Thought id share my webasto sunroof cover replacement and general overhall.
My advice would be to let a pro do it. It was a tw*t.
But i digress, things to look out for and get before even attempting it -
In the factory webasto roof there is wire ropes that run along the NS and OS edge, one of mine had rotted through.
You will likely need a new headliner, mine fell to pieces during removal.
If your roof also closes on an angle youll likely need new roof motor cables.
A small 12v supply will be handy to open and close it on a bench.
The front, rear windows need to come out.
There are no drain pipes plumbed in, but ill be fitting some on refit.
This was my experience.......
One power plug at the rear above the passenger seat.
Once unplugged take out the numerous 10mm nuts and the secure rails.
The assembly might be well stuck, dont be scared to add some heat to the underside to soften the seals up. Mine wasnt bonded.
Drop it roof up and use a 12v supply to open it about 10".
Flick it over and undo the 6 philips headed bolts at the rear.
Unhook the front liner to access some 10mm nuts holding the front flap.
Flip it roof up again.
The rear portion of the cover will fold forward and youll be able to slide it forward a bit. This will give you access to the runner access plates.
Remove the 4 philips head bolts, 2 on each side, and the access plates.
Youll be able to gently slide the full roof assembly backwards lifting a section out at a time.
The outer cover is hooked in place but also secured with some small cable ties. Cut the ties and unhook as much as possible. Its also bonded to the front and rear flap assemblies.
Peel or cut the front and rear sections off.
The wire ropes are held in with clamps which are riveted on. Drill these out, 4mm. I refitted with 4mm stainless bolts.
My wire ropes were kaput so i ordered some 2mm stainless wirerope and crimp ends off amazon and made some replacements.
Refit in reverse.
Whilst in bits i cleaned and regreased my runners. Ive added white grease for the plastic guides.
Rebonded the front and rear sectiins with some double side tape and strong evo stick.
Picture purge so people can see the pain.
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Edited by Jghs83, 01 February 2026 - 05:11 PM.
