Section C:Top Sealing

As mentioned earlier in this information, some water entering is considered normal. For example, water running down the inside of the door glass is permissible providing it does not run over the top edge of the inner door panel onto vertical surfaces.

Attempts to repair water leaks in areas where the door glass meets the top seals must first be carried out by moving or shimming seals as necessary at the windshield frame and Cabrio top frame. Adjustments to the door glass mechanism should only be made if moving or shimming seals fails to produce satisfactory results.

Figure O:

Proceed as follows:

1. Concern: "A" pillar top joint: The seal flap (arrow, Figure O) folds over when closing the door.

Figure P:

Correction: Pull the windshield frame seal out at the upper corner. Feel behind the seal joint to locate an opening in the back of the seal. Insert a length of rubber piping (or roll a small length of one-sided adhesive foam into a tubular shape) into the opening of the seal (Figure P). A light application of petroleum jelly will ease installation of the rubber insert. Close the door to check the position of the seal flap. When the proper position is reached, re-glue the windshield frame seal to the windshield frame.

Figure Q:

2. Concern: Front lower corner joint - water entering at corner of vent wing (Figure Q).

Correction: Use the same technique as with the "A" pillar top joint (Concern 1). See Figure Q for location of the hole in back side of seal.

Figure R:

3. Concern: Top side rail seal and top rear rail seal: Alignment of seal ends and position of the seal relative to the door window glass.

Correction: to obtain proper positioning, the seals can be shimmed (arrows, Figure R) using flat washers of appropriate thickness between the top frame and seal. The maximum shim thickness should not exceed 4 mm. Also, the foam rubber between the top frame and seal must be installed.

Figure S:

To prevent possible water entry into the area of foam rubber, apply flexible sealing putty between the top frame and seal (Figure S) on the outside. The joints that form where the top rail and rear rail seals come together need not match in profile. They must, however, come together to form a seal.

Figure T:

4. Concern: Insufficient tension of hollow tube seal to body. (Excess water may run on windshield seal.)

Correction: Locally obtain approximately 5 ft. (1.5 m) of 5 mm O.D. (1 mm wall) plastic tubing. If the end piece of the seal is molded one-piece to the hollow tube seal, carefully cut the seal at the passenger side and install plastic tube into hollow seal (Figure T). Work the plastic tube across fully to the other side end piece. Reseal the opening using instant bonder.

Some seals have separate end pieces glued to the hollow tube seal. This type seal allows for easy removal and reinstallation of the end piece without cutting.

Figure U:

Figure V:

5. Concern: Additional support may be required for the front lower corner joint seal on the door and for the "B" pillar base seal.

Parts required:
PN 911 505 311 00, Rubber Pad (qty. 4).

Correction: Partially remove the rubber seal exposing the opening beneath it (arrows, Figures U & V). Use shears or scissors to cut the rubber pad (PN 911 505 311 00) to the approximate shape of the opening. Leave the rubber pad slightly oversized to help support it over the opening. Use weatherstrip adhesive to glue the rubber pad into place and reinstall the rubber seal over the pad. Reglue the rubber seal to the support and to the body.



6. Door Seal: If water accumulates in the door and drains when the door is opened, cut out small areas of the door seal (arrow 2) to allow for free flow of water from the drain holes in the lower edge of the door shell. (A new seal has been introduced in production.)