Okay hier ist die kopierte Anleitung aus dem amerikanischen Corrado-forum. (Bilder wie was wann wo wie fest geschraubt werden muss gibts da auch) - http://www.corradoclub.com - TOPIC: retrofit moonroof
Here it is:
My '92 Corrado VR6 sunroof had started to misbehave...a
common occurrence on the Corrado. The roof panel started to jam during closing
from the fully retracted position. The paint on the driver's side back
corner of the panel was beginning to scratch (only clear coat affected
thus far). I decided not to risk any further damage so I stopped retracting
the roof and I have used only the tilt function for the last 1.5 years.
This summer I decided to try to get it working again. Since I didn't really
know for sure which parts were the problem, replacing all the major moving
parts at once seemed the thing to do to be sure of a fix. Checking the
local dealer for replacement part prices, I was taken aback. To replace
just the 3 sliders on both sides of the track would cost over $300. Having
heard about Corrado's getting retrofit with sunroofs and even glass moonroofs
from other VW's, I decided it was time to give it a try. Found a '96 Passat
moonroof at GermanAutoHaus (formerly Bug World; http://www.bugworld.com) for $400
(without motor) plus $60 shipping. The Passat roof is said to be a close
fit to the Corrado's, so it seemed the best choice.
Thus begun the adventure of retrofitting my roof. Below
you will see a number of images I put together to assist others in planning/performing
similar retrofits.Feel free to contact
me with questions.
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Diagram 1: 1996 Passat Moonroof track parts exploded view.
Seems my visit to the dealer wasn't a waste of time. This diagram shows
all the major parts of the actual track, including the air deflector (14),
the drive motor (17), interior dome light housing/motor cover (23) and
the interior track trim piece (1). This trim piece is easy to pry off of
and push back on the track's inside edge. This piece was a cream color on the replacement roof so I reused the Corrado grey one instead. Since the diagram was provided
by the dealer, I assume all labeled parts are available as replacements.
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Diagram 2: Sunroof & Moonroof mechanism components,
exploded view. Note that the Passat SUNroof is depicted in
the upper part of the diagram while the glass panel MOONroof
is shown below. I've added labels to the components I call sliders (because
that's what they do!). Note the part number 36 near the rear edge of the
moonroof track. This little part is a rubber bump stop for the headliner
panel and it seems to be only on the moonroof track; the Corrado's (and
Passat's) sunroof track doesn't have it. Again, I assume all the labeled
parts are replaceable... but not necessarily cheap. I had to replace the
drivers side rocker slider since my replacement roof's was damaged (rocker
lever pivot arm broke off)...it cost $65 USD. The front slider with its
air deflector arm attached (20) was $99...thankfully, mine didn't need
replacing. Also, the felt-covered glass panel sealing bead is not shown.
I decided to replace the worn out/torn one that came with my moonroof.
Cost was $50. It was fairly easy to pull the old one off the glass panel.
Replacing with the new bead was a NIGHTMARE! Easily the most difficult
part of the entire roof retrofit! The seal is made of a fairly inflexible
plastic, not rubber. It has a lower and upper edges that must be engaged
in upper ? lower grooves all the way around the glass panel. Took me
over 3 hours to get it in place, using various methods of force and lots
of soapy water to lubricate. My hands ached for three days! Proceed at
your own risk!
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Fig. 1: Drivers side interior with headliner, rear roof
trim, B-pillar and A-pillar trim panels removed. B-Back
of car; F-
Front of car. Loosening the front part of the C-pillar panel also helps
in headliner removal. Note positions of B-pillar panel mounting screw holes.
The upper hole also mounts the coat hanger bracket. Middle screw is located
behind a small plastic cover plug in the B-pillar trim panel. Red line
shows approximate location of the "hidden" mount screw behind the lower
side panel. To reach this screw, it was necessary to partially remove the
lower side panel so that a small 90 degree ratcheting driver, with Phillips
head attached, could be used. This lower panel has one mount screw located
down near the door sill. Fold the rear seat down to expose two plastic
nuts that help loosen the panel further.
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Fig. 2: Corrado's stock roof after headliner removed.
Some of the sunroof track mounting bolts are indicated as well as the passenger
side locating pin position. Bentley states to remove the roof panel prior
to removing the track.This is really only important if you want to re-use
or re-sell parts of the assemble later on, since you can only access the
components with the roof panel removed. To do this, it's necessary to tilt
the roof and slide the headliner back to gain access to the roof panel's
mounting bolts. Bentley shows a special tool for sliding the headliner
back. I think it could be easily done by pulling the inner liner down with
a large putty knife blade or similar flat tool until it's even with the
outer liner. Then push both liner parts rearward to disengage the liner's
frame from the main sunroof track. Since I removed the roof with it in
the closed position, I had to re-attach the motor drive and operate the
roof on my work bench to attain the tilt position and then proceed with
disassembly. If you're just going to discard the stock assembly, go ahead
and remove in the closed position with headliner in place. However, if
you're like me and have a "pack-rat" mentality, you will see a lot of the
track parts are fully interchangeable with the Passat roof, so they might
be handy one day.
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Fig. 3: Close up of drivers side rear drain barbed fitting
and it's disconnected hose. Another track bolt is visible near the middle
of the image.
