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Discovery - How to repair a leaking sunroof guide

Discussion in 'Technical Archive' started by Mantamad, Feb 27, 2010.

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  1. Mantamad

    Mantamad New Member

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    I originally did this guide back in 2006 and posted it onto the web. The hosting site has cancelled the page and I have lost my text back up so hopefully the new instructions listed below make sense!

    The plastic outer surround can leak at the joint between the metal roof and the surround, often the leak can be cured by simply applying silicon sealant all the way round as indicated by the red line.

    [​IMG]

    To investigate further, you need to start dismantling, some fixings are crosshead screws, others are Torx (T20 from memory) begin by folding down the sun visors and remove the screws holding the plastic visor frame to the roof. Remove the centre screw for the sunroof winder (if manual roof)

    [​IMG]

    Prise out the blanking plate below the centre light to reveal a further screw.

    [​IMG]

    Unplug the light connections and remove the visor assembly.

    [​IMG]

    [​IMG]

    Next you need to remove the grab handles, use a screwdriver to prise open the cover plates

    [​IMG]

    Then unscrew and remove.

    [​IMG]

    Prise up the cover on the coat hooks and unscrew

    [​IMG]

    Next pull the trim around the edge of the head lining to remove and pull on the alarm interior sensor to remove, then disconnect the wiring.

    [​IMG]

    [​IMG]

    Next pull on the door rubbers to remove - you only need to remove enough of the rubber to access the clips holding the trim panels in place on the B pillars.

    [​IMG]

    Remove trim clips with a screwdriver then pull the trim piece off - there is a securing clip at the top as shown

    [​IMG]
    [​IMG]
    [​IMG]

    Pull the headlining down to access the underside of the sunroof - if you are only doing the front roof, you can get away with leaving the headlining hanging down rather than removing completely.

    [​IMG]

    Unscrew the sunroof winder (manual roof shown - electric will be slightly different), the plastic spacer lifts off. Note the rust on mine where water has been leaking in.

    [​IMG]
    [​IMG]


    Next unscrew the fixings holding the inner sunroof to the outer plastic frame, pull off the rubber drain tubes and lift the inner drain channel away. I cannot remember the exact details of how the glass comes out, IIRC it just lifts out but it will be self explanatory at this stage.

    [​IMG]
    [​IMG]


    As well as leaking through the winder, my roof was leaking where the drain tubes attach at each side. For some bizarre reason, Land Rover make a metal drain channel then attach plastic boxes to allow the rubber tubes to attach. They are sealed to the metal with mastic and this degrades over time.

    You can reseal these with silicon, I used Arldite because one of the plastic drains had snapped where the rubber hose slides over. I made a new plastic drain from those plastic connector screws you use in kitchen unit assembly (B & Q etc should sell). I drilled out the middle of the screw, ground the head down and Arldited it in place.

    [​IMG]
    [​IMG]
    [​IMG]

    Now its just a case of re-assembly, fix the inner drain channel back in place, apply silicon to the underside of the plastic outer piece and screw back together. Next re-attach the winder using plenty of silicon as shown in the photo.

    [​IMG]

    Only other point to watch is when re-fitting the trim panels over the B pillars, make sure the cut out locates over the seat belt mounting bolt so that the adjustable height system works.

    [​IMG]
     
  2. lrjohn

    lrjohn Member

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    Exceellent article!! as I have just bought a Disco with two badly leaking sunroofs this will help tremendously - thanks:)

    Where do the sunroof drain pipes exit the vehicle on a Disco 1, do front and rear exit at the same place?
     
  3. ben 84

    ben 84 New Member

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    This article is spot on if you have leaky sunroof some dirty bugger put black silicone between the glass and the plastic trim nightmare to clean but looks the part now plus no leaks.
    Spot on mate.
     
  4. motobiz

    motobiz New Member

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    Nice one its a good idea thanks
     
  5. biggeeeee

    biggeeeee Retired - Living the dream

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    Fed up with water dripping on me when I leave the Disco out in the rain, first job when it dries up.
     
  6. biggeeeee

    biggeeeee Retired - Living the dream

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    Spent the morning removing the headlining to repair the leaks in the roof, had water coming thru the front and also the rear A/C vents.
    Everything looks dry on the roof and the drain pipes are in tact. I'm going to reseal booth sunroofs.

