Sunroof - Water Leaks Onto Headliner: Overview
BULLETIN NO.: 99-T-35AISSUE DATE: May, 2000
GROUP/SEQ. NO: Body-11
CORPORATION NO.: 99-08-57-020A
SUBJECT:
Water Leaks onto Headliner (Inspect and/or Repair Sunroof Module Drain Hoses, Open End of Front Drain Hose Grommets, and/or Reseal Various Locations on Sunroof Module)
Due to changes under MODELS AFFECTED and PROCEDURE, this bulletin is being revised and supercedes bulletins 99-T-35 and 98-T-48, which should both be discarded.
MODELS AFFECTED:
1996 - 2001 Saturn S-Series Sedans and 1997 - 2001 Saturn S-Series Coupes with sunroof option (RPO CF5)
CONDITION:
Water leaks onto headliner, causing possible water stain on headliner.
CAUSE:
1. Sunroof front and/or rear drain hose connections loose at sunroof module.
2. Front drain hose pinched by roof panel attachment bolts and/or rear drain hose kinked due to assembly of the grommet to the hose on vehicles built before and including VIN WZ246268.
3. Grommets at lower end of sunroof module front drain hoses may be obstructed by debris and/or be too restrictive on vehicles built before and including VIN XZ301802.
4. Void(s) in body seam sealer used at various locations on sunroof module.
CORRECTION:
Follow the procedures in this bulletin to diagnose and repair water leak(s) as required.
PROCEDURE
General Diagnostic Information - All Models
IMPORTANT:
Before removing any vehicle components, thoroughly water test vehicle to determine if leak is originating at any of the follow areas:
^ Front windshield
^ Rear glass
^ Door openings
IMPORTANT:
If customer reports vehicle is parked on an incline when water leak occurs, all water leak diagnosis should include raising end of vehicle that is "up" when customer parks on an incline. Raise one end of vehicle to simulate incline under which water leak occurs.
1. Refer to "Windnoise/Waterleak Customer Diagnosis Form," in the General Information section of the Body/Repair service manual (1996-1999) or Windnoise/Waterleaks/Appearance A section of the Body/Electrical Volume I service manual (2000-2001) and fill out the Customer Comment Worksheet.
2. Remove headliner.
^ On 1996 - 1999 model year vehicles, refer to "Headliner - Coupe" or "Headliner - Sedan" removal procedure in the Vehicle Interior Systems section of the appropriate model year Body/Repair service manual.
^ On 2000 - 2001 model year vehicles, refer to "Headliner - Coupe" or "Headliner - Sedan" removal procedure in the Interior Trim section of the appropriate model year S-Series Body/Electrical Volume II Service Manual.
3. Water test vehicle in the water leak location described by the customer. (Refer to "Waterleaks" in the General Information section of the appropriate model year Body/Repair service manual [1996-1999] or Windnoise/Waterleaks/Appearance section of Body/Electrical Vol. I service manual [2000-2001].)
^ If water leak occurs in front area of sunroof module, refer to "Sunroof Drain Hose Clamps," "Sunroof Housing Front Drain Hoses," Sunroof Module Front Drain Hose Grommets," and "Reseal Front of Sunroof Module" in this bulletin.
^ If water leak occurs in rear area of sunroof module, refer to "Sunroof Drain Hose Clamps," "Sunroof Housing Rear Drain Hoses," and "Reseal Rear of Sunroof Module" in this bulletin.
^ If water leak occurs in any area(s) other than the headliner, refer to "Diagnosis and Repair" under Water Leaks in the General Information section of the appropriate model year Body/Repair service manual.
4. Once water leak has been repaired, install headliner.
^ On 1996 - 1999 model year vehicles, refer to "Headliner - Coupe" or "Headliner - Sedan" installation procedure in the Vehicle Interior Systems section of the appropriate model year Body/Repair service manual.
^ On 2000 - 2001 model year vehicles, refer to "Headliner - Coupe" or "Headliner - Sedan" installation procedure in the Interior Trim section of the appropriate model year S-Series Body/Electrical Volume II Service Manual.
Sunroof Module Drain Hose Clamps - All Models
A water leak at sunroof module drain hose locations where they attach to sunroof module can be identified by watching around edges of sunroof module from inside vehicle while water test stand is running. Allow ample time when water testing for water leak to occur.
^ If water leaks between the hose and sunroof module drain, refer to the following procedure.
^ If water is not leaking between hose and sunroof module drain, refer to the other procedures in this bulletin.
1. Inspect for clamps on all drain hoses of sunroof module.
^ If sunroof module drain hose clamps are present, tighten clamps and retest for water leak.
^ If sunroof module drain hose clamps are not present, continue to next step.
2. Remove all drain hoses from sunroof module.
3. Feed sunroof module drain hose clamps (P/N 01626260) onto hoses.
4. Push hoses back onto sunroof module so that they fully seat.
5. Tighten clamps.
Left front shown. Others similar.
6. Water test vehicle in sunroof module area.
PARTS INFORMATION
CLAIM INFORMATION:
To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System as shown.
IMPORTANT:
Claims for the specified sealing material will be reimbursed in the following amounts:
Seal Rear of Sunroof Module - Seam Sealer - Retailer Cost of $2.00 x 30% $2.60
Seal Front of Sunroof Module - Seam Sealer - Retailer Cost of $2.00 x 30% = $2.60
Seal N ' Caulk - Retailer Cost of $0.21 x 30% = $0.27
It will be necessary to sell sealer and caulk to the CSO as material, using net item code "M." Claims exceeding the above amounts will be returned to the Retailer with reason 143 - material amount greater than maximum allowed.