Water Leaks Onto Headliner - Sunroof Drain/Module (98-T-48)

SUNROOF HOUSING FRONT DRAIN HOSES ALL MODELS

Most likely cause of an obstruction may be the front sunroof housing drain hose(s) pinched by the cockpit attachment bolts during assembly.

1. Open sunroof glass to the full open position.
2. Using a standard measuring cup, pour two cups of water directly into the sunroof housing front drain hole. The water should be able to be poured into the sunroof housing front drain hole in under 60-80 seconds without water collecting along the sunroof housing drain channel and spilling over into the vehicle. Repeat this procedure for the other sunroof housing front drain hole.
   • If water pours through each sunroof housing drain in under 60-80 seconds refer to REAR SUNROOF HOUSING DRAIN HOSES-SEDANS  , or REAR SUNROOF HOUSING DRAIN HOSES-COUPES  sections or go to the SUNROOF MODULE SEALER-ALL MODELS  section in this bulletin.
   • If water does not pour through each sunroof housing drain hole in under 60-80 seconds proceed to the next step.
3. Using a standard air gun, limited to 207 kPa (30 psi), blow into the sunroof housing front drain hole(s) with the obstruction and attempt to clear the obstruction.
4. Water test again, using a standard measuring cup, pour two cups of water directly into the sunroof housing front drain hole that was obstructed. The water should be able to be poured into the sunroof housing front drain hole in under 60-80 seconds without water collecting along the sunroof housing drain channel and spilling over into the vehicle. Repeat this procedure for the other sunroof housing front drain hole if it was also obstructed.
   • If water pours through the sunroof housing front drain hole(s) in under 60-80 seconds, obstruction has been removed.
   • If water still does not pour through each sunroof housing front drain hole in under 60-80 seconds, proceed to the next step.
5. Replace sunroof housing front drain hose(s) with new sunroof housing front drain hose(s) (P/N 21052828) and new sunroof housing drain hose clamp (P/N 01626260). (Refer to "Front Drain Hose Grommet" in the "Vehicle Interior Systems" section of the appropriate year Body/Repair Service Manual.)

REAR SUNROOF HOUSING DRAIN HOSES-SEDANS

1. Remove the roof rear panel assemblies (rear roof appliques) from the left and right side of the vehicle. (Refer to "Panel-Roof Rear Outer-Sedan" in the "Roof, Rocker Panels and Attaching Components" section of the appropriate year Body/Repair Service Manual.)
2. Remove the quarter outer panel hole plugs on the left and right side of the vehicle. (Quarter outer panel hole plugs are located under the rear of the roof rear panel assembly.) See Fig 1 .
3. Inspect both sunroof housing rear drain hoses through the quarter outer panel holes to determine if they are kinked. (The sunroof housing rear drain hose(s) may have been kinked by the installation of the sunroof housing rear drain hose grommet(s), which are located below body plug.
   • If either of the sunroof housing rear drain hoses are kinked, remove the kinked sunroof housing rear drain hose(s) and replace with a new sunroof housing rear drain hose(s) (P/N 21052849) and sunroof housing drain hose clamp(s) (P/N 01626260). (Refer to "Rear Drain Hose Grommet-Sedan" in the "Vehicle Interior Systems" section of the appropriate year Body/Repair Service Manual.)
   • If neither of the sunroof housing rear drain hoses are kinked, remove each sunroof housing rear drain hose from the sunroof housing and proceed to the next step.
4. Using a standard air gun, limited to 207 kPa (30 psi), blow into the sunroof housing rear drain hole(s) with the obstruction and attempt to clear the obstruction.
   • If air flows freely through both sunroof housing rear drain hoses, there is no obstruction. Reattach sunroof housing rear drain hoses and refer to in this bulletin.
   • If at first air does not flow freely through either of the sunroof housing rear drain hoses, then starts to flow freely, obstruction has been removed. Reattach sunroof housing rear drain hoses.
   • If air does not flow freely through either of the sunroof housing rear drain hoses and obstruction cannot be removed, replace sunroof housing rear drain hose(s) with new sunroof housing rear drain hose(s) (P/N 21052849). (Refer to "Rear Drain Hose Grommet -Sedan" in the "Vehicle Interior Systems" section of the appropriate year Body/Repair Service Manual.)

Fig 1: Quarter Outer Panel Hole Plugs

REAR SUNROOF HOUSING DRAIN HOSES-COUPES

1. Remove headliner from vehicle. (Refer to "Headliner" removal procedure in the "Vehicle Interior Systems" section of the appropriate year Body/Repair Service Manual.)
2. Raise the front of the vehicle so all water flows to the rear of the sunroof housing.
3. Water test the vehicle with the sunroof closed. (Refer to "Waterleaks" in the "General Information" section of the appropriate year Body/Repair Service Manual.)
   • If water runs over the rear portion of the sunroof module during the water test, remove the sunroof housing rear drain hoses from the vehicle and proceed to Step 4.
   • If water does not run over the rear portion of the sunroof module during the test, proceed to SUNROOF MODULE SEALER-ALL MODELS  in this bulletin.
4. Using a standard air gun, limited to 207 kPa (30 psi), blow into the sunroof housing rear drain hoses to dislodge any possible obstructions.
5. Reattach sunroof housing rear drain hoses to sunroof housing and water test the vehicle again.
   • If water runs over the rear portion of the sunroof module during the water test, proceed to Step 6.
   • If water does not run over the rear portion of the sunroof housing during the water test, the obstruction has been removed. Install headliner to vehicle. (Refer to "Headliner" installation procedure in the "Vehicle Interior Systems" section of the appropriate year Body/Repair Service Manual.)
6. Replace the sunroof housing rear drain hoses with new sunroof housing rear drain hoses (P/N 21052828) and sunroof housing drain hose clamp(s) (P/N 01626260). (Refer to "Rear Drain Hose Grommet-Coupe" in the "Vehicle Interior Systems" section of the appropriate year Body/Repair Service Manual.)

SUNROOF MODULE SEALER-ALL MODELS

1. With headliner removed from previous leak detection, inspect butyl sealer that is placed around copper drive cable tubes as they exit the front of the module for water leaks. If the water leak occurs from this area, use a thumb-grade butyl to add to the area until the leak is corrected. See Fig 2 .
2. Inspect for leakage where the sides of the sunroof module are joined to the front of the module. Inspect for cracked module. If no cracks are present, apply a bead of Kent Industries Quik Leak Check, P/N 10510 (or equivalent) as shown in Fig 3 . If cracks are present, replace module.

Fig 2: Copper Drive Cable Tube