Sunroof - Water Leaking Between the Glass
90vw06Subject: Sunroof Drain Hose Installation
Model(s): Fox Sedan, Wagon
Group: 67
Number: 90-02
Date: Jul 31, 1990
Sunroof equipped Fox models which have water leaking between the glass panel and seal require the installation of a water management system, Part No. 302 877 005.
Note
The precise location of the water leak must be determined prior to the installation of the subject kit. Leaks due to missing glass hardware gaskets and/or sealant voids between the roof panel and outer frame will not be corrected by this procedure.
In order to install this system, refer to the following procedure:
^ Remove the sunroof glass panel and the weatherstrip beading.
^ Remove the sunroof latch cover.
^ Carefully remove the glued on headliner from the sunroof frame. Reinforce corners of the headliner cut out with masking tape to avoid tearing.
^ Remove both sun visors and the right side assist grab handle.
^ Remove the fasteners for the sunroof frame. Carefully remove the lower sunroof frame from inside the vehicle.
^ Clean all old sealant from the upper frame.
^ Remove "A" pillar trim (Left & Right) and the hood release lever.
^ Pull back door seals and kick panel carpeting (Both sides).
^ Remove spare wheel, trunk close out panels and the filler neck cover.
^ Measure and cut "A" pillar drain hoses to 1,520 mm (60").
^ Install mechanic's wire through "A" pillars to assist in hose installation. Install "A" pillar drain hoses.
^ Measure and cut "C" pillar drain hoses. Sedan 2,100 mm (82"), Wagon 2,660 mm (104") Install "C" pillar drain hoses.
^ Center punch and drill 13 mm (1/2") holes (left/right) in trunk for drain hose exits as shown.
^ Install tie straps to secure hoses in trunk.
^ Clean and prime hole surfaces, install hoses through holes and seal with silicone.
^ Water check all drain hoses.
^ Install filler neck and trunk close out panels. Install spare wheel.
^ Install kick panel carpeting, hood release lever and door seals.
^ Install "All pillar trim and sun visors.
^ Install "butyl sealant" at latch opening on lower sunroof frame.
^ Install sunroof frame to temporarily rest in opening on headliner.
^ Apply silicone sealant to all four drain tubes in frame and attach all drain hoses to frame.
^ Apply sealant to lower sunroof frame perimeter.
^ Install lower sunroof frame applying sealant to all fasteners.
^ Install headliner to sunroof frame. Install weather strip beading.
^ Install right side assist handle, latch cover and glass panel.