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  #1  
Old 09-08-2010, 09:08 PM
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Join Date: Jul 2010
Location: Hamilton Ontario Canada
Posts: 394
W201 190D sunroof fixed + tutorial

Just fixed my sunroof. Problem was the clip on the end of the cable. One bolt had fallen out and the clip was cracked. I removed the cable and welded washers to the clip to reinforce the bolt holes. The hard part was tryng to find a tutorial on gaining access to the sunroof mechanism. For the benefit of others, here is my tutorial.

If you need to access your sunroof's inner workings on this model car, the fabric cover will come down without taking anything else off. It clips in at the back, free hanging in the front and travels in a track at the sides. Other than the clips, there are no fasteners holding the cover on. The fabric cover just has a wire frame around it. The frame will bend during removal but can easilly be repaired / bent back into shape. Construction is similar to a canvas painting on a wooden frame.

Pull down at the front center of the cover and it will start to pull out at the sides. Work it free and the clips will come out at the back. They just push in, there are around 6 of them.

Once you get the sunroof working again, open the roof up. The cover will slide back in from the outside of the car (from the top of the sun roof opening). Once the cover is back in the closed position, close the sunroof on top of it and push the clips back in.

The hard part is getting the cover off for the first time. Once you see how it is constructed and how it fastens on you will see how easy of a job this is.

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  #2  
Old 09-08-2010, 09:26 PM
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Join Date: Mar 2008
Posts: 4,626
it is preferrable to open the sunroof halfway, then remove the front half of the liner.

then remove the entire liner through the roof.


doing as you suggest implies you will have to bend the liner and possibly damage it.
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  #3  
Old 09-08-2010, 09:33 PM
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Join Date: Jul 2010
Location: Hamilton Ontario Canada
Posts: 394
I agree it would have been preferable to remove the panel with the sunroof open. Since the clip on the end of the cable had broken, I was unable to open the sunroof. I tried everything I could think of to get it open.
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  #4  
Old 09-08-2010, 09:36 PM
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Join Date: Mar 2008
Posts: 4,626
you need to wind the cable up, as I mentioned in your other post

then force the sunroof towards the trunk using some thin prybar.

Pound the sunroof down as it would normally operate, then continue to push it back

Sorry I was not more explicit previously
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  #5  
Old 09-08-2010, 10:32 PM
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Join Date: Jul 2010
Location: Hamilton Ontario Canada
Posts: 394
sounds like that would cause more damage would it not? I tried pryng the roof back but it would not budge. once I had access to the slide bar it moved freely. I was pressed for time so didn't really look overly hard at the mechanism. Are there any locks that hold it in place?
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  #6  
Old 09-09-2010, 02:12 AM
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Join Date: Mar 2008
Posts: 4,626
a 'prybar' that you use for removing 16d nails sounds like it would cause damage. But a thin piece of metal or even a plastic shim would do the job... thats all I meant.

there is no 'lock', really, but the mechanism that forces the panel up as the cable moves it forward acts as one. This is why you must push the rear of the panel down as you push it back towards the trunk.

I will be the first to admit that it is not easy to slide the 25 year old roof back manually after it has been stuck.

Ultimately, the reason your roof failed is primarily due to poor lubrication on the sliding surfaces. Sure, the motor can take the stress, but the cable and its connection wear out quickly when they have to oppose all that friction.

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