Body - Sunroof Water Leaks
No: 76/16/98/NASRef: TIB 76/26/96/US
Cancel TIB 76/08/95/US
Issue: 1
Date: 10/02/98
Early Design Sunroof - Component Compatibility
AFFECTED VEHICLE RANGE:
DISCOVERY (U) Up to TA174805
Up to TA505712
SITUATION:
EARLY DESIGN SUNROOF COMPONENT FITMENT
Continuing improvements to sunroof design and changes to component configuration may require the use of spacers to ensure proper alignment and function of components.
Water ingress is one area where the correct alignment of components is critical. A water leak may be the direct result of combining newer and older components in the same sunroof assembly without the use of the spacers during assembly. The spacers are required to ensure the proper match of new and old designs.
RESOLUTION:
DETERMINE CAUSE OF LEAK AND CORRECT AS REQUIRED
Upon customer complaint of a water leak, test the affected sunroof to identify the source of the leak:
^ Ensure sunroof is fully closed
^ Run water over the sunroof area to determine the location of the water ingress.
When the source of the leak has been determined, follow the procedures outlined in this TIB to ensure that the components are correctly matched and spaced to rectify the leakage.
PARTS INFORMATION:
STC3194 Spacers (4 spacers per kit)
Use 2 or 4 spacers to perform repairs as required and outlined below.
WARRANTY CLAIMS:
NOTE:
THIS TIB IS INFORMATIONAL. THE INFORMATION AND PARTS INSPECTION PROCESS OUTLINED ARE PART OF REPAIR PROCEDURES PERFORMED DURING NORMAL SUNROOF SERVICING
FAULT CODE: N
Normal warranty policy and procedures apply
REPAIR PROCEDURE:
INSPECT SUNROOF FOR COMPONENT CONTENT
1. Refer to TIB 76/26/96/US and verify that:
^ The proper gasket is in position.
^ Thin spacers (STC2991) have been installed under the roof glass.
2. Perform repairs as required in TIB 76/26/96/US.
COMPONENT COMPATIBILITY VERIFICATION
NOTE:
Whenever new components are installed in a sunroof assembly it is vital to ensure that the installed components are fitted with the correct spacers to adapt them to the surrounding parts as outlined below.
Following the improvements to the sunroof, lower tray (STC1686) and the guide tube assembly (STC1683), a spacer kit (STC3194) will be required if either the sunroof lower tray or the guide tube assembly is independently changed in vehicles prior to VIN TA174805 or TA505712
1. When replacing either the sunroof tray or the guide tube assembly, inspect the parts to identify which configuration is in the vehicle. Refer to Figures 1, 2, 3, and 4.
NOTE:
A late design guide tube. (Figure 1) does not require installation of spacers.
2. When fitting the modified lower tray to the unmodified early design guide tube (Figure 2) install two spacers from kit STC3194 on the guide tube as follows:
^ Gently lift the guide tube assembly off the two locating pegs on the upper frame to gain clearance.
^ Insert the spacers over the two inboard holes as indicated in Figure 2.
^ Reseat the guide tube assembly.
NOTE:
The later design lower tray has a 'U' shaped impression around the corner hole. (Figure 3)
3. When fitting a late design guide tube assembly to an unmodified early design lower tray, fit four spacers to the inside of the lower tray as follows:
^ Identify tray as early design without "U" shaped impressions. (Figure 4)
^ Position four spacers on the inside of the lower tray. (Figure 5)
^ Install the tray with spacers in place.