Repair Procedure

Regardless of where the water is leaking, perform steps 1 through 24 on both sides of the car, then proceed to step 33.

1. Open the door and lower the window.

2. Remove the mounting screw at the top of the quarter glass window frame.





3. Carefully remove the glass run channel from the front of the quarter glass window frame, and from the front window guide.



4. Using channel lock type pliers, carefully pinch the front glass guide to a uniform width of 13 mm.

NOTE:





Wrap the jaws of the pliers about four or five times with duct tape to avoid damaging the front glass guide.






5. Apply 3M Ultrapro Auto Body Sealant-Clear (P/N 051135-08302) to the top edge of the quarter glass window frame as shown.



6. Spray the outside edge of the quarter glass window frame with silicone to help in reinstallation of the glass run channel.

NOTE:
Avoid spraying silicone on the top edge of the frame.

7. Carefully reinstall the glass run channel by installing the inside edge first, then roll the outside edge into the channel.





8. Install the mounting screw, then apply 3M Ultrapro Auto Body Sealant-Clear (P/N 051135-08302) to the upper outside edge of the glass run channel as shown. Remove any excess sealer with 3M General Purpose Adhesive Cleaner (P/N 051135-08984) on a shop towel.



9. Pull the door glass side of the glass run channel out of the front glass guide.






10. Cut a piece of EPT Sealer 3T to an approximate length of 6 x 400 mm. Apply the EPT to the outside edge of the glass run channel as shown; then reinstall the run channel into the front glass guide.



NOTE:
Make sure that the EPT is not sticking out of the front glass guide after installing the glass run channel.





11. Roll up the window, and check that the top of the door glass pushes up on the run channel rubber approximately 1 - 2 mm when the window stops.






12. If necessary, adjust the window glass height. Roll the window down completely, then unlock the front and rear stopper plates. Turn both of the stopper plate adjustments equally, one full turn counterclockwise, to move the window up 1-2 mm.






13. For del Sol S models below VIN 003394 and del Sol Si models below VIN 004060, inspect the A pillar weatherstrip for a drain hole in the drip rail area.



14. If there is no drain hole, drill a hole using a modified feed pipe (P/N 22722-PF4-000). Modify the feed pipe by using a medium grit grinding wheel to grind the tip to a 60-degree angle.






15. Place the modified feed pipe in the drip rail channel approximately 1 mm behind the molded bump. Using light pressure, spin the feed pipe back-and-forth between your hands until a hole is made through the outside portion of the A pillar weatherstrip.






16. Check that the roof side seal and A pillar weatherstrip are flush at their mating surfaces. If the roof side seal is not flush with the A pillar weatherstrip, adjust the roof side seal.



17. Unlock the roof, and lift up the front edge of the roof. Place a shop towel between the roof and A pillar weatherstrip to support the roof.






18. Adjust the roof side seal by bending its metal core in or out to obtain a flush fit with the A pillar weatherstrip. Remove the shop towel, a check the fit.






19. Once a flush fit is obtained, place the shop towel back under the roof at the A pillar weatherstrip. Pull down on the top edge of the roof side seal; then apply a 50 mm long bead of 3M Ultrapro Auto Body Sealant-Clear (P/N 051135-08302) under the side seal along the top edge.






20. Apply sealant into the gap on the end of the roof side seal as shown; then remove the shop towel from the front of the roof.






21. Raise the rear of the roof, and insert a bent screwdriver into the hole at the end of the roof side seal. Push the existing soft plug up to create space.






22. Cut a piece of EPT Sealer 10T to an approximate size of 10 x 15 mm to form a soft plug.






23. Insert the soft plug into the roof side seal as shown.






24. Lock the roof, and check the outside of the seal. The additional soft plug should create a rise in the outside surface of the roof side seal of 1-1.5 mm.



NOTE:
If the water was leaking from above the sunvisor area in the initial leak test, continue to step 25. If the area above the sunvisor was not leaking, proceed to step 33.

25. Remove the roof, and store it in the trunk.

26. Remove the round clips from the top and bottom of the A pillar weatherstrip on both sides, with a clip removing tool.





27. Remove the two screws on both sides; then remove the A pillar weatherstrip.



[NOTICE]
The A pillar weatherstrip has a metal core. Remove it carefully to avoid scratching the paint.

28. Remove all traces of the old sealer from the A pillar and weatherstrip with 3M General Purpose Adhesive Cleaner (P/N 051135- 08984) and a shop towel.






29. Apply 3M Ultrapro Auto Body Sealant-Clear (P/N 051135-08302) along the roof molding as shown, and down the full length of the A pillar.






Be sure the sealant is on the inside and outside flanges of the roof molding.



30. Press the weatherstrip into position, and allow the sealant to set.





31. Apply 3M Weatherstrip Adhesive (P/N 051135-08011) to the underside of the weatherstrip as shown.

NOTE:
This application of weatherstrip adhesive is not necessary for a new replacement A pillar weatherstrip.



32. Reinstall the screws and clips on each side of the weatherstrip.






33. Reinstall the roof, roll up the windows and close the doors; then water test the area to check for leaks in the following areas:

^ Where the A pillar weatherstrip contacts the roof side seal. Proceed to step 34 if leaking.






^ Where the top of the glass run channel meets the A pillar weatherstrip. Proceed to step 37 if leaking.



^ If no leak is found, the car is repaired.






34. Unlock the roof, and adjust the roof side seal by bending its metal core in and forward to increase the seal tension.



35. Lock the roof down, and water test the area to check for water leaks.

36. If the leak persists, inspect the A pillar weatherstrip and the roof side seal. Replace as necessary, and reseal as outlined in this service bulletin. Retest the area for water leaks.





37. Place pieces of masking tape on the top edges of the glass run channel and the roof. Make reference marks on both pieces of tape with a pencil as shown.






38. Open the door, and place a 4-inch piece of wood on top of the striker; then carefully close the door until it touches the wood.






39. Measure and record the distance from reference mark to reference mark.






40. Adjust the window camber inward 1 mm from the measured distance by carefully bending the quarter glass frame. Sit in the seat, and support the inside of the door with your knee; then pull the top of the quarter glass window frame toward you with firm, slow pressure.



41. Re-position the wooden block on the striker, and measure the distance. The distance should be 1 mm less than the original measurement.

42. Once the distance is correct, water test the area to check for leaks.