How-to remove an opensky roof

This isn't a guide listing every tool needed and nut and bolt but it will give an overall help to anyone planning to replace their opensky sunroof. I've assumed that by attempting to do this yourself you have at least a basic DIY mechanic skill level.

First up is just the basics of disconnecting the battery and discharging the system (attempting to open a window is a good source).

Next remove all of the interior trim that will prevent the roof lining from being removed. This includes the sunvisors, interior light units, grab handles and all A and C and D pillar covers.
2vmu4xj.jpg


Then remove the B Pillar covers. To do this you will need to remove the top mounts of both front seatbelts with a 17mm socket.
ma8llg.jpg


Now that you've removed all the items above its time to remove the headlining. The headlining is held in place by a series of clips around the sunblind of the opensky and also the edges of the headlining. It's also held in place by 2 hex head screws and 2 8mm bolts. The photos below show the locations.
Photo 1 shows the two in the recess where the front interior light used to be
ziom86.jpg

and photo 2 shows the mounting points at the rear which are underneath the D pillar covers.

Next you will need to manually open the roof. In the centre of the electric motor for the roof is a small hole for an allen key. Insert an allen key head onto a ratchet and turn anticlockwise to open the roof. This will then reveal a hex head screw in the runner of the roof. The photo here shows the location but with the screw removed.
112egk5.jpg


Now that the headlining is removed and the two screws in the runner are done its time to remove all of the 10mm bolts that actually hold the frame in place.
The first photo shows the location of the mounting points at the rear.
sg3imw.jpg

and photo 2 shows the mounting points at the front.
245brx3.jpg


These bolts are also accompanied by 3 further 10mm nuts along the front of the roof and 2 at the rear but their location is more than obvious when removing.
 
Click to expand...
johnyfartbox said:
Update to removing the headliner guys.
Ive just done this and followed the destructions, the only thing that is missing regarding screws holding the headliner in is the little secret sun visorView attachment 41578 also has a screw holding it in place and the headlining.........otherwise quite an easy jobView attachment 41579View attachment 41580
Click to expand...
Hi, to me the issue isn't the hidden sun visor removal, but the 2 sunvisor clips and the vanity lights, by the rear view mirror. I see the flat hole on both clips, but after using a flat screw driver, it doesn't move at all. I tried an allen key too and after a few tries, it actually broke into half, must like my plastic one before. That plastic cover is tough. Same with the lights. I see the marks on the sides, but whatever I do it doesn't move, the cover actually cracked bit after trying to remove it a few times. Am I missing something? Thanks

Edit: In case someone comes across the same issue, here's the solution.
The cover was actually so thin, you only need to insert the L shape tool in like 3-4mm. I thought it's a thick cover so I'd inserted the tool like half an inch like I was trying to remove the whole part at once. Once it was clear,
20190821_190421.jpg
both came off with no issue and undamaged.
 
Last edited:
Sylvester said:
Hi, to me the issue isn't the hidden sun visor removal, but the 2 sunvisor clips and the vanity lights, by the rear view mirror. I see the flat hole on both clips, but after using a flat screw driver, it doesn't move at all. I tried an allen key too and after a few tries, it actually broke into half, must like my plastic one before. That plastic cover is tough. Same with the lights. I see the marks on the sides, but whatever I do it doesn't move, the cover actually cracked bit after trying to remove it a few times. Am I missing something? Thanks
Click to expand...

You need go insert a very small flat head screwdriver at the front edge of the opening for the hook. Then lever out and down. I ca now remove these Every time without any damage but a good few clips died over the years mastering the technique :)

In terms of the vanity lights, again use a flat head screwdriver and prise them downwards at one edge. They are reasonably tough so shouldn't break.
 
A2Steve said:
This isn't a guide listing every tool needed and nut and bolt but it will give an overall help to anyone planning to replace their opensky sunroof. I've assumed that by attempting to do this yourself you have at least a basic DIY mechanic skill level.

First up is just the basics of disconnecting the battery and discharging the system (attempting to open a window is a good source).

Next remove all of the interior trim that will prevent the roof lining from being removed. This includes the sunvisors, interior light units, grab handles and all A and C and D pillar covers.
2vmu4xj.jpg


Then remove the B Pillar covers. To do this you will need to remove the top mounts of both front seatbelts with a 17mm socket.
ma8llg.jpg


Now that you've removed all the items above its time to remove the headlining. The headlining is held in place by a series of clips around the sunblind of the opensky and also the edges of the headlining. It's also held in place by 2 hex head screws and 2 8mm bolts. The photos below show the locations.
Photo 1 shows the two in the recess where the front interior light used to be
ziom86.jpg

and photo 2 shows the mounting points at the rear which are underneath the D pillar covers.

