Body - Water Leak From Sunroof
NUMBER: 07-67-12DATE: 08/14/12
APPLICABILITY:
2009-2011MY Forester
SUBJECT:
Water Leak From Sunroof
INTRODUCTION
The purpose of this bulletin is to provide the procedure for sealing the front sunroof guide rail end caps.
COUNTERMEASURE IN PRODUCTION
A countermeasure was incorporated into production after VIN# B*768230
PART INFORMATION
3M brand "Super Silicone Sealant", part number 08662 (3oz. tube), readily available from most auto body supply shops.
SERVICE PROCEDURE / INFORMATION
If you receive a customer concern of water leaking from the sunroof area, there may be excessive sealer between the end cap and guide rail causing a restriction of water flow to the front drains. This restriction can allow water to collect and eventually, leak into the passenger compartment.
For improved access to the front end caps, remove the screws holding the air deflector guides. Protect the front corners of the roof opening from the deflector guides as shown.
Carefully trim the excess sealer from around the cap area using a sharp knife (e.g., x-acto hobby knife) or a single-edge razor blade. Make sure you trim the excess sealer away completely. DO NOT rip or tear the excess sealer as you remove it because doing so may disturb the remaining, un-cut sealant and cause the leak to persist.
Once the excess is trimmed away as shown below left, clean the area thoroughly to look like the photo shown below right.
The photo left shows the "wall" formed by excess sealer used with the end cap. Any sealer above the level of the end of the guide rail in the area outlined in red must be trimmed away as it can restrict water flow to the sunroof drains. The photo below right shows how the sealant should look at the end of the guide rail so water can pass freely to the drain up ahead. As specified previously, DO NOT rip or tear the excess sealer as you trim it because doing so may disturb the remaining un-cut sealant and cause the leak to persist.
Once any excess sealer has been removed from above the wall(s), make sure the area is thoroughly cleaned. Using the specified 3M part number 08662 sealer, apply in the area shown then level it out with a straight-edge.
The sealer will cure from the outside in. At conditions of 75 degrees (f) with 50% relative humidity, it will form a tack-free skin after about 20 minutes. A 1/8" thick bead will fully cure in 24 hours. Do not try to work or tool the sealant once the skin begins to form. Cure time is affected by temperature, humidity and thickness of the sealant bead. Higher temperature and/or humidity will shorten cure times while lower temperature and/or humidity will extend it.
Before re-installing the deflector guides, clean the guide rail at the attachment points and apply sealer as shown in the photos below. Torque the deflector guide screws to 8 +/- 1 inch pounds (.9 +/- .2 nM).
Once proper curing of the sealer has been confirmed, position the vehicle with the front lower than the rear so water will flow through the guide rail toward the front cap and drain tube area of the sunroof frame. Carefully run water into the guide rails as shown and verify both front drains operate normally. After approximately 10 minutes, re-inspect for any leaks coming from the inside of the guide rails.
WARRANTY / CLAIM INFORMATION
For vehicles within the Basic New Car Limited Warranty period, this repair may be claimed using the following information:
NOTE:
Up to $5.00 may be claimed in Sublet to cover the cost of the 3M # 08662 silicone sealant.
Disclaimer