Volvo Maintenance Hints for 7xx/9xx - Bill Garland's Nuclear ...

like my 965, and I will not address them. I will discuss adjustment and control mechanism
replacement.
When you have determined the extent of the problem and want to continue, open the sunroof to
the ventilation position. From the outside, release the spring clips from the sunroof lining, a pair
of needle nose pliers works for this.
● Close the sunroof.
● Pull down on the headliner just forward of the interior lights.
● Pull the sunroof lining back so it is inside the roof.
● Look at the control mechanisms to determine the extent of the repair. Are they ok, are
screws missing or are they loose? If the screws are loose, tighten them, if missing, find
and replace.
● If the sunroof needs more extensive repair, remove all screws and lift out the sunroof.
● Remove the electric motor or manual crank. Doing this will allow for proper control
mechanism centering, a procedure I needed to repeat.
● Replace the mechanisms by removing the two SMALL circlips with a small screwdriver.
Do one side at a time so the other can be used for reference.
● Transfer the spring to the new control mechanism and place the new one where the old
one was, make sure the small plastic covered tab is in it's slot and on top of the flat metal
'spring'.
● Replace the circlips, again needle nose pliers work here.
● Do the same to the other side.
● Align the control mechanisms with the slots for the small plastic covered tabs, slight back
and forth motion works here.
● The control mechanisms should now lay flat and be loose, not tight under tension. The
sunroof is supposed to be closed after all.
● You will notice the cranking mechanism is nothing more than a modified worm gear
arrangement.
● Make sure the sunroof retracting mounts, up front and to the side, are properly positioned
and as far forward as possible.
● Replace the sunroof.
● Replace the screws leaving them loose so the sunroof can be adjusted for height, which
will be done now. Do not try to operate the sunroof at this time since it is loose and the
liner would be pushed back into the bowels of the car never to see the light of day!
● Adjust the sunroof height by operating the sunroof SLIGHTLY in the rearward position
and also in the ventilation position, flipped up in the back.
● Close the sunroof and make adjustments. It should sit down slightly from the roof but
there should be no gaps. Make sure the spring clips are installed in the rear edge of the
sunroof and the large springs are attached to the large pin on the control mechanism.
● Apply oil or grease to the control mechanism slots which should be an annual event. I
found one of mine had dried out grease and was nearly ready to break.
● When you are happy with the positioning of the sunroof, move the liner forward and flip
up the sunroof to reattach the clips to the lining.
● Operate the sunroof and enjoy.
See it wasn't that bad! Take your time, have a friend assist, maybe even videotape the entire
procedure, just in case.