Volvo V90/S90 Sunroof Gap Plug

A common issue observed in Volvo SPA platform vehicles equipped with panoramic glass roofs is the shrinkage of weather stripping due to UV exposure. A new part number (32342701) has been introduced, featuring two-sided tape on one side. Technical Journal 35503.3.0 recommends the use of special super glue (Würth catalogue PN 0893092) to secure the side sections of the gasket to mitigate this issue in the future. Despite these measures, there remains a possibility of failure over time with continued environmental exposure. Consequently, a gap may develop between the end of the plastic bracket and the weather stripping.

When consulting with the dealership, they might refer to this condition as "normal," citing the complexities and risks associated with sunroof removal, which could potentially damage the headliner. It is important to note that water infiltration through this gap will not occur unless the drains are obstructed. The true concern lies in debris entering the track through this gap, potentially causing partial or complete blockage of the drain. In heavy rainstorms, water may accumulate within the track area, resulting in overflow into the vehicle interior, thereby damaging the headliner and causing additional complications.
 

During my search for a solution, I was offended by people selling this simple model to others. So, I bought a new sunroof seal for $100 and used it to design the model shown here. Several sizes are included; if the size isn't right for your installation, scale the model in the Z axis only (assuming you print hole side down) to fit your needs. Note that enlarging will extend the end pin and hollow end, which might make installation harder but won't cause issues.
 

Installation is straightforward. Use a 90º pick to pull back the gasket, allowing room to insert the printed fill piece. Press the piece into the gap, ensuring the upper and lower hooks clip onto the sunroof gasket lip. Use the pick to push the part so the tab inserts into the hollow end of the part. Adjust the gasket so the tab fits into the hollow portion of the seal. With some finesse, everything should lay flat and cover the gap. Be careful not to puncture the car's weather stripping. My pick was blunt from use and age, and I recommend doing the same if purchasing a new tool for this job.
 

Feel free to use this model and share it with other Volvo enthusiasts who might need it. Printing the parts yourself or using an online print shop can be more cost-effective than purchasing them.  I have the design files from Fusion360 as well should someone need a very specific size.  If requested I can post up that custom size.

I have included the PDF of the Technical Journal so that you can provide it to the dealer if you're interested in getting this done through warranty.