2003 EVMV with a leaky sunroof and no drains

[Hawkridesdirt]

After doing some research and investigating the pillars and drain areas of the vehicle, I have determined my sunroof lacks drains.

I can't understand why VW would do that, but nevertheless, I would like to hear what people have done to remedy this unforthunate circumstance.

Thanks
Toby Hawk
03 Eurovan MV
04 Land Rover Discovery II SE7
02 Land Rover Discovery II SE
97 Land Rover Discovery I SD7

[GreasyRider]

Hey TH, I had a leak that went away after cleaning the seal thoroughly and then wiping a thin coat of Vaseline on the seal where it contacts the glass. No more leaks on what has been one of the wettest winters on record in Seattle.

[Hawkridesdirt]

Thanks Greasy. I will try that before I pull the headliner to install the plumbing.

[vwjoel]

I've had a leaky sunroof issue with my 99 EV whenever we get a good rain, which is often in Seattle. I did clean the seal and it helped slow it down but I still get a steady stream of water on my pants on the first good right turn in the morning. The motor cover is missing so it just pours right out. After the last time it doused my wife in the passenger seat I decided I needed to do something about it before the van is doomed. A new seal is not available and if it as it was only sold as a complete unit with the sunroof. Not and option. Really, the Eurovan sunroof just needs drains like every other sunroof in the world. So, I added drains. This is how I did it:

The headliner around the sunroof is a separate piece and comes our pretty easily. The Bentley manual has you take out all the A-pillar trim but that is not necessary. Remove the sun visors and trim piece between the front and rear headliners. Peel back the felt seal holding the headliner to the sunroof assembly and it will pull out.

The sunroof water tray is held in place with large head Philips head screws. It drops down from the rear and will come with the sun shade assembly. Once it is out the drains can be added.

I added drains only to the front. Most real sunroofs have drains on all 4 corners but I opted to try out the front first and see how it works. The front of the rain tray has low spots in the outer corners where the water collects.

I drilled a 1/4" hole in the front corners as close to the bottom of the tray as possible and glued in 1/4" OD nylon tubing. I used my favorite polyurethane cement, ShoeGoo. It is flexible and sticks well. Rough up and clean the surfaces first for a good bond.

I installed the rain tray back in the van and ran rubber hoses through the hole in the body above the windshield and down into the A-pillars. To make it perfect I should have ran the hoses outside the body but water in the A-pillar will be better than water in my lap.

The headliner went back in over the tubes with no issues. Hopefully in the next heavy rain I'll stay dry.

[Zeitgeist 13]

What a bizarre oversight that they didn't add factory drains. Nice work
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Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[Abscate]

Mine has drains but they only work when you plug in the OBD for testing
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.ssS!

[strandomatic]

Hey VWJoel, I have a new to me 2003 Eurovan and roof is leaking bad. Did your DIY drain system end up working and solving this issue for you? No seals are available for purchase anymore, so I am out of luck unless i use silicone on the outside seal or install some drains. Thanks.

[VolksVelo]

It's a Volkswagen thing. My previous 2010 Sportwagen TDI sunroof leaked so badly that it filled up the spare wheel well with rain water all the way to the rim. VW bought the car back after that infamous dieselgate mess. Our current car, a Golf Alltrack came with NO sunroof as we specifically ordered.

[vwjoel]

@strandomatic, The drains I added worked great as long as I parked with the nose down hill. If you're going to go through the trouble of pulling everything apart to add drains it would be worth while to add two drains in the back as well that go down the B pillars. If you are feeling really ambitious you could rout the drain tubes outside the cabin so they don't soak the carpet. I wasn't that ambitious with my '99 but a wet carpet was a step in the right direction away from wet pants. I eventually fixed my sunroof problem permanently by selling the Eurovan and 'upgrading' (in my opinion) to a Vanagon.

[Whridlsoncestood]

Vaseline trick worked for me a few months ago. If I have to do it once or twice a year I won’t really complain.
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2001 EV MV

[volkybus]

The best sunroof ever on any vw is the folding ones on the early bugs.I have one from a 63 in my storage area but can't bear to make a hole in the roof of my 93.MV Overniter( weekender w no pop top) it hasn't proven itself worthy yet..Bill

[MrPulldown]

I use silicon spray for rubber seals. Has worked great on my vehicles. Petrol jelly might eat up the rubber.
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2002 EVC