Repair Procedures

1. Header Seal Repair Procedure (Up to VIN 1F_8V016303)





Verify that header seal retainer (seal guides) is not damaged.

^ If damaged, replace header seal. See Repair Manual, Body Exterior Group 61 - Windshield Frame Seal in ElsaWeb.





^ If rubber strip is separated from retainer, re-attach using 3M(TM) adhesive Part No: 3M 08011.





Remove all dirt and debris from seal and windshield frame.

^ Apply general purpose cleaner Part No: D00940104 to clean cloth.

TIP:

DO NOT use silicone products as a cleaning alternative.

^ Using a Trim Removal Wedge Part No: 3409 separate the seal from windshield frame and clean area.





^ Cross-sectional view -top- of Application OK adhesive location.

^ Cross-sectional view -bottom- of Application NOK adhesive location.





^ Observe the lower lip of the seal.

NOTE:
Adhesive -arrows- must be applied to windshield frame (from A-Pillar to A-Pillar) above seal lower lip mating surface and over top of seal guide holes.





^ Apply protective tape across top of header bar prior to adhesive application.

^ Insert Dispenser tip 3-4 mm below header bar upper surface.

^ Using Dispenser Part No: VAG 1628, apply a 3 mm bead of 3M adhesive Part No: 3M 08690 to entire length of windshield frame (A-Pillar to A-Pillar).

TIP:

For easy application, apply adhesive at temperatures approximately 75°F. In cold climate areas let vehicle stay over night indoors.

^ Remove protective tape.

^ Remove any excess adhesive with general purpose cleaner Part No: D00940104 and a clean cloth.

^ Recap adhesive tube and preserve for future use.





^ Secure seal to windshield frame at the A-Pillars.

^ Begin by attaching tape to seal and wrap toward front of vehicle.





^ Secure tape to windshield frame.

^ Close the roof and leave to dry for minimum one hour at 80°F. Allow for increased sealant dry time in colder temperatures.

^ Remove tape from both sides of windshield frame.

TIP:

To prevent seal separation from windshield frame, peel tape away from seal and pull toward front of vehicle.

^ Adhesive requires an additional cure time of 3 hours at 70°F.

TIP:

If customer is to pickup vehicle during cure time, advise customer to not operate roof for 3 hours.

^ Go to 2. Sunroof Drain Hose Repair Procedure.

2. Sunroof Drain Hose Repair Procedure (All 2007, 2008 vehicles)





Water leaks can occur at sunroof drain hose(s) connection - arrow-

Inspect sunroof drain hose for presence of adhesive at connection -arrow-

If adhesive is NOT present, proceed with repair.





^ Detach drain hose -arrow-

^ Dry surfaces with a clean rag.





^ Apply 3M 08690 urethane adhesive to drain hose -arrow-





1. Install hose as shown -arrows- with hose clip in lower hole.

2. Allow to dry for 3 hours at 70 degrees F.

Go to 3. Header Seal Modification at Side Bar.

3. Header Seal Modification at Side Bar (Up to VIN 1F_8V016303)





^ Build up header seal to side bar seal mating surface (both sides) with a 50 mm length of hose Part No. 1JM133001, placed under header seal cutout area.

^ Perform 4. Repair Verification.

4. Repair Verification

^ After required cure time, lightly pull on header seal to confirm adhesion.

^ Use water hose with spray nozzle to perform water test on each side of vehicle for three minutes.