten the sunroof panel fasteners to 39 inch lbs. (4.5 Nm).
    8.  


Motor
  1. If necessary, make sure you have the radio code.
  2.  
  3. Make sure the sunroof is closed.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Unclip the cover from the sunroof drive motor.

    Click image to see an enlarged view

    Fig. Unclip the sunroof motor cover (1)

  8.  
  9. Unclip and disconnect connector.
  10.  
  11. Remove the motor mounting bolts, then remove drive motor for sunroof.
    NOTE
    The sunroof motor bolts for the drive motor are microencapsulated and must always be replaced with new bolts upon assembly.



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    Fig. Unfasten the sunroof motor mounting bolts (arrow), then remove the motor-Webasto sunroof



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    Fig. Unfasten the sunroof motor mounting bolts (arrow), then remove the motor-Rockwell (Meritor) Sunroof

  12.  
  13. Installation is the reverse of the removal procedure. Tighten the motor mounting bolts to 3.5 Nm.
  14.  

 
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