DIY: Sunroof removal

[old skool]

The obvious first step is to remove the headliner.

After you remove the headliner you will notice the fiberglass frame of the sunroof cassette mounted to the roof of the car. It is attached around the perimeter by torx screws. It has drain tubes on all four corners. It also has the sunroof motor mounted through it.

First unplug the wires to the sunroof motor. The motor can be operated manually with a 4mm hex wrench. More information is provided later in this writeup.

[old skool]

Locate the drain tubes on each of the four corners.

[old skool]

disconnect them and let them hang there.

[old skool]

This is what the torx screws look like

[old skool]

You can safely remove these without fear of your sunroof falling on your head.

[old skool]

As you remove these, the sunroof cassette will start to droop but this is normal.

[old skool]

the back of the sunroof is held in by torx screws that allow you to adjust the position of the sunroof because there are slots. Remove these screws as well.

[old skool]

Remove them and you will see that the sunroof is still held in place by the black metal spring clips.

[old skool]

The next step is to remove the sunroof motor. There are three torx screws holding this in place.

The two small torx screws on the right stay...but the three outside screws need to be removed like the one in the center of the picture.

[old skool]

When you release the black metal spring clip the back side of the sunroof cassette will drop down and it is heavy so be prepared.

[old skool]

This part of the sunroof cassette is the only thing now holding it up. Be careful not to break it and slide the whole assembly towards the back of the car to release the front tab from the metal support it is wedged into.

[old skool]

As you can see the sunroof cassette is huge, heavy and awkward. It fills the entire car and has somewhat sharp edges. I would personally recommend taking the seats out and having two people. however it can be done with the seats reclined and only one person. Be careful not to damage your seats when you try to slide it out of the car. I would put some kind of towels or padding down if you want to keep your seats in the car.

[old skool]

The roof of the car sans sunroof.

[old skool]

Top of the car looking in.
The black rubber seal is attached to the metal with double sided tape.

[old skool]

The cassette out of the car

[old skool]

The motor out of the car and you can see which screws needed to be removed and which can be left.

[old skool]

I am bumping this because there are always questions about it.

[snakebit8]

What would be the best way to plug the hole when you are done. Im interested in it I just need to know what to do once its out.

[old skool]

I would recommend welding sheet metal to fill the hole and then grinding the welds smooth and paint over it. But you have to get a headliner for a non-sunroof car.
Another way I have seen done is to remove the metal part of the sunroof, rivet its tabs hanging down into the cabin to the tabs for the roof, leaving the gasket there to seal it up.

[Robstah]

Dude, you need your own DIY site. Your stuff is amazing and is always welcomed here at BF.C.

[XmEnNiNjA]

Dude, you need your own DIY site. Your stuff is amazing and is always welcomed here at BF.C.

agreed and the pictures are what make all your diy threads great. nice work.

[WildStorm]

Agreed, a lot of the DIYs have pics that look like someone used a camera phone.

[fredo328]

I agree, it is a great DIY. But why did you remove the sunroof?

[ICTBMW]

Is there any way you can open the cassette? ie. to take the interior panel out if it is stuck in the cavity

[old skool]

I agree, it is a great DIY. But why did you remove the sunroof?

I am going to sell it. But before I do that I am going to swap the fabric shuttle to my new car. It is black to go with my M3 black headliner conversion.