Hi Folks,

If you are plagued by a sunroof leak, like me, please keep reading.

The problem I had with my series 1 car was the drainage pipes were crimped by items of trim. This reduced the flow rate from the sunroof drainage tray, causing the exesswater to overflow and drain out through the holes and gaps in the drainage tray. The water then continued to run onto the top of the fibreglass sheet that forms the headlining, and down the C-pillar into the boot, under the back seat, and into rear passenger footwell.

You will see in these pictures where the drainage pipe is crimped by the trim.

http://www.tamudabay.co.uk/main.php?g2_itemId=375


http://www.tamudabay.co.uk/main.php?g2_itemId=379

Now for the proposed solution/moficiation. I bought some new plastic piping and slipped some ducting that electricians use over the top of the plastic pipe, to stop if from crimping, and re connected it to the sunroof drainage tray. There was some corrosion (surprise surprise) on the metal tubes where the pipe joins onto. I put some waxoyl on the outside and smeared a bit on the inside of the tube as well.

http://www.tamudabay.co.uk/main.php?g2_itemId=382

http://www.tamudabay.co.uk/main.php?g2_itemId=385

I had a lot of difficulty refitting the headlining and the c-pillar trim. The new pipes with the ducting on the outside was of a larger diameter than what was there previously, the problem was made worse, since the trim squeezed the original pipe when it was fitted properly. I was left with some gaps around the edge of the c-pillar trim, unfortunatly its not perfect, but not very noticeable, and much better than having wet carpets!

Good luck if you decide to undertake this task. Make sure you have competent assitance when refitting the headlining!

Nice guide Robert. Thanks.

I've just discovered that my sunroof leaks so thanks for this.

I knew the car was leaking somewhere, as it steams up a lot, but just discovered where from the last time it rained. I'd left the sunroof cover open, which I don't usually do, and there was a pool of water in the gear-lever gaiter

check around the roof aerial too as this can cause water to ingress and leak out through the roof console. Also the front screw holding the sunroof motor in place.

rgds
Dave

Dripping from the sunroof opening and surrounding area would be a bit of a bandit if the car had an immobiliser!!!

it's a lot of fun on the S1's where the IR receiver is in the roof console.

random lock/unlock - very helpful when the keys are in the car & wondows all shut.
very handy too when the roof decides to open when you're driving along in the rain, or starts to flip/close as you're moving.

Dave