Wagon sunroof fixed!

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Wagon sunroof fixed!

Postby bigBADbenny » Sun Oct 21, 2012 7:38 pm

Jump to gen4 wagon sunroof motor brushes replacement & FSM info:
viewtopic.php?f=6&t=18970&p=442589#p442589

1: check fuse: eg if elec windows still work go to step 2.
2: make sure the sun blind pusher rods are seated in the sun blind, eg move sun blind, observe operation.
3: find the motor manual crank access plug in the headliner to the rear of the sunroof.'
Crank sunroof shut slowly observing if the mechanism operates properly esp the tilt. Don't force it. Look for further issues with the mech. Damaged tilt parts may need fabricated replacements or replace whole mechanism cassette. If it closes go to next step.
4: close the sun blind manually, open the rear hatch, remove top and D pillar trims, pull down the rear of the roofliner, reach in with eg your towhook in hand and give the sunroof motor a few technical taps to reseat the brushes.
Try the sunroof switch again, if it opens, you've found the issue: sunroof motor replacement or refurb :)
It drops out easily with 5x 10mm head nuts or bolts. Do not operate any part of the mech with the motor out!

Parts, diagnostics, sunroof reset procedure & fsm etc here
viewtopic.php?f=6&t=34980

For me the sunroof is one of the most awesome features of my wagon and I was absolutely crushed when, at the the end of last summer, it ceased working without warning.
At least I could crank it shut using a long allen key. That meant that the mechanism was probably ok - great stuff!

I checked the fuses, but as the electric window fuse is on the same circuit and that was OK... that was not the issue.
I studied the service manual looking for a relay but it looked to be hidden under the headliner, which is a monster job to remove.
I got a verbal quote from Docklands for repair: $XXXX for a new motor and labor.
They don't do sunroof repairs themselves, but sub those out to a sunroof specialist, so fair enough.

In the end I took the long DIY route. I hung out to remove a complete sunroof from a wreck (thanks Gambit!).
In taking that approach I'd have spare parts on hand if required, plus experience with removing the roof liner trim.
With winter beckoning, having an opening sunroof wasn't an issue anyway the sunshade blind was still capable of opening.

After waiting a few months I got the go ahead to remove the sunroof which took the best part of an afternoon.
I used the service manual and posts on this forum, Nasioc and LGT for guidance.
The most difficult part has to be removing the A pillar trims, luckily they were already damaged so I didn't need to take care, and in fact I still dont know how to remove them intact.
I got the sunroof home, having removed the glass, cured some surface rust, cleaned it up and put it, sans motor, in storage.

This weekend with warmer, dryer weather seemed to be a good time to take on replacing just the motor.
I simply detached the negative terminal on the battery, removed the D pillar trims, 2 screws from headliner, popped rear headliner with a trim tool (use the shallow end for more leverage - cleaned the replacement motor and swapped it in...
WORKING SUNROOF!!! :shock:

For good measure I gave the various rails and hinges a few drops of syn lube.
I also reattached the blind pusher rods back onto their anchors - when the glass is closed, those are right above your head - it's a simple interference fit for an MY07. I hadn't realized from where mine had come loose and had to put up with the ends rattling.

I removed the cover from the inoperative sunroof motor to take a peek.
It was full of graphite powder from the brushes which had probably shorted the motor out.
Before:
Image
After:
Image
I literally blew it out, lubed the bushes and reassembled it.
I daresay it would be good for another few years before requiring new brushes.

Very happy with the result, even though I could probably have had it fixed within an hour of it crapping out, I've saved a heap of brass, learnt a bunch about the car, have spares to hoard or sell and most importantly, knowledge to share! Now I plan to get the front door glass and now-working sunroof tinted to match the rear glass. With that one in the bag, I got onto another tasty project and then took my lovely wife for a nice open-air adventure-drive! 8)
Last edited by bigBADbenny on Tue May 08, 2018 9:05 pm, edited 4 times in total.
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Re: Wagon sunroof fixed!

Postby al_cam » Mon Oct 22, 2012 7:12 am

Bad,

Did you check that that old motor still worked?

Only I replaced the brushes in a Dyson vacuum cleaner after the old ones had worn away. I think some chunks must have come off and bounced around though 'cause it turned out that half the windings had been broken, or burnt out.

I found that out when started the bare motor after replacing the brushes. Was holding it clasped to me chest to guard against starting torque and the commutator was sparking like a Catherine wheel. Damn near shat myself.

Oh and thnaks for the warning about the A pillar trim, I was going to remove mine to do some work and I thought it sounded easy.

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Re: Wagon sunroof fixed!

