Anyone done this? Advice? Is it covered in anyone's service manual?

Thanks!

I think driverdriver will chime in with instructions on how to do it exactly.

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Just think, at least it wont leave the car incapacitated in case you have to go somewhere.... Most delicate part is going to be taking the headliner down without destroying clips... it can be done, but look at it this way, the dealer is going to be less concerned about being careful, just getting it done as fast as possible.

Its pretty straightforward to do. Just long and tedious.

I'm pretty sure I'm not going to like the answer

Don't roll back the headliner or lining material, it will crease badly-I think this has something to do with age of the material.

In my experience, I didn't remove the backseat, I did remove the front seats and tarped the back seat with painters drop cloth. It is a little harder to remove the headliner from its rear clips but not impossible.

It helps if you have an assistant for some of this work. I paid a few buddies with beers and a BBQ. It helped that one was a mechanic and the other an engineer. These guys are creative in solving problems on "the fly".

The most important advice is to be patient when doing this work. Get rid of any distractions (i.e. wife, girlfriend, etc) - I sent my wife (and my buddies did the same) to a spa downtown for the day, so we could work in peace.

I would recommend at least removing the passanger seat tho.

I guess I'll have plenty of time to really read and re-read the TSB on this so I am fully confident I can get 1/2 way through it before the beer-fridge gets opened

Here's what you do... Open sunroof about half-way. You want to open it just enough to fit your head in the opening. Kneel on the driver seat (facing rear of car) and look between the outer lid (the outer metal part) and the felt lined part. On the right and left sides, you'll see two black spring loaded plastic clips that you have to unhook. I used a couple putty-knives for this. The trick is to push the felt liner towards the back of the car as you pull up on the spring loaded clips.

Basically you're trying to separate the liner from the sunroof lid to expose the six bolts that attach the lid to the sunroof rail. Anyway, as the felt-lined half starts to slide back close the sunroof a little more, this will allow the felt piece to slide further. You'll need to keep doing this until the sunroof is completely closed and the felt liner half is basically slid all the way back. Don't worry, it can't slide too far back (there's a metal bracket in the back of the assembly that keeps the felt from going too far back).

Anyway, once the 6 bolts are exposed, you can easily remove the lid and replace the seal/weatherstipping. Put the lid back on and reattach the 6 bolts.

Once finished, open the lid all the way. Opening the lid all the way will make the metal lid slip back over the felt-lined half and you'll hear the spring-loaded clips re-engage. Close the sunroof and both halves will close like the always have.

Good luck.

I was looking for a spring-clip but that isn't what it was. Rather, it's a lever type device witha spring on it to hold it down. Once I figured out what needed to move, it was very simple.

I just installed the new weather-stripping and am waiting for the silicone to dry enough to put the lid back on.

Thanks for all the help and a special thanks to carlos...his post saved me an entire day and who knows how much headache!

It was at a stage where there was a little bit of water leaking when I would go through car washes etc. but rain wouldn't come in.

I just pushed up the seal from the sides what it was come off from and used a resin epoxy (super glue) mixture and mader it a permenant seal. Now there's no water entering and the rusty parts are hidden and covered nicley too. There is still a gap between the liner at the rear side of the sunroof but I am just going to fill it up with a clear sillicon paste which is removable anytime and will fill up the gap nicely.

All the posts were very nice though. Was good to learn various techniques!