Got fed up with my sunroof just 'clicking' and leaking all over the place so I decided to remove the roof lining and investigate the causes. First thing was to remove all the plastics that was holding the lining in.
Mines a 5 door so I started with the bottom surrounds in the rear, pretty simple undo the seat-belt fixings
and a couple of screws four luggage clips all done.

Next the same to the panels above them. 3 screw fixings, then gently pull the top to release a few clips

Next I moved to the coat hanger/ handles above the doors, 2 bolts on each

The rear interior light, which just pulls off

Moving to the front interior light, 2 screws, simple

Sunshades, 2 screws one end and a electrical plug and one bolt the other

Now just 5 push studs (2 back, 2 middle and 1 at the front)

Now remove the lining

The sunroof comes out with 6 nuts and 2 bolts, 2 on each side, then the it drops down.

I took the motor off first and I could see that the cog was worn, so that was the cause of the clicking - Got a new cog of eBay £4:50 sorted.

Once I got the sunroof on the bench I could see how bad it was.
3 corners of the frame was completely rusted through, so the next step was to remove the runners and fittings from the frame

The clamps at the front of the runners are first they are held in with 2 screws, then the runners are next, they come out with 3 screws on each side (the right hand runner leaves behind the rear cam follower, pick it out and put it somewhere safe)

The motor bracket is next, one rivet to remove, now the runners can be pulled free and you're left with a well rusted frame

The rest is down to welding in plates, killing rust and repairing the holes

With the frame repaired (welded, rust killer and a lick of paint) it's just a case of putting everything back together

I did put in a new seal around the top of the frame as the foam one had nearly fully rotted away



Now I have a fully working watertight sunroof

Brilliant thread Tiny. I haven't got a sunroof in mine but will be happier about buying one in the future.
Thanks bud.

does the sunroof have any drains that go down the A or B posts??

It has a drain on each corner (picture 3 and 4 post 2), so it don't matter what type of slope you're parked on it should never hold water