Sunroof - Water Entering Through Map Light Area
NUMBER: 12-68-00DATE: 06/02/00
APPLICABILITY:
2000 MY Legacy Vehicles
SUBJECT:
Water Entering the Map Light Area
If you have a situation where water is entering the vehicle through the front map light area of the interior panel, then this bulletin will help identify the source of the water entry. While this condition has mainly been noticed in the 2000 MY Legacy Outback with dual sunroof, there are also cases of 1999 MY Legacy sedans with the same type of leak. The actual condition is not a sunroof condition but a seam sealer void on the painted surface of the vehicle. Water could take up to two hours or more to migrate to the map light area.
The new style sunroof has a dedicated drain track making it impossible for water to migrate under it to the center roof area. The sunroof is not designed to be 100% watertight. Some minor leakage will occur through the seal; insure that all dams and channels are in proper working order (not bent or misdirected) to guide the water to the ground through the drains.
Equipment Needed:
1. Flashlight
2. Mirror
3. 3M UL Trapro Autobody Sealant (P/N 05113508301) or equivalent
4. Primer
5. Touch-up Paint
CHECKING PROCEDURE:
1. Verify that there is water in the front map light. If there is water leaking in a different location, another type of leak is the cause.
2. Open the rear sunroof to the full open position.
3. If necessary, remove or slide back the roof rack cross bar.
4. Open both the rear doors for easy entry and the best possible view. Caution should be taken so the customer's seats are not soiled or damaged.
5. While positioning yourself on the rear seat with your head in the sunroof opening, inspect the painted surfaces on the left and right sides of the sunroof opening. Use the flashlight and mirror if necessary to check the areas that are difficult to observe.
6. Most of the leaks have been in the left front corner of the rear sunroof, but the entire rear opening should be checked where there is overlapping metal that should be sealed with seam sealer. The sunroof glass gasket would cover the painted area you should be looking at if the sunroof glass was closed on the rear opening. All painted seams must be inspected for the absence of seam sealer, a crack in the paint, or a small pinhole in the painted surface.
7. What you are looking for is a very small line where the metal panels were folded and there is sealer missing from the edge of the painted metal. It may be necessary to look at an upward angle from the rear seat area. The roof panel is the top panel folded (bent) in a downward position; the seam area under this metal could be void of any sealer.
8. If a crack or sealer void is found in the rear sunroof opening it should be sealed with the body sealer listed in this bulletin, painted, then water tested extensively. The water in the map light area should be blown out, which is done by removing only the front map light, so that any residual water will not drip on the customer. At this time the repair would be complete.
9. If this did not repair the leak then further inspection of all sunroof opening seams (front & rear) will be necessary, including under the front sunroof.
10. If you are checking the drains, the rear sunroof has two drains. There is one in each corner of the rear opening. It will be necessary to use something to split the drain area in half, such as a rag. Check the front drain on one side; then the rear by pouring water in each half while checking the drain rate. The front sunroof has one drain in the front that T's into the front drain of the rear sunroof under the headliner.
11. A blocked or restricted drain would cause water to overflow the drain channel and overflow into the passenger compartment, (not in the map light).
REPAIR PROCEDURE:
1. When you have found the sealer void location, clean this area of all dirt and grease. Make sure what you use for a cleaning agent, will not damage the painted surface.
2. Application of 3M ULTRAPRO Autobody Sealant (part number 05113508301) in a small quantity will be used to seal the void area. Only seal the suspected leak point, too much sealer buildup can create additional leaks by holding the glass up or not allowing the gasket to seal flat against its mated surface.
3. There should be no sealant added to the area under the center portion of the gasket that separates the two sunroof glasses. This would raise the gasket height and glass allowing excess water to enter the drains.
4. To smooth out the sealant, you will need to put a small amount of water on your finger and wipe the sealant. Each time you want to wipe the sealant, your finger needs to be wet or it will not smooth out properly.
5. After the sealant has dried, apply a small amount of primer to the sealant then use the body touch up paint to match the paint color of the body.
6. The map light should be removed and air blown throughout this area to dry any water that is present from the previous leak. CAUTION:The center map light screws are longer than the front screws and will cause roof panel damage if not replaced in their original holes.
7. If the sunroof glass was removed for any reason, let it seek its own center position by closing it before tightening the nuts. Then, if necessary, gently push it in the desired direction to slow down any water infiltrating past the seal. If a gurgling sound is heard, too much water is getting past the glass seal.
8. A water test of at least two hours will is advised, but this test can be done without a technician manually operating the hose for that period of time.
For vehicles within the Basic New Car Warranty period, this repair may be claimed using the table as shown.
DISCLAIMER