Volkswagen Eurovan 2000-03

Sunroof

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Power Sunroof



Removal & Installation
Glass
  1. Move sunroof into "closed" position.
  2.  
  3. Slide sun shade toward rear of the vehicle.
  4.  
  5. Move the trim frame toward rear (clipped on in front area and secured with Velcro strip and guided by pin in rear area).

    Click image to see an enlarged view

    Fig. Slide the sun shade (1) to the rear, move the trim frame (2) toward rear (clipped on in front area and secured with Velcro strip (3) and guided by pin in rear area)

  6.  
  7. Remove the mounting bolts.

    Click image to see an enlarged view

    Fig. Remove the mounting bolts (2) (three bolts with lock washers (1) on each side)

  8.  
  9. Remove glass panel upward.
  10.  
  11. Remove trim frame (as needed) at top toward front out of roof cut-out.
  12.  

To install:

  1. Sunroof must be installed in 0-position (sunroof closed).
  2.  
  3. Check parallel movement, adjust if necessary. Refer to the procedure under Sunroof Motor Removal & Installation.
  4.  
  5. From above, insert the sunroof glass panel and secure with the mounting bolts and lock washers. Make sure the centering pins are properly seated on rear side of lock washers. Tighten the mounting bolts to 2-5 Nm.
    NOTE
    Tighten the mounting bolts after following height adjustment.


    NOTE
    If both of the centering pins have broken off, the clamping washer must be replaced.

  6.  
  7. Perform height adjustment:
    1. Loosen all six mounting bolts for glass panel (floating centering in roof cut-out).
    2.  
    3. Perform sunroof height adjustment at front and rear on both sides by tightening the front and rear mounting bolt on each side to 3 ft. lbs. (5 Nm).
    4.  

  8.  
  9. Check seating of panel seal, adjust if necessary:
    1. Use a strip of cardboard, about the thickness of a business card, to check that the pre-tension between the panel seal and roof frame is even all around. The cardboard should slide between panel seal and roof frame with firm resistance.

      Click image to see an enlarged view

      Fig. Use a strip of cardboard, about the thickness of a business card (a), to check the pre-tension between panel seal (2) and roof frame (1) is even all around. The cardboard should slide between panel seal and roof frame with firm resistance.

    2.  
    3. If pre-tension is inadequate, press the panel seal open using a wedge or, if pre-tension is excessive, close panel seal. To adjust panel seal, you must remove the glass panel.

      Click image to see an enlarged view

      Fig. If pre-tension is inadequate, press the panel seal open using a wedge (1) or, if pre-tension is excessive, close panel seal. To adjust panel seal, you must remove the glass panel (2)

    4.  

  10.  
  11. Move trim frame forward and clip in.
    NOTE
    Lift trim frame only at front when clipping in.

  12.  
  13. Check sunroof for proper function.
  14.  

Motor
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the weatherstrip from the area of the electric drive motor cover.
  4.  
  5. Press the retaining tabs- in direction of travel using screwdriver or similar tool and disconnect.

    Click image to see an enlarged view

    Fig. Remove the weatherstrip (1) from the are of the electric driver motor cover. Press the retaining tabs (2) in the direction of travel using a suitable tool, then disconnect

  6.  
  7. Swivel the cover for electric drive motor downward, then disconnect from the brackets.

    Click image to see an enlarged view

    Fig. Swivel the cover (1) for electric drive motor downward (arrow), then disconnect at the brackets (2)

  8.  
  9. Disconnect the harness connector.
  10.  
  11. Unfasten the retainers, then remove electric drive motor.

    Click image to see an enlarged view

    Fig. Detach the harness connector (1). Unfasten the bolts, then remove the motor. Note: the microencapsulated bolts (1) must be replaced during installation, but bolt (3) may be reused.

  12.  

To install:


NOTE
When installing the motor, the microencapsulated bolts must be replaced. See the illustration for details.

  1. Before installing electric drive motor, check parallel movement, and adjust as follows, if necessary:
    1. Move the sunroof glass panel into the "closed" position.
    2.  
    3. Slide sun shade toward rear of the vehicle.
    4.  
    5. Move the trim frame toward rear (clipped on in front area and secured with Velcro strip and guided by pin in rear area).

      Click image to see an enlarged view

      Fig. Slide the sun shade (1) to the rear, move the trim frame (2) toward rear (clipped on in front area and secured with Velcro strip (3) and guided by pin in rear area)

    6.  
    7. The latching hook (with roller) must be engaged in guide rails, as shown in the illustration.
      NOTE
      Engagement of catches is audible when driving sunroof from position "opened" (slid back) into position "closed". Parallel movement is adjusted correctly when engagement occurs simultaneously on both sides.



      Click image to see an enlarged view

      Fig. The latching hook, with roller (1) must be engaged in guide rails

    8.  
    9. The bolts must be within the markings (notches), as shown in the illustration.
    10.  
    11. If this is not case, adjust parallel movement as follows:

      Click image to see an enlarged view

      Fig. Adjust the parallel movement (arrows)

    12.  
    13. Removing the sunroof glass panel, as outlined in this section.
    14.  
    15. The electric drive motor must also be removed.
    16.  
    17. The latches (with roller) must be engaged in guide rails.

      Click image to see an enlarged view

      Fig. The latches, with roller (1) must be engaged in guide rails

    18.  
    19. Move rear guides with bolts only from front toward rear between notches, as shown in the illustration.

      Click image to see an enlarged view

      Fig. Move rear guides with bolts (1) only from front toward rear between notches (arrows)

    20.  

  2.  
  3. Install electric drive motor (0-position) in this position, as follows (refer to the accompanying illustration):
    1. If electric drive motor is replaced, it must be installed in 0-position (sunroof glass panel closed).
    2.  
    3. Connect harness connector electric drive motor/wiring harness sunroof.
    4.  
    5. Operate switch - 1 - and count rotations of drive pinion - 2 - : 0-position of electric drive motor lies between end shut-off point - A - and - B - . End shut-off point - B - is reached by drive pinion rotating toward right and end shut-off point - A - is reached by rotating toward left.

      A - End shut-off point, panel opening function = 3 rotations to 0-position.
       
      B - End shut-off point, panel sliding function = 17 rotations to 0-position.

      Click image to see an enlarged view

      Fig. The sunroof electric drive motor must be installed in the 0 position

       

    6.  

  4.  
  5. Install the sunroof glass panel, as outlined in this section.
  6.  
  7. Installation is the reverse of the removal procedure.
  8.  

 
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