Postby mynameisdaniel » Mon Oct 22, 2012 7:25 am

Must use you sunroof a LOT :P
The A pillar trims are easy to get off once you know how. There's a chunky metal clip towards the top. You need to peel it back a bit and push the clip closed with a long/thin screw driver.
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Re: Wagon sunroof fixed!

Postby bigBADbenny » Mon Oct 22, 2012 7:55 am

Thanks for the advices! So lock out - pull trim directly out away from pillar?
Cos the drains are going to need attention eventually.
I'll post pics of the drain locations on the spare sunroof for reference.

I do use it a lot - I have half of my sons Bball team on board and we really need the fresh air! :shock:
I guess the previous owner loved it too.
Plus the wagon doubles as a family sized convertible... 8)
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Re: Wagon sunroof fixed!

Postby al_cam » Mon Oct 22, 2012 9:37 am

Bit late now for Bad, but from the manual:

A pillar trim removal.jpg
A pillar trim removal.jpg (50.87 KiB) Viewed 4248 times


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Re: Wagon sunroof fixed!

Postby bigBADbenny » Mon Oct 22, 2012 10:29 am

Awesome! Just CBF'd RTM sometimes, thus paid the price in frustration...
But seriously, no damage done.
Easy then to access the drains for cleaning, might have to remove the entire headliner... just for fun! :shock:

Calling Rob Tait to line up a tint appointment - strike whilst the iron is hottt!
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Re: Wagon sunroof fixed!

Postby bigBADbenny » Thu Oct 25, 2012 10:38 pm

To celebrate the sunroof fix, I got it tinted along with the front windows by Rob Tait at Car Tint.
Having read the reviews both here and on Impreza WRX Club, I got a quote and got it done.
I was booked for 8.30am, we got started at 8.10am and it was done and dusted by 10.30-ish.
Rob showed me how to pull apart the door trims and even let me have a go! Too easy!
He used a metalized tint on the sunroof, mirror-like from the outside, plus the darkest legal tint for the front door windows.
We had a great chat whilst he worked and I went over the lib with detailing spray...
Highly recommended, all I can say is get a booking before the heat sets in!

Here you can compare the tinted front doors to the privacy tint. I'd say the sunroof would be around midway between the two...
Image

Here's the Lib, tint drying in the sun prior to the final trim...
Image
WOOOOOOOT!!!
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Re: Wagon sunroof fixed!

Postby Dropz » Thu Oct 25, 2012 10:56 pm

Great to see you fixed it yourself. It gives alot more pleasure working it out yourself and knowing you saved some coin.
Built not bought, it's a way of life.
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Re: Wagon sunroof fixed!

Postby bigBADbenny » Thu Oct 25, 2012 11:24 pm

It was simply colossally easy in the end and I saved an epic amount of brass! :mrgreen:
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Re: Wagon sunroof fixed!

Postby bosc0 » Fri Oct 26, 2012 6:46 am

Nice BBB (better if BBD.... funkeeeee), what did Rob say about the rears and UV protection yo?
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Re: Wagon sunroof fixed!

Postby bigBADbenny » Fri Oct 26, 2012 7:10 am

He casually dismissed the idea that the rear privacy glass lets in lots of UV.
He had a solar or spectral transmission meter that had a range of 0 to 500 somethings. BTu's?
So direct 10am sunlight read 250 somethings and the tints including privacy glass were in the 40 -50 somethings range.

The front door glass tint is a little green (which I like) compared to the neutral privacy tint, but as Rob said - one's eyes adjust immediately to whatever you're looking through.
I simply wanted to take the path of least resistance to increasing comfort levels in the car during summer - GOAL!
I cant see the bird poo stain on the sunroof blind now either! :P

The tint is still drying so no detail pics yet.
Rob is very into promotion on the internets and forums so I may ask him to weigh in with his info.
Otherwise he gave me an info package with samples of the tints etc.
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Re: Wagon sunroof fixed!

Postby bosc0 » Fri Oct 26, 2012 7:38 am

Interesting. I guess it's just a matter of who you choose to believe then hey? :P
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Re: Wagon sunroof fixed!

Postby bigBADbenny » Fri Oct 26, 2012 7:47 am

Subjectivity is the essence of existence... :P
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Re: Wagon sunroof fixed!

Postby bigBADbenny » Sat Oct 27, 2012 10:12 pm

Image

I love off roading, long grass = moar low 8)

I'm surprised at how dark the front glass looks, very similar (in this pic at least) to the privacy glass...
Bonus cosmetic upgrade!!! :D
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Re: Wagon sunroof fixed!

Postby bigBADbenny » Mon Oct 29, 2012 11:58 am

Image

A bit to arty, but just to give you an idea of the metalized sunroof tint, seen here reflecting bright sun.
Extensive testing on the weekend reveals it definitely keeps the cabin cooler... 8)
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