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The problem you are encountering is two fold. I've discussed this before, and I REALLY WISH they would stick my answers in the FAQ so I wouldn't have to repeat myself consistently, but I'll post a brief explanation here to get you up to speed:
1) Sunroof Design Flaw
Earlier sunroof models used a different design for the support bars that control the venting component of the sunroof than later models. This original design put too much stress/force on the two metal bars that slide back and forward to push the roof up and down (controlling venting). As a result, the bars would snap in half at the thinnest point where teh back and front of teh bar are held together by a 1/4" square piece of metal. The reason I know this is because I did a study of sunroofs across various junkers and discovered that ALL the older designs (without fail) had broken in the EXACT same spot, while the newer designs were still intact.
If and when this happens the sunroof will perpetually sag and fail to achieve a solid seal that prevents water from entering the cabin and affecting both the sunroof headliner and teh headliner surrounding the sunroof opener.
On a sidenote, there are actually two adjustable screw bracket that allow you to alter the sitting position of teh sunroof (silver coppery color, one on eitehr side in the back). It is possible for these toi become loose and allow the sunroof to drop down a bit, and tightening these while propping the roof to the proper sitting position can work. However, if the rods have broken as previously mentioned adjusting these screws will do nothing, since the piece you are screwing them into has no support to hold it up.
The fix for this is to replace your sunroofs supports and mechanics with the newer design from a junker. It is time consuming, but it isn't nearly as much troubvle as it might sound. The sunroof roof itself is only held into place by 6-8 screws, and lifts out once you get access to these and remove them. You only need to replace the support struts and accompanying components btw, not the roof itself (but removing it makes it easier to access the elements).
2) Worn Sunroof Seal Guard
Over time the sealing ring around teh sunroof's edge becomes worn and frayed, allowing water to leak in regardless of how the roof is seated.
The fix is to pull the sunroof roof itself and replace the sealing ring with a new one or one that is at least less worn. Note: you HAVE to remove the roof to do this since the ring slips off from the bottom.
Good luck with your fix. I could go into replacing the headliner now (I'm kind of a volvo 700 roof savant), but I've given out enough infornmation on this subject and need a little break. ;)
(Let me just say that you want to use 1/8" headliner EVERYWHERE, not just on teh sunroof. Don't listen to what anyone else tells you... trust me and ask for 1/8" material. If the store you go to (a fabric store) doesn't have it have them order a new roll. The reason for this is that the headliner must go under various edges around teh car (including under that plastic edge at the sunroof opening) and the 1/4" is too thick to fit. Also, the 1/4" material is much heavier and will pull off the headliner backing board over time faster than the 1/8".)
Good luck,
Rick
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