Next you will need to manually open the roof. In the centre of the electric motor for the roof is a small hole for an allen key. Insert an allen key head onto a ratchet and turn anticlockwise to open the roof. This will then reveal a hex head screw in the runner of the roof. The photo here shows the location but with the screw removed.
112egk5.jpg


Now that the headlining is removed and the two screws in the runner are done its time to remove all of the 10mm bolts that actually hold the frame in place.
The first photo shows the location of the mounting points at the rear.
sg3imw.jpg

and photo 2 shows the mounting points at the front.
245brx3.jpg


These bolts are also accompanied by 3 further 10mm nuts along the front of the roof and 2 at the rear but their location is more than obvious when removing.
Click to expand...
Hi can you tell me how to get sun visor off on the clip side l have sun visor side off thank as l am changing the roof. Regards Mick
 
Michael Clarke said:
Hi can you tell me how to get sun visor off on the clip side l have sun visor side off thank as l am changing the roof. Regards Mick
Click to expand...

The clip needs to have the cover taken off. You do this by sticking a very small flat headed screwdriver between the inner and outer parts and pulling it towards you.
 
bretti_kivi said:
there are two things that go wrong:
- the cog on the main motor starts slipping
- the wires aren't taut.

There's no real reason to replace a roof completely, there are parts available if you go looking for the above issues and some others to avoid issues happening in the first place.

- Bret
Click to expand...
Please elaborate on this :)
I don't understand why the OP is removing the roof in the first place.
It can't be repaired in place? What is wrong with it?
Which repairs can be done without disassembling half of the car?
Thank you.
 
hdlo said:
Please elaborate on this :)
I don't understand why the OP is removing the roof in the first place.
It can't be repaired in place? What is wrong with it?
Which repairs can be done without disassembling half of the car?
Thank you.
Click to expand...

There are a number of reasons for needing to remove the roof unfortunately, I had to remove mine because the seals had degraded so that water was coming in from where the roof meets the body of the car. Other reasons could be shattered front or rear panels which can only be removed with the OSS frame out of the car. @Kleynie is the expert on all things OSS on this forum I think so I am sure can help our with other reasons for the whole assembly needing to come out.

Personally having had it out the main difficulty is actually the weight and size of the unit rather than the removal of all the nuts and bolts to get it loose. Even if it does look like you have removed half of the car when there's a gaping hole where the roof used to be ?
 
A2Steve said:
This isn't a guide listing every tool needed and nut and bolt but it will give an overall help to anyone planning to replace their opensky sunroof. I've assumed that by attempting to do this yourself you have at least a basic DIY mechanic skill level.

First up is just the basics of disconnecting the battery and discharging the system (attempting to open a window is a good source).

Next remove all of the interior trim that will prevent the roof lining from being removed. This includes the sunvisors, interior light units, grab handles and all A and C and D pillar covers.
2vmu4xj.jpg


Then remove the B Pillar covers. To do this you will need to remove the top mounts of both front seatbelts with a 17mm socket.
ma8llg.jpg


Now that you've removed all the items above its time to remove the headlining. The headlining is held in place by a series of clips around the sunblind of the opensky and also the edges of the headlining. It's also held in place by 2 hex head screws and 2 8mm bolts. The photos below show the locations.
Photo 1 shows the two in the recess where the front interior light used to be
ziom86.jpg

and photo 2 shows the mounting points at the rear which are underneath the D pillar covers.

Next you will need to manually open the roof. In the centre of the electric motor for the roof is a small hole for an allen key. Insert an allen key head onto a ratchet and turn anticlockwise to open the roof. This will then reveal a hex head screw in the runner of the roof. The photo here shows the location but with the screw removed.
112egk5.jpg


Now that the headlining is removed and the two screws in the runner are done its time to remove all of the 10mm bolts that actually hold the frame in place.
The first photo shows the location of the mounting points at the rear.
sg3imw.jpg

and photo 2 shows the mounting points at the front.
245brx3.jpg


These bolts are also accompanied by 3 further 10mm nuts along the front of the roof and 2 at the rear but their location is more than obvious when removing.
Click to expand...
Dear Steve, did you remove the pictures from this post or are there some technical issues with them? I only see these"This picture is no longer available" pics. Cheers: George
 
bento said:
Dear Steve, did you remove the pictures from this post or are there some technical issues with them? I only see these"This picture is no longer available" pics. Cheers: George
Click to expand...
The host site no longer exists sorry and I don’t have the photos anymore.
 
bento said:
Dear Steve, did you remove the pictures from this post or are there some technical issues with them? I only see these"This picture is no longer available" pics. Cheers: George
Click to expand...
There's a German video showing bits and bobs about the oss, just search on YT.
 

OSS the German way

In German but worth a look . just to warn you, its 53 mins long but it just goes to show you its a very complicated piece of kit Nice leather seats and very unusual,
www.a2oc.net www.a2oc.net
 
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