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rover_25
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Rover 25, water ingress around sun roof seals front off side, new seals fitted however recurring issue.
Lowered roof lining, giving access to the excess water collection hopper, black steel pressed item, covered factory drilled hole (it had no purpose), filed a channel in the casting situated at the front of the sunroof track to allow any ingress to freely flow into the collection hopper. Appears to be fixed.
The bit that was filed is an aluminium casting that is silver and black and is at the front of the slide guide that the sunroof runner rests on.
 

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'06 MG ZR +120 (HQM) '04 MG ZR 105 (IAB)
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Thank you for that information; it may be of use to people who cannot afford a new rubber seal, or are unable/unsuccessful in repairing their sunroof.

Water leaking through the sunroof seal is invariably due to rusting of the metal frame which is bonded to the glass, and round which the seal fits (which in turn usually happens because the seal has not been lubricated regularly to keep it waterproof - something specified on the service sheet to be done annually), so it becomes porous and allows moisture to get at the metal frame. The rust swells and pushes the seal away from the glass, allowing water to get past it.

In time, the rust scale from the decaying metal frame falls into the recess under the sun hatch, and eventually blocks the sunroof drains, and then the water overflows and wets the headlining and/or drips into the passenger cabin.

The only successful long term cure (short of welding a plate over the sunroof!) is to remove the seal, and hope that there is enough solid metal left around the flange of the metal frame to allow you to remove all the rust scale, soak thoroughly with a rust killer such as Kurust, repaint and still have enough metal to re-attach the seal. It is quite rare for the seal to have detriorated in such a way as to need a new one sourcing (although care needs to be taken in removing the existing seal without causing damage).

To be honest, your fix is really a last resort if all else fails (either a new seal is too expensive, or the metal frame is too far gone to achieve a successful refurbishment - increasingly likely now these cars are at best nearly 14 years old) - if there is any significant amount of water getting past the hatch, there is something else amiss.

If the seal is correctly fitted (and bonded) to the metal frame, and the sun hatch is positioned correctly on its mountings, and therefore sits perfectly within the roof aperture, there should be little or no water ingress (unless perhaps directing water at the roof from a pressure washer).
 
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