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Fig. 4: Corrado's drivers side front drain barbed fitting
and its disconnected hose. The plastic drain fitting my on Passat roof
was damaged in shipping (despite warning them to protect these fragile
areas!). Since the dealer does not sell these separately, I cannibalized
the one off the Corrado track (identical). It's held on by plastic posts
(opposite side location shown in picture) welded through holes in the metal
track. Prying off the drain shears most of these posts cleanly off.
I was able to align the few remaining posts and used black silicone sealant
and some clamps to attach it to the new track. You might be able to save
more posts by grinding/drilling off the flattened head of the posts inside
the track groove from above.
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Fig. 5: A damaged A-pillar panel can be easily repaired
with fiberglass cloth and a little polyester resin. The panel had cracked
nearly completely in half near the point where the mounting screw went through
the mount hole (shown above). The outside "leatherette" skin was undamaged,
the the panel was flimsy and in danger of further deterioration. I cut a
couple of layers of fiberglass cloth to shape and applied the resin with a
small brush, being careful not to put excessive amounts on and get it all
over the other side. After the 3 hour set time, the panel was stiffer & stronger
than the stock panel from the other side of the car. The resin, cloth &
catalyst can be purchased in a low cost kit at any good automotive supply
store with body repair supplies.
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Fig. 6: Driverside Corrado sunroof mechanism in detail after
removal. The only real difference from the '96 Passat system I could detect
was the inner headliner tilt mechanism.
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Fig.7: Passat roof track installed with sliding headliner
panel (shown pushed back). The track bolts right up to the stock roof holes.
Even though the locating pins (see Fig. 2 for the drivers side pin
location) are slightly longer on the Passat track, they still fit perfectly.
Perhaps they just provide a little bit more roof clearance for the glass
roof. Note that the headliner's frame is pushed back fully and is not even
visible here. This completely exposes the drivers side roof panel mechanism
(shown in the roof-closed position) with the mounting points for the panel
labeled. These mounts allow some adjustment in the roof panel's position.
When the panel is installed, just slightly tighten the bolts and check
the roof position. I initially pushed the panel as low as possible to ensure
clearance with the roof opening. Later, after a few test runs, I adjusted
it up a little to better fit the roof line. I had to replace the rocker
slider on this side since the original one was damaged. The new one is
black instead of chrome, but basically identical otherwise. The rocker
looks something like a type of beer-bottle opener.
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Fig.8: View from outside, looking down at passenger side.
Here you can see the headliner's frame almost fully forward. The headliner
runs along a track in this frame. The metal clip engages in the rubber
grommet on the post when all the way forward (you'll feel it snap in) and
this holds the frame in place during normal operation. The only time you
need to push it back is to gain access to the roof panel's mounting bolts.
Note the original Passat chrome rocker at left (I could not tell the difference
with the new one or even the Corrado's rocker...interchangeable?).
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Fig. 9: A close up of the passenger side rocker and the
cable slider in front of it. This is in the roof closed position. According
to Bentley, the cable slider pivots must be aligned with the notch in the
track before connecting the motor to the track. The rocker back end must
also be engaged in a notch in the track (not visible here...see Fig.
8 for detail). Also, the motor must be in the roof-closed position.
To obtain this, with the motor detached from the track, plug it into its
electrical connector and operate the roof switch. The closed position is
reached when the motor stops turning between the fully tilted (two turns
away) and fully retracted (nine turns away) positions. Note the position
of the rubber bumper on the left end of the rocker. This little O-ring
is what the CCA website garage section mentioned should be replaced on
the stock roof (using 3mm cloth-covered vacuum hose) to help prevent roof
failure. Although changing it eliminated the popping sound during roof
operation, I still ended up with roof jams & scratches less than 2
years afterwards. I don't believe it's the whole story...just one of many
wear items on these mechanisms.
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Fig. 10: A close up of the drivers side rocker & cable
sliders in the roof closed position (the roof panel is actually installed
in this picture). Note the rocker end engaged in the rear track notch and
the cable slider's pivot positioned above the forward track notch. The
rocker wheel can also be seen here, but the rubber bumper O-ring is just
out of the picture to the left of the wheel.
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Fig. 11: Finished moonroof in closed position while headliner
pushed back. Fit is very close all around, perhaps a little less snug than
stock. Note the light appearance of the outer sealing bead is due to reflection
from the camera flash…it is jet black in ambient light.
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Fig. 12: The tilted position.
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Fig. 13: Fully open. Note the inner trim piece used was the
original gray cloth one from the Corrado. Headliner is indicated pushed all
the way back. The air deflector was identical to the stock unit is shape and
position and is thus a prefect fit.
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Results:
I am extremely pleased with the final results. The new roof looks/fits/operates
just as if it was a stock one. I took the headliner panel into a local
automotive upholstry place and selected a light charcoal grey cloth (it
came with a light cream colored cloth and plastic handle) to have it re-covered
and I removed the plastic handle and repainted it in "Soldier Grey" spray
paint. From the inside it really blends in perfectly. From the outside,
the roof panel is level & even all the way around the opening and the
felt sealing bead is also evenly aligned (although somewhat higher than
the roof opening & glass panel) all the way around.
Okay - wie gesagt - genauer ist es auf deren Seite http://www.corradoclub.com beschrieben!
Ciao
Patrick
PS: Passt nicht gibts nicht - alles ist machbar - es muss nur jemand genug Zeit Wissen Geld und Gedult mitbringen........
Ciao Patrick