Body - Sunroof Water Leak
NO: 83-34DATE: 9-2-2005
MODEL: XC90 (03-)
M. YEAR: MY03 -
SUBJECT: Water Leak from Sunroof, Fault Tracing and Service.
REFERENCE: VADIS
This Tech Note supersedes the previous 83-34 dated 2-18-05. Please update your files.
Update is to correct an incorrect Labor Op number.
DESCRIPTION:
Several root causes have been found for possible water leakage from the sunroof.
This TNN describes fault tracing and service methods for the most common problems.
FAULT TRACING AND SERVICE:
There can be different symptoms indicating water ingress into the passenger compartment. The fault tracing steps below will cover most commonly known problems. If the leak is not found after going through these steps, continue with normal fault tracing (AC drainage hoses, front windshield, other...). The different checks are in logical order according to ease of the check and number of parts to be disassembled.
Step 1.1 Check front drainage holes (both sides):
Open the sunroof and check the drainage holes
at the left and right front corner from the sunroof
cassette. Both holes should be free of leaves and
dirt.
Service: remove any dirt or debris.
Step 1.2 Check fitting of the sunroof towards the roof:
Sunroof must be in fully closed position.
Checking the vertical position at front end rear edge of the glass panel:
Front edge: The top of the glass must be flush or
maximum 0.04 inch (1 mm) under the roof panel.
(See dimension A).
Rear edge: The top of the glass must be flush or
maximum 0.04 inch (1 mm) above the roof panel.
(See dimension B).
Checking the horizontal position of the glass panel:
The sunroof must be centered in the opening.
Verify that there is even pressure on the seal on
both sides and along front and rear edges of the
glass panel.
This can be done visually and with a piece of
paper (e.g. business card).
Insert card and pull out to feel the pressure between
the seal and the roof plate.
Compare all four sides to determine if the sunroof is
not centered.
Service:
If the sunroof fitting is not according to specification, follow instructions as per VADIS for adjustment. (Function Group 8, Repair and installation instructions, Sunroof, adjusting).
Step 1.3 Check front sound traps in the A-pillar (both sides):
Disassemble A-pillar panels according VADIS.
Pull the rubber sound traps out of the holes in the
front A-pillars and verify that they are open and clear
from debris or dirt.
Verify connection of drainage hose and sound trap.
Make sure the hose is fully inserted.
Verify proper assembly of the rubber grommet on the
sound trap into the hole in the A-pillar.
Service:
Clean the sound traps. Enlarge the opening of the front sound traps on cars with chassis number between 000690-171367.
Step 1.4 Check front drainage pipes along A-pillar (both sides):
Check routing of the hose along the A-pillar and
verify that the hose is free of dirt and debris.
Service:
If the hose is clogged, clean or replace the hose.
If the hose is kinked, replace the hose.
Hint:
A similar type of hose with better rigidity
than the original hose can be used to avoid
kinking.
*Semi-rigid Polyethylene tubing.
Outer 1/2", inner 3/8".
Manufacturer Watts (Part ref # 42141525)
Available at Home Improvement Outlets or
an automotive supply store.
Step 1.5 Check upper part of front drainage (both sides):
Disassemble the sun visors and the front interior
light panel according to VADIS.
Release the headliner from the rubber seals in the
door opening and the B-pillar panel.
Pull the headliner down to allow inspection of the
drainage hoses behind the headliner.
Note:
Gently pull down just a little of the headliner to avoid permanent crease marks!
Verify routing and look for possible kinking.
Verify that the hose is clear of dirt and debris.
Service: Replace the hose if kinked or clogged.
Verify connection between the hoses and the
gutter pipes at the front left and right side of the
sunroof cassette.
Make sure the hose is pushed all the way onto the
gutter pipe.
Step 2.1 Check foam between cassette and roof, front center:
Under certain conditions, a small gap might occur
at the foam between the sunroof cassette and the
roof plate. The critical area is in the front center
where a hole is punched in the sunroof cassette.
Check the position of the foam; it should be covering
the complete hole.
Service: Use PUR sealant or similar to close the gap.
WARRANTY CLAIM INFORMATION