Technical Sunroof/moonroof stuck up one corner

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Technical Sunroof/moonroof stuck up one corner

Oz500

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I am hoping that someone here knows how to remove the sunroof, or if anyone could point me to a manual with instructions on how to remove/dismantle the sunroof of a 2007/2008 Fiat 500?

The sunroof/moonroof on my 2008 Fiat 500 Lounge broke yesterday. I took the car to a nearby dealership and the legends in the workshop were able to get it almost all the way closed.
The left front corner of the glass will not go down (it is sitting up and open by almost an inch).
There are small pieces of broken black plastic from somewhere on the roller shade, so something has definitely broken.

I have looked online for sunroof fixes, but most are about the button reset procedure.
also, I cannot find anything online for a 2007/2008 (everything seems to be for 2012-onwards).
 
I cant help but don't loose the broken part, a guess is that's its the part to keep it closed, if all else fails disassembled you may be able to 3D print a new part from the two pieces? Or repair it?
Thankyou, if I can find out how to uninstall the sunroof I might be able to see what is broke.
whatever is broken has disintegrated into a hundred tiny pieces 😕
I don’t know how to get the glass off to get a good look at the rails/mechanism.
 
Ok here’s some info for the next person who finds themselves with this issue.

1. if your sunroof will open enough to access the two small (T15) torx screws on each side of the frame (looking from the outside of the car), near the front, then undo those two screws and the whole track system will pull/slide out forwards (glass and all).
The photo is showing my sunroof upside down on the floor, because I had more bits broken and I have pulled out more than just the sunroof. Keep reading if you need to know more.
257D9EAF-CF55-4373-95A2-C7C357B6B61A.jpeg


2. The most common part to break is the cable strap (a fine metal strap covered in plastic).
FC3B0D09-166A-4E8D-97D1-D6BCF871E094.jpeg


68A88FB0-3FE9-4069-94B9-30EE488D8FAE.jpeg

This strap cannot be bought as a standalone piece, it’s part of the rails/tracks. In the parts diagram, it is #2 (and you should replace both sides at the same time).
6DFCAAFE-B034-44B4-B677-47F29FCFEC96.jpeg


3. If you need to remove the entire assembly because you can’t open the sunroof to get to the side torx screws, or for any other reason (as I did, due to also having a broken cable casing , which is #5 in the parts diagram), you need to remove the hood lining.

4. Pull the door rubbers, then undo all the head lining accoutrements (sun visors, switch panel, coathooks, etc). Undo the front seatbelts top bolt, pop off the plastic trim. Undo the two screws in each side of the boot trims, and pop them off.
The roof lining should lift out of the front (A-pillar) trims and drop down & out through the boot.
I used this as an opportunity to thoroughly clean my roof lining of random stains etc 😁
CDF8B41E-3420-445F-9AAA-08C704CDA352.jpeg

5. Undo 2 torx screws at each end of the roller blind, remove roller blind.

33BB2ECD-D8EB-43A7-8659-851D32A807D7.jpeg

6. Remove the 3 T25 torx screws from the sunroof motor, and drop the motor from the roof.
2F3D520C-26FB-43D4-886D-967C97906A68.jpeg
7. I cut the cable ties, ”popped” the cable covers from the cable casing, and removed the cable casing from the cables (because my cable casing was broken on one side). Remove single T20 torx screw from cable casing.

1C45D475-0186-43F4-B610-FC108BB8543D.jpeg
8. motor and removed screws (inc cable casing screw) show sizes
94C978E4-B93F-47BD-AF04-F657CD50E60A.jpeg


9. Remove 5 black & 2 silver T25 torx screws from each side of tracks/rails frame. The entire unit will now lift up and forward (with some manipulation), out over the windscreen.
8A61BE0E-6F89-435D-A29C-92CE9DC6E95C.jpeg


I will add to the thread when I get new parts and go to put it all back together.
 
Can someone (anyone) please tell me if the vessels for the Fiat 500 (or Abarth 595) sunroof match part numbers
77364 256 Right side
77364 257 Left side.
many thanks in advance
 
Ok, the internet (and google translate) have yielded some information (for the next person looking for it, hopefully this is helpful).
The Fiat 500 VESSELS (guides) have two different original part numbers (I presume EU and US) for each side.

Right side: K68111540AA (2007- 500) = 77364629 - now apparently this is the exact same as 68111540AA (new part number / 2019 500)
Left side: K68111541AA (2007- 500) = 77364630 - now apparently this is the exact same as 68111541AA (new part number / 2019 500)
 
Ok, the internet (and google translate) have yielded some information (for the next person looking for it, hopefully this is helpful).
The Fiat 500 VESSELS (guides) have two different original part numbers (I presume EU and US) for each side.

Right side: K68111540AA (2007- 500) = 77364629 - now apparently this is the exact same as 68111540AA (new part number / 2019 500)
Left side: K68111541AA (2007- 500) = 77364630 - now apparently this is the exact same as 68111541AA (new part number / 2019 500)

Information provided by Carparts-Pros
77364629 has changed to 77368911
77364630 has changed to 77368912
 
Information provided by Carparts-Pros
77364629 has changed to 77368911
77364630 has changed to 77368912
Oz500 this is incredibly helpful as i have been struggling for days and have now finally seen that the cable casing has completely let go in one side. As hard as I've tried though i can only find an american part number for it (68111539AA) did you manage to find one in the UK at all?
For anyone else as a consequence of this debacle and a very unscrupulous eBayer I have a used roof with glass and runners but no cable casing that I’ll be selling soon!!
 
Oz500 this is incredibly helpful as i have been struggling for days and have now finally seen that the cable casing has completely let go in one side. As hard as I've tried though i can only find an american part number for it (68111539AA) did you manage to find one in the UK at all?
For anyone else as a consequence of this debacle and a very unscrupulous eBayer I have a used roof with glass and runners but no cable casing that I’ll be selling soon!!
Hi,
I am in Aus so unfortunately I can’t answer for the UK.
Considering that all the other SUNROOF parts are interchangeable (UK to USA to AUS), I would expect that the American part 68111539AA would work.
A resource I use in Aus is to ask the Fiat dealership for a quote on a part. Sometimes I need to send them a screenshot of the parts diagram/picture.
They usually reply to my enquiry with a written quote that includes the genuine Fiat part number.
 
Hi,
I am in Aus so unfortunately I can’t answer for the UK.
Considering that all the other SUNROOF parts are interchangeable (UK to USA to AUS), I would expect that the American part 68111539AA would work.
A resource I use in Aus is to ask the Fiat dealership for a quote on a part. Sometimes I need to send them a screenshot of the parts diagram/picture.
They usually reply to my enquiry with a written quote that includes the genuine Fiat part number.
Thanks for the reply Oz500…your user name now makes a lot more sense 😂 I gave up and ended up buying a whole new roof from a scrap dealer as Fiat were completely unresponsive! It arrives tomorrow so I’ll post on here with anything that might be helpful for others but suspect there little to improve in the original post
 
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