I'm looking for some help on how to get my headliner out to fix my water leaks. I was able to get the driver side headliner down about 2"-3" to see the problem, but I can not get it to budge more, especially around the sunroof. I disconnected everything, a/b/c pillars, dome light, rear view mirror, sun visors, sun visor lights, grab handles, but like I said, the headliner wont move more than a few inches. What am I missing, what's ths trick?

Also, the sunroof drain rotted out about and inch, and the pre-existing tube doesn't reach now, what's the fix?
Pics for reference
​​​​​​​https://flic.kr/s/aHsm9XYPw2

 

If you have the head liner pulled free from the "dual lock" patches in the back then the whole headliner has to slide to the rear to release the catch in the rear and the steel channel that clips to the front portion of the frame surrounding the sun roof opening. The whole headliner should slide back about an inch before it falls free.

 

Oh that's terrible!
I have seen that before, there was an old post here from someone I thought in China or Japan...

Were you able to see it (the problem) only when you dropped the headliner?
I know WIS says that when installing a new one (as yours looks compromised and separating/re-glue with Super90) you will get a fold/crease and this is normal when done properly and will go away. Of course that is when you remove the center console...

You can see a bit of how it was installed at the factory here @ 3:58
and of course there is no glass to get in the way there!

Time to add IMS!
Also - look into the TSB for Butyl chord...I am not sure if that affects ALL w203s or post face lift only...
Here is a post from earlier this year...
https://mbworld.org/forums/c-class-w...r-removal.html

Update the thread when completed successfully please.

 

Not sure what the "dual lock" patches are?
Slide to the rear? The video below shows them installing it by pushing it back, you state otherwise.
The steel portion in the front of the sunroof frame that just pulls up is the only thing I need to remove from that area? How about the rails on the sides with the 3 torx screws?

The "problem"(front drain nipple) fell out when I lowered the headliner a few inches.

As for IMS, there's absolutely no reason for that. Also checked the TSB thread, don't see anything that says "BUTYL".

Does anyone know if the sunroof frame from an 05 clk will fit?

Pretty SAD the w203 has been around for such a long time, every sunroof leaks, but there are no documented fixes in any threads. Sure if there was, it would be a sticky.

 

Been a while since I have removed the headliner. You'll find a metal channel that holds the headliner to the sunroof opening. So now that I think about it yes, it goes forward to come off as the front of the headliner is held up by the OCP and sunvisors. The dual lock is a 3M product, its heavy duty velcro. It kinda snaps on and off. There is also a hook back there.

135,000 miles, no sunroof leaks. I just replaced the seal around the glass this summer and noticed just a little rust behind the seal.

 

Here is info on the TSB.
https://mbworld.org/forums/e-class-w...eak-issue.html

Here are some images of the back of the headliner. I hope this helps.
Good Luck!

I would stick to a w203 part

.

 

I've seen them in the shop with rusted sunroof trays. A new sunroof module is the only way we fix them sadly. Always costs more than the car is worth.

The headliner usually doesn't survive removal if it's been wet enough times. Best to remove the front seat/console to not have to fold it, if you bend it, it will never be straight again, and a new headliner is also more expensive than the whole car.

 

Okay, just double checking. I don't want to destroy the headliner by pulling/tugging in the wrong direction. I looked into the 3m dual lock, so I know what it is, heavy duty velco, like you said. lol

Just picked up this car about a month ago, 126,000 miles. Unfortunately, the previous owner(s) neglected the sunroof drains, which got backed up, and just rusted out. I did not know this. Because of this W203, any future car I may ever think about purchasing that has a sunroof, will get the water test! A leaky sunroof is one nasty surprise.
I will look into that TSB link, and those pictures help a ton. Now I know exactly what/where is on the backside!
I'm not sure if my whole sunroof tray is rotted out, but I can see a little rust near the front, and obviously where the two front drain nipples rotted off.

You say a new sunroof module is the only fix, I can get a 05 clk sunroof assembly with no rust for cheap, that's why I asked if it fits. I looked up the part numbers and they don't seem to interchange. Kind of figured that beforehand, was just hoping to get lucky.

Another problem of mine, I am fully capable of getting this headliner down, but some MOMO who owned the car before me used wood glue to hold down the shifter surround. Not sure why, when the shifter surround is cheap. In order to get the headliner down, console must come out, which means it might destroy the aluminum where the shifter surround is glued down. I can't win.

With all that said, I might, as a temporary fix, silicone the sunroof closed until I feel like doing this. Me personally, I'm not going to use it anyway, I hate the idea of a sunroof. A car with a sunroof is less rigid, lets unwanted light into the car, adds weight to the roof(not good center of gravity), and leaks water? The sunroof has to be one of the biggest gimmicks in the automobile market. I've only owned one new car, and was able to order with my specific options. One of them was NO sunroof! It sucks that 99% of used cars have them.

 

On a side note, I've been getting water instrusion for years now, not really sure where it was coming from.
I'm in a C coupe with pano. Last year I had major problems because of water, which finally resolved after the car
dried out, and a trip to a speedo shop who miraculously brought my instrument panel back to life.

Recently the pano gears etc finally gave out, so I used the z handle hex to tighten the sunroof, and
then disconnected the motor.
Surprise, after the last big storm no water! So I guess the sunroof was not closing tightly all those years.

So if you're having an issue with leakage perhaps pop the overhead panel, cinch down the sunroof tightly with the z wrench (if it's still with the vehicle...had mine for
15+ years before I had the occasion to use it)
or metric allen, and disconnect the motor, at least until the rainy season end.

 

I wouldn't silicone it...then you might have another mess...
I would buy a cheap magnetic sheet and cut to fit. It almost looks like a sunroof with rounded corners.
IF you don't want unwanted light - this is perfect. It lets in no light.
You MAY want to electrical tape the front leading edge so it doesn't lift off...if you plan to drive with it on.
https://www.ebay.com/itm/Magnetic-Roll-Sheets-24-inches-x-3-feet-White-Best-deal/161105738364?epid=1948537144&hash=item2582a67a7c:g :-sMAAOSwXLpZvK9s

Then...get a European (as you mentioned, most w203s in America have a sunroof) UCP without sunroof...you can use that too if you cinch down as above mentioned...
https://www.ebay.de/itm/Mercedes-Ben...UAAOSwLJ9aCKfc

 

Now that you mention a magnetic sheet, how about getting the roof vinyl wrapped? I wonder just how waterproof vinyl wrap is. I just googled it and vinyl wrap stopped a few ppl's sunroof leaks leaks lol

 

For detailed information you can refer www.workshop-manual.com

 

Ok. I’m guessing the red arrows I added to this photo are pointing to the Velcro attachment points? What’s the trick to get in there and release the stuff? I’ve tried thin wood wedges and everything else I can wedge in there. Afraid it just going to tear a hole in the headliner...

Thanks,

 

Todd,

This is SO CORRECT!
I was having wind noise for a while to the point that I looked into getting a new seal.
Turns out the motor grease was so dried out out and gear engagement was the issue.
I did my motor re-enforcement mod and re-greased the motor and part of the screw cables that I could get to and works faster and seals great now.

Thanks,
Dave