Well I have finally gone ahead and did it, I heard many rumor's that it could be done and many that it couldn't and yes I do know I have made my car more top-heavy with glass but glass is just so great, love seeing the moon at night, and my steel panel sunroof had some nasty scratch's where the sunroof broke, fortunately the last owner paid for a brand new sunroof and I can swap them for the same price but enough about that......
I proceeded to take apart my interior. The A B and C pillar trim had to go (the side trim panel's from front of car to rear). Careful of the nasty black stuff on the screw's (my tan leather show's a little wear after this mod) and take the A Pillar trim off carefully (very fragile). Next I removed the sunroof motor cover and sun visor's and the rear panel trim (carefully pull hard it will come loose). The Bentley said to "loosen" C pillar trim (pull hard it pop's out). I only popped out 2 hole's but the trim was still very tight and I had trouble pulling the headliner out, the small strip that fills the gap between headliner and windshield went next or tried to. The book said to pop it off with a wedge but no such luck every time I popped another connector broke, perhaps they were meant to be a one time deal. If anyone knows let me know. I loosened it enough to take the headliner out by hand. Oh and sunroof user's take the trim that hug's the interior headliner where the sunroof gap is. Then I pulled the headliner out, all the while tearing out my hair thinking the fragile thing was going to crack on me. Because of the chassis, the headliner it is meant to bow down when sliding it out, it will come just do it slowly, your almost done.
Behold the sunroof assembly, make sure the sunroof is in Closed position. I unscrewed the sunroof motor and dropped it down, then took the 10 bolt's out of the assembly itself. You might want to have somebody hold it while you unscrew it is a bit heavy, but not as heavy as the glass, as my good for nothing bro was inside sleeping i just used my C's Recaro's to help me by extending to full height so they bore the weight of the assembly while I unfastened it. This helped greatly when positioning the Passat Sunroof, I had the passat motor with the sunroof but the wire connection's don't fit up with my C's wiring so I used the C motor and it work's just fine. The passat frame bolted right up. Then checked the height of the front and rear. The front should be 1 mm below roofline and rear should be 1 mm above roofline. You need a t-25 torx to adjust. Made the adjustment's and the glass is a bit higher in the middle but then goes beneath the roofline as it proceeds to side back of the car.
I don't think the seal is as good as my C's seal was, but hey that is what the drain plug's are for right? One person did need to replace the weather-stripping around the glass and said it didn't fit quite right until he did that, but I saw nothing wrong with mine. I have to do some adjusting to the height of the front and rear as the sunroof stop's halfway going into the roof. The only problem is when you adjust it back down you are widening the gap on the rear corner's=more water. Then it will go inside neatly though I did notice some very small scratch's in the sunroof where the glass is raised higher but very small, the roof actually seems to flex a little with the sunroof going inside, noticeable but not extreme. The C motor seems straining when it is pulling the glass and the inside felt panel back so I always pull the panel back before I pull the glass back. Other than all that it does look good and it does fit quite nice and look nice on the inside, it has rained a little and no leak's so far, but the heavy rain is yet to come. I guess I will have to start cleaning out my drain plug's more often now. If anybody else has done this with better result's please let me know.
I will get a scanned pic out of the sunroof soon, hope it helps you I know many people have wanted to know if this worked and I was surprised there is no talk about it on the website so here you are email me if you have any Q's. It Tilt's...... it Slide's.... it hasn't leaked yet ;)
One word of advice if anybody ship's sunroof assembly frame's please make sure the drain plug's are wrapped up tight with foam they are fragile and once some fool at UPS drops it there gone and it make's the frame useless as you cannot buy the individual drain plug's.
Matt
90 Black G60
VwRacerG60@Aol.com
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