WATERLEAK AT DOOR GLASS AND QUARTER WINDOW AREA. Pontiac Sunbird 1994

For 1990-2009 cars

# WATERLEAK AT DOOR GLASS AND QUARTER WINDOW AREA

#### SUBJECT: WATERLEAK AT DOOR GLASS AND QUARTER WINDOW AREA (DIAGNOSTIC/SERVICE PROCEDURE)

#### MODELS: 1988-94 CHEVROLET CAVALIER 1988-94 PONTIAC SUNBIRD (ABOVE VEHICLES ARE CONVERTIBLE MODELS ONLY)

#### CAUTION:

TO HELP AVOID INJURY TO YOU OR OTHERS WHEN RAISING OR LOWERING THE CONVERTIBLE TOP, KEEP YOUR HANDS AWAY FROM ANY HINGES AND LINKAGE AND CLOSE ALL LATCHING HANDLES.

THIS BULLETIN IS BEING ISSUED TO HELP IDENTIFY POTENTIAL AREAS OF WATERLEAKS AT: A-PILLAR WEATHERSTRIP TO FRONT RAIL WEATHERSTRIP, FRONT RAIL WEATHERSTRIP TO CENTER RAIL WEATHERSTRIP AND CENTER RAIL WEATHERSTRIP TO REAR RAIL WEATHERSTRIP.

BEFORE PERFORMING ANY REPAIR PROCEDURES, VERIFY WITH OWNER THAT PROPER CONVERTIBLE TOP OPERATING PROCEDURES AND CONDITIONS HAVE BEEN OBSERVED AS FOLLOWS:

- NEVER RAISE OR LOWER THE TOP WHILE THE CAR IS MOVING. THE WIND COULD GET UNDER IT AND CAUSE DAMAGE.

- IF AUTOMATIC CAR WASHES ARE USED, IT IS RECOMMENDED THAT A SOFT CLOTH CAR WASH BE USED AND THE VEHICLE CLIMATE CONTROL SYSTEM SHOULD BE SET TO "VENT" AND THE FAN BE SET AT ITS HIGHEST SPEED. THIS WILL PREVENT THE HIGH PRESSURE WATER FROM ENTERING AROUND THE CONVERTIBLE TOP.

- DO NOT TRY TO LOWER OR RAISE THE CONVERTIBLE TOP IF YOUR VEHICLE IS OUT IN COLD WEATHER, 41 DEGREES FAHRENHEIT (5 DEGREES CELSIUS) OR BELOW. THE COLD CAN CAUSE CRACKS AND OTHER DAMAGE TO THE CONVERTIBLE TOP AS IT IS BEING LOWERED OR RAISED.

- DO NOT LOWER THE CONVERTIBLE TOP IF IT IS DAMP OR WET. AFTER THE CONVERTIBLE TOP IS DOWN, THE TRAPPED WATER CAN CAUSE STAINS, MILDEW AND DAMAGE TO THE INSIDE OF THE VEHICLE. BE SURE TO DRY OFF THE CONVERTIBLE TOP BEFORE YOU LOWER IT.

- MAKE SURE THERE IS NOTHING IN THE CONVERTIBLE TOP STORAGE WELL (THE AREA BEHIND THE REAR SEAT WHERE THE CONVERTIBLE TOP WILL GO) OR UNDER THE WELL IN THE TRUNK. EVEN A SMALL ITEM COULD DAMAGE THE REAR WINDOW OR CONVERTIBLE TOP WHEN IT IS LOWERED.

- THE CONVERTIBLE TOP IS NOT DESIGNED TO CARRY WEIGHT. NEVER LET ANYONE SIT ON THE CONVERTIBLE TOP, AND DO NOT PUT ANYTHING ON TOP OF IT WHEN IT IS UP OR DOWN, OR IT COULD BE DAMAGED.

- ALL SIDE WINDOWS MUST BE PARTIALLY LOWERED BEFORE LOWERING OR RAISING CONVERTIBLE TOP TO PREVENT WEATHERSTRIP AND SEAL DAMAGE OR DISPLACEMENT WHICH COULD RESULT IN WATER AND/OR WIND LEAKS.

GATHERING DETAILED INFORMATION FROM THE VEHICLE OWNER IS A VALUABLE TOOL IN LOCATING AND REPAIRING WATER LEAKS. IT MAY BE NECESSARY TO ASK LEADING QUESTIONS TO THE LOCATION AND CONDITIONS WHEN WATER LEAKS OCCUR. SOME HELPFUL QUESTIONS MAY BE ASKED AS FOLLOWS:

1. WHAT AREA OF THE VEHICLE DOES WATER APPEAR? 2. DOES WATER LEAK OCCUR WHEN IT RAINS? 3. DOES WATER LEAK OCCUR WHEN VEHICLE IS WASHED? 4. IS VEHICLE WASHED IN AN AUTOMATIC CAR WASH OR IS IT WASHED BY HAND? 5. HAVE SEALS OR WEATHERSTRIPS BEEN SERVICED PREVIOUSLY? 6. HAVE DOOR OR QUARTER WINDOWS BEEN SERVICED PREVIOUSLY? 7. HAS VEHICLE BEEN IN A COLLISION AT ANY TIME?

AS AN AID IN DIAGNOSING WATERLEAKS, THE FOLLOWING VIDEO SHOULD BE REVIEWED: "PONTIAC TECH TRACK SUNBIRD CONVERTIