More details on the Sunroof removal!

For those of you wondering, heres how we got the sunroof out.

Because the sunroof was jammed, and the liner was both torn and held in place with screws (thats not stock as far as I can tell) I cut it. Turns out that its possible to get the liner free without cutting it (as you might expect). You simply need to have the sunroof slightly back and pull the liner forwards. On the right side of this image you can see the clips the hold the liner frame in place, I had to bend them to get the frame loose. The brace running through the middle of the image is part of the liner frame.
The liner frame itself sits in a track (the same parts as the roof, but the track is seperate and a fraction lower) and can be pushed back out of the way once free.

At the front corners are 2 pairs of screws, these are what hold the roof to the track followers and are also used to adjust the height and levelness of the roof.
You need to unscrew all 4 of these, its much easier if you can move the roof back an inch or two!
Once the screws are out the brackets that run in the track will come free (quite possibly falling in your face).







Next are these devices on the right.

They make the back of the sunroof drop down as it moves back, ours had poked holes in the headliner. I have no idea if thats because of a lack of padding or if maybe they are bent.

Behind them you can see a long clip that hooks under the far side of the long rod with the spring. You need to press that clip down and away so it frees the end of the rod. You also need to remove the circlip and spring.

Once the circlip and spring are removed you can slide the block that holds the top pin back. This frees up the back of the sunroof!

You can now (with 2 people) lift the sunroof out).

And discover, like us, that the aluminium track is corroded and not flush in places.

I don't have pictures, but you can also look back into the area where the sunroof hides and see the 'interesting' design.

Heres a shot of the track and the cables. Most of the brown around the track is dirt, but theres a lot of rust there. The seals were long gone and one of the 4 roof drains was blocked (the back ones might be blocked too, but its hard to tell). Theres also a ton of surface rust back in the box where the sunroof hides. But its fairly recent and not deep.

The originalty of the sunroofs motor was something we discussed a lot. The wiring certainly didn't help convince us, not only is there lots of duct tape and random splices, but the supply wire coming from engine bay doesn't seem to be original. Its a skinny little wire thats not even close to the 16A rating of the designated fuse in the fuse box, plus its not bundled in with the wiring loom.

That said, the bracket for the motor and switch certainly looks original.

I think it must be stock, but for some stange reason a PO messed with the wiring.

But hopefully this post inclues usefull information if you need to work on a 2002 sunroof!