Repairing and Sealing Sunroof
Minor repairs (i.e. lid adjustment, sealer strip replacement) will address the majority of complaints. More extensive repairs (i.e. blocked drain tubes, leaks between frame/tray) which would necessitate removing the vehicle headliner require prior authorization from your RSM.
CAUTION:
The procedure outlined in this bulletin supersedes the procedure published in TP 30803/1 regarding sunroof frame removal. The frame is not to be removed through the sunroof opening. It may only be removed from the bottom. Control mechanisms and drive cables are available separately eliminating frame replacement for these items. Removing/installing the frame through the roof opening can result in leakage into the tray area after reassembly.
This bulletin is applicable to the following vehicles with chassis numbers up to and including:
744 - 159020
745- 98644 The sunroof system has been changed on
764- 30573 vehicles after these chassis numbers.
765- 13700
REQUIRED PARTS: Description Part No. Quantity
Strip caulk 277253-1 2 x 1200 mm
1 x 550 mm
2 x 200 mm
Butyl tape 1342927-9 200 mm
Rear seal (white foam) 1334381-9 1 (sedan only)
Rear seal, center (white foam) 1355689-9 1 (wagon only)
Side seal, short (white foam) 1355688-1 2 (wagon only)
Clips 1334115-1 2
Two-sided adhesive tape 1160600-1
Windshield sealant 3M 08513
(ref. 245 SB 84-108)
SPECIAL TOOLS:
Heat Gun
Stiff cable
(i.e. P-20 hood cable)
Pump applicator with a
flatpointed nozzle 210163-2
Supports (wooden clamps) see page: 8
NOTE: Surgical gloves will avoid excessive cleanup, fingerprints, etc. from headliner.
DIAGNOSTIC CHECKS 1 TO 4; OP. # 836323
The following 4 checks must be performed on all vehicles to properly diagnose the extent of needed sunroof repairs. Proceed in the recommended sequence below before starting any repair.
1. Visually check adjustment and operation of sunroof. If adjustment is needed, proceed with remaining checks and perform all necessary repairs before adjusting. The adjustment of the sunroof is the final step. Sunroof adjustment, see pages 15-16.
2. Check that the lid seal is correctly installed and not damaged. If adjustment or replacement of seal is needed, perform labor operations 836103, 836314. See pages 4-5.
3. Check drain tubes to ensure that they are not kinked or blocked by inserting a stiff cable or a rubber hose (i.e. P-20 hood cable) into each drain tube. If drain tubes are clear and the routing is OK, proceed to check #4. If, however, it is difficult to insert, the drain hoses must be cleared and routing must be corrected.
NOTE: Contact your RSM before proceeding; check four can then be performed while the headliner is removed.
4. With sunroof removed or in vent position, pour soapy water onto rear cross gutter and check that rear cross gutter, side gutters, and hoses drain properly. If needed, adjust gutter. See page 12.
Perform any repairs indicated by the results of the 4 diagnostic tests, except for drain tube rerouting. If drain tube rerouting is indicated, or no faults were found, contact your RSM before proceeding to sunroof frame resealing.
NOTE: With the lid removed, a leak between the frame and tray can be verified as follows:
- Plug the rear drain pipes.
- Pour water into side gutters.
- using a flashlight, look between the roof and the tray. If leak is not immediately apparent, let car sit at least 20 minutes to allow for any seepage which may be occuring to appear.
There should not be any leakage into tray area. If there is, the frame must be resealed. If drain tubes were not open (as in step #3 above), drain tubes must be properly routed. Use operation 836312. See pages 4-16.
Be prepared to provide your RSM with complete details of current and previous repairs if it is necessary to move to this stage.