Body - Sunroof Drains

VOLUME
2

GROUP
Body

NUMBER
019

MODEL
Optima

DATE
August 2001

SUBJECT
Optima Sunroof Drains

This bulletin provides information related to the repair of 2001 Optimas with water leak complaints. If water or dampness is present at the rear foot well(s), rear seat(s) or C-pillar trim(s), then one or both rear sunroof drain tubes may be pinched between the headliner and roof.





To correct the condition, use the repair procedure described in this bulletin.


REPAIR PROCEDURE:




1. Remove both C-pillar trim panels.




2. Remove three headliner trim clips (push-in type).




3. Remove both rear passenger assist handles at headliner.




4. Slightly pull down rear section of headliner; a styrofoam spacer block will be visible at the rear corner of the headliner. Using a steady pressure push the styrofoam spacer block away from the headliner, until block releases from headliner, use care to not break styrofoam block.




4a. Remove styrofoam spacer block from headliner and set aside. Do not remove adhesive residue from foam block.




5. After removing right side styrofoam spacer block, slightly pull down rear section of headliner. Reach between headliner and roof, locate sunroof drain tube. Simultaneously squeeze drain tube hose clamp and pull drain tube off sunroof drain port.




6. Pull drain tube outside of headliner.

7. Insert four inch length of stainless steel spring into rear drain tube; spring must be positioned in drain tube where pinching occurred.








8. Re-install drain tube onto the right side headliner drain port.




9. Locate styrofoam spacer block removed in step 4. Place styrofoam block on suitable work surface. Measure 1 9/16 inch from the inboard side of the foam spacer block. Draw a line at this location.




10. Using a combination square or similar tool continue the line drawn in step 9.




11. Measure 1/2 inch on both sides of the line drawn in step 10. Draw a reference line for cutting.




12. Using the lines drawn in steps 10 and 11 as a guide, cut a V-shaped groove into the styrofoam spacer block.




13. The cut V-groove should measure approximately one inch across its widest portion.




14. Reinstall styrofoam spacer block onto headliner (adhesive residue on block and headliner will hold spacer block in position). Make sure C-pillar trim clip mounting hole is not covered.

15. Repeat steps 4 through 14 for left side drain tube.




16. To reinstall the headliner, hold headliner up to the roof, secure it in place using the three push-in type trim clips. Verify both rear sunroof drain tubes are properly located into the spacer block V-grooves.




17. Reinstall both C-pillar trim panels.




18. Reinstall both rear passenger assist handles.

19. To verify the tubes are functioning properly, park the car on a level surface. Slightly open the sunroof, only enough to break the seal between the sunroof glass and weather-strip. Use a garden hose or its equivalent; spray a small amount of water onto the rear portion of the sunroof. Water should drip from both rear wheel wells, indicating the sunroof drain tubes are unrestricted.

AFFECTED PRODUCTION RANGE:
2001 Optimas with production dates prior to 3/8/01.

PART NUMBER INFORMATION:




WARRANTY CLAIM INFORMATION: