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!!!
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:
After:
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!