    Whilst I've got the headlining off and on the livingroom floor want to give it a quick clean. What's the best stuff to clean it with, it has no major staining or anything just looks a little grubby when you see it lying on the floor. - Tried Vanish carpet cleaner as I found it under the sink but doesn't seem to do a very good job
     
  7. roller disco

    roller disco New Member

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    can anyone tell me where the drain tubes go to on a Disco 2 rear sun-roof so that I can checke they are not blocked?
     
  8. Dippypud

    Dippypud Never Knowingly Understood

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  9. treloarfarm

    treloarfarm New Member

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    I'm in the process of removing half a ton of silicone sealeant the previous dipstick used to try and fix the leaking rear sunroof.... I have it all in bits and cleaned..the drain hole trays have been resealed and looking good the top has been sealed where it meets the roof outside ...the glass doesn'nt seem to sit right then I noticed there is no rubber seal that the glass sits on like there is on the front hence the half a ton of silicone...I'm assuming there should be some sort of seal or gasket that the glass would sit on when closed...can anyone verify this and would you know where I can get one with a part number please...?

    On a side note my engine was out head and block skimmed new shells rings and other essentials replaced...it runs sweet especially after blocking off the EGR valve....
     
  10. Disco_Street

    Disco_Street New Member

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  11. treloarfarm

    treloarfarm New Member

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  12. Disco_Street

    Disco_Street New Member

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    Your welcome.
     
  13. biggeeeee

    biggeeeee Retired - Living the dream

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    That's not the seal that usually leaks on the Discovery sunroof, its the one stuck to the underside of frame that is supposed to tighten onto the roof. The seal is flimsy hence the need to use silicone IMO.
     
  14. treloarfarm

    treloarfarm New Member

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    The silicone in this case was there because there was no rubber seal what so ever...excessive would be an understatment..... the seal on the front sun roof is quite narrow and it needs to be as I reckon it sits in the channel( as you see in the jpg where the little flecks of white silicone are) then when the sun roof is closed the glass sits onto the rubber giving a good seal...
    [​IMG]
     
  15. Disco_Street

    Disco_Street New Member

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    Yep thats where that rubber goes, and if its the front all be fine once its in. However as i found cause of the curve of the roof at the rear the rubber curves aswell and leaves a small gap between it and the glass at the rear of the sunroof, and water got in, So a bit of silicon on the top of the rubber fixed that problem for me.
     
  16. treloarfarm

    treloarfarm New Member

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    Yes it is the rear one and I did scan it with my eye and can see exactly what you mean indeed there appears to be 2 dips along the back edge.....thanks for tip....:)
     
  17. supaflycowboy

    supaflycowboy Member

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    hi all,
    after only 6 weeks of having the discovery and repiaring meny lil faults on the poor thing,
    i decidied to tackle the leaking sunroof. the easy part was removing the headling, which came off preety easy, including the fabric :frown: which now gives me another job blimy,
    Before i thought id dismantel the sun roof i decided to pour i bit of water to see were the leak were, and have found it not the roof thats leaking but the seal around the windscreen,
    the sunroof leakd very just slightly, and jus a good clean of the seals and rail its totaly leakless, apart for a little surface rust around sunroof (next job)
    any ideas on how to repair the windcreen seal?
    or should i jus bound with a windscreen sealent?
    thanks
    :):):)
     
  18. Disco_Street

    Disco_Street New Member

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    No worry buddy :cool: :5bcheers2:
     
  19. RAKWilliams

    RAKWilliams New Member

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    I read this article and carried out the fix by repairing the broken hose fixing above the driver's seat. It has just rained for the first time and the usual internal waterfall has resulted so I will have to sit on plastic bags next time I drive! I suspect that the tubes are blocked but not at the top. Can anyone tell me precisely where they come out under the car front and back please?
     
  20. The Mad Hat Man

    The Mad Hat Man Well-Known Member LZIR Despatch Agent

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    They dont. The front ones finish inside the A pillar and are the start of the rotten bottom A pillar syndrome. Landrover have executed a nice double wammy there :d.. Best thing is to replace the complete tube and ensure it sticks out of the bottom of the A pillar.
     
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