dreaded sunroof ...

my TD4 HSE 2006 is suffering the dreaded sunroof clicking problem and not closing properly on one side, so I purchased the repair kit off ebay which is pretty good except no instructions :-(
So, I took the roof apart, removed the rails and 3 hours of fiddling around fitted the new parts, interesting though, nothing was actually wrong with the rails, the slider that 'normally' breaks was in perfect condition. Put it back together, and yes, still clicking and doesn't close properly on one side.
With the repair kit you also get a plastic gear cog, not the same as fitted to the actual motor , and I am assuming it is this cog that has gone or the actual motor cog.
The problem is I cannot see where this plastic cog should go, it isn't the cogs in the rails.
I have downloaded the RAVE manual but my CD writer is knackered so i can't access it, would some kind comrade do me a big favour and post an image of the Sunroof schematics that show this cog and where it fits?

This image below is the cog in question ,part no SRLR004.

Also, does anyone have a picture of what the metal cog on the actual motor should look like , the one on mine looks a bit worn, and can you get just this cog as a replacement rather than a complete new motor?
thanks for any help you can give.
cheers

just had a quick look on rave and microcat and i can't see that cog listed as a seperate part so i imagine it would be the main cog on the motor and is just supplied with the repair kit to be replaced if needed...

Hi Mark thanks for the reply, it definitely isn't the outer gear on the motor as that is metal, maybe the motor has an internal plastic cog, I will have a look at the weekend.
cheers
Chris

Ere's the cog on the sunroof motor. Cog is metal. Don't like the idea of a plastic one.


P1091896 2cDZo4x

And thers's a white/cream screwdriver slot to allow you to turn the cog manually, but yer has to put the screw driver in, and push the slot gently inwards, to disconnect the drive wheel from the motor, to allow yerself to turn it. Squerted some stuff in mine yesterday as advised on ere to sovld me motor drive problem on me sunroof.


P1091899 WPjLFGA

Your best bet is to shut it up and remove the fuse. These are so prone to failing that I question whether or not they're worth having in the first place.

If you want a bit of fresh air in the cabin, what you can do is open the back window and the 2 side windows and that does the trick without causing too much drag or too much road noise. (unless there's anyone in the back!)