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Sunroofs

Honest989

New member
Joined
Jan 12, 2024
There's enough 240 sunroof threads around (but most are old and lack pictures) so hopefully this is a different enough couple of questions:

#1 Has anyone removed the front drain tubes before and replaced them? Asking as I've got a blockage. I think it's the plastic pin the a-pillar mounts to. Even if I remove it, I doubt the deformation will resolve itself. Is it easy? Pic attached

#2 is there a decent, recent, thread with pics on how to remove the sunroof and roof liner? Water seems to get past the seals, run over the liner and then trickle down the interior door trim to the floor carpet.
 

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You don't need to remove the sunroof. You do need to at least lower the headliner. It doesn't have to come out of the car. The drain lines run down through the A-pillar into the door jamb. Home Depot sells plastic tubing the correct diameter to use for replacement lines.
 
... You do need to at least lower the headliner. It doesn't have to come out of the car. ...
When you say "lower" does that mean what I envision to be gently prying down just the corner of that stiff fiberboard structure enough to get hands on the tubing? Is that possible with a careful approach? I haven't had a need to do this, and I fear a backed up drain might leak all over the top of the headliner making it easier to break. And what to keep from smudging the white interior side with the slightest touch? I've had 4 240s made with a hole in the roof, two of which I've sent to the crusher, but never a leaky one.
 
So the good news is there's a you tube vid that gives you a view of what's behind it at c. 48 seconds.

But this leaves me a little stumped as having got fat enough with the headliner, the edges look glued round the sunroof lip - the blue circled area is an indicator of what I mean.

There is one other thread in this forum that might have done this job but it's from 2008 and all the pics are dead.
 

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When you say "lower" does that mean what I envision to be gently prying down just the corner of that stiff fiberboard structure enough to get hands on the tubing? Is that possible with a careful approach? I haven't had a need to do this, and I fear a backed up drain might leak all over the top of the headliner making it easier to break. And what to keep from smudging the white interior side with the slightest touch? I've had 4 240s made with a hole in the roof, two of which I've sent to the crusher, but never a leaky one.
No, I detached the headliner and let it sit as low as I could, yet, didn’t remove it from the car. I don’t remember whether it will tilt down while hanging from 3 clips along the glass, or, if I took those out as well. It has been at least 7 years ago that I did that job.
 
No, I detached the headliner and let it sit as low as I could, yet, didn’t remove it from the car. I don’t remember whether it will tilt down while hanging from 3 clips along the glass, or, if I took those out as well. It has been at least 7 years ago that I did that job.
Are you able to confirm if I need to unpeel the liner from the sunroof lip?
 
Success. I tend to err on them side of caution when doing things for the first time or with something that might break with no replacement. When I resize the photo, I'll show you. But there is lots!! Of water
 
Success. I tend to err on them side of caution when doing things for the first time or with something that might break with no replacement. When I resize the photo, I'll show you. But there is lots!! Of water
I'm glad you got it taken care of. Did it go the way I described? The car I did this on was a 242. IIRC, I let the headliner sit on the steering wheel and the passenger seat that was flipped forward. That kept it from being too stressed in the area of the sunroof opening. That area is really fragile.
 
Follow up:
Adventures in sunroof seals. When/if you order a 240 seal your options are these two replacement parts.

Sunroof front seal: 3540456
Sunroof Rear seal 1255335

They are wrong. Personal experience, talking to brookhouse volvo and Carglass and trim, we all find a 1mm gap is left at the back. It also sits proud of the sunroof.

Good news and bad news though:
Porsche 911 seals are an exact replica -
KlassicLine parts :
(91156419300/8) - rear
(91156419100/8) - front

The front is too short by about 20 cm. For now, I've ordered two but I'm going to see if it's possible to get custom lengths.

Photos attached. The one with the blue background is what you get as the Volvo replacement part. (At least in Europe)

The other two are Porsche seals with the old, original Volvo ones on the left and the new Porsche on the right. 1000018231.jpg1000018232.jpg
 

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