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Here's a description the sun roof
Power Sunroof System Components
The power sunroof system consists of the following components:
• Sunroof module
• Sunroof switch
• Sunroof motor, with 2 hall effect sensors and limit switch
• Sunroof window
• Sunroof sunshade panel
• Power supply for the sunroof module: RAP 25 A
• Ground G402
The override function is used when needing to force a closing of the sunroof window. To override the system:
Turn ignition to ON.
Rotate the sunroof switch to the close position.
The sunroof switch data 6 circuit, or override circuit, will become grounded at the sunroof module. As long as the sunroof module sees this input, it will continue to slide the sunroof window to close, regardless of the other sunroof switch data circuits inputs.
Sounds like the timing is out. Pull the headliner down enough so that you can get to the motor. Close the sunroof and allow it to stop where it wants to. Then remove the bolts holding the motor on, pull the motor out of the way of the gears and push the sunroof closed. Then remount the motor. It should work correctly after that.
I had a friend with a similar problem. the gears in the motor are plastic they tend to wear down to the point they stop making contact. Have someone press the botton and you can pull on the sunroof in the derection to close it. This is what i did for my friend and it worked out fine.
First check your fuse box, for any fuse blow, position 26 in the Passenger Fuse Box (Box C), then keep in mind that the power sunroof is controlled by a switch that selects the
direction of travel of the sunroof. The switch changes the polarity of
the voltage going to the sunroof motor. This changes the rotation of the
motor, thereby changing the direction of sunroof travel.
REMOVAL & INSTALLATION (see Figure
Open the sunroof to the ventilation position.
Disconnect the battery ground cable.
Push down the sunroof headlining with a finger. Unhook the
retaining springs with a bent piece of wire.
Pull down on the headlining sufficiently to pass beneath the
gutter rail. At the same time, slide the sunroof to the rear to release
the catches at the front.
Do not pull the sunroof too far to the rear; otherwise, it will be
difficult to remove again.
Unhook the spring retaining brackets.
Remove the retaining screws from the sides and front.
Remove the sunroof.
Fit the sunroof into position and install the retaining screws.
Install the spring retaining brackets.
Slide the sunroof forward to engage the catches in the front.
Install or reposition any trim moved for access.
Connect the negative battery cable.
Fig. 1: Exploded view of the sunroof assembly (click for zoom)
THE ELECTRIC DRIVE SYSTEM FOR POWER SUNROOF IS NOT ADJUSTABLE.DONT REMOVE THE SUNROOF MOTOR UNLESS THE SUNROOF IS COMPLETELY CLOSED.OTHERWISE A NEW MOTOR WILL HAVE TO BE INSTALLED AND TIMED WITH A TOOL THAT COMES WITH THE NEW MOTOR.THE GLASS PANEL CAN BE ADJUSTED.OPEN THE INTERIOR SUNSHADE ALL THE WAY BACK AND OPERATE THE SUNROOF UNTIL FULLY CLOSED.THERE ARE THREE GLASS MOUNTING SCREWS ON EACH SIDE OF THE SUNROOF OPENING.INSIDE THE VECHICLE LOOSEN THE SCREWS SET THE FRONT EDGE OF THE GLASS TO BE JUST 1MM BELOW THE SURFACE OF THE ROOF.ADJUST THE GLASS AT THE REAR EDGE TO BE JUST ABOVE 1MM THE ROOF AT THE REAR TIGHTEN THE SCREWS.
The fuse and relay box on the E30 and E36 models is located in the engine compartment. The E36 models also has relay boxes located under the left side of the dashboard. Circuit Breakers Resetting & Replacement Circuit breakers are located inside the fuse panel. They are automatically reset when the problem corrects itself, is repaired, or the circuit cools down to allow operation again.
One of the less known about fuses that can cause all this to go out is the fuseable link. It is in a black plastic box near the battery. It is an appx 60A thin metal strip fuse. Check the website link to the right for more info.
Also, I suggest check your Fuse Diagram in the BMW 525i Owners Manual here. Power Sunroof Emergency Closure Operation The sunroof is equipped with an emergency closure feature should the sunroof motor fail or the vehicle has lost electrical power. To close the sunroof under these conditions:
Remove the front headliner trim panel.
Using the 6mm hex key that is included with the tool kit, insert the key into the hex socket and turn the socket to close the sunroof.
Fig. Remove the trim panel to access the sunroof motor
Fig. Insert the 6mm hex tool from the tool kit and turn the hex socket to close the sunroof
Removal & Installation E30 Models
Fig. Sunroof components-E30 3 Series shown, E36 similar
Fig. Sunroof lid retainer clip location-E30 3 Series shown, E36 similar
Open the sunroof lid 2-4 inches (5-10cm).
Unclip the roof liner frame and push back into the opening.
Close the sunroof lid and loosen the screws on each end of the gates.
Pull in the retainers, remove the center screws and lift off the lid.
Remove the cover over the motor and gearbox. Close the sunroof lid, if not already closed.
Disconnect the wiring harness and remove the 3 mounting screws. Remove the motor and gearbox.
Push the cables back evenly on both sides. Remove the rail covers and pull the cables out of the guides.
Place the cable in the center position of the gate and press off.
Install the cables to the gate. The cable are marked with the proper side of installation. Do not lubricate fabric covered cables.
Pull the cables through guides and align the cables. Insert a hex key through the gate and cable at the 0 position.
Install the motor and gearbox. The motor and gearbox must be synchronized with the hole in the drivegear aligned between the centers of the 2 gears. Torque the bolts to 2.0 ft. lbs. (2.8 Nm).
Install the sunroof lid. Use new screws and torque to 2.5 ft. lbs. (3.5 Nm).
Adjust the sunroof lid. Pull the roof liner frame into position and clip into place.
Close the sunroof fully. With a quick actuation of the sunroof opening button, open the sunroof so the back edge of the lid depresses 0.08-0.12 inches (2-3mm).
Slowly push the roof liner panel back into the roof. Do not force or use a quick motion or damage could occur.
Remove the mounting screws and pull the lid off at the rear side. Do not operate the sunroof with the panel removed.
Install the lid and check that the hooks and levers align. Install the screws with threadlocker or use new micro-encapsulated screws. Torque to 2.5 ft. lbs. (3.5 Nm).
Adjust the sunroof lid. Lower the rear of the lid by operating the motor. Pull the liner forward and clip into place.
The problem is probably the 'flap' of metal that's popped up, just above the where the handle is. The runners/rails have undoubtedly corroded, and now there isn't anything to pull it down. Luckily, as a 'Get the roof shut cos it's p*^%g down' solution,,. You can just hold your finger on the flap, to hold it down, in between the sunroof, and hole as you shut it. Just remember to remove your finger Before you finish closing the sunroof. Happy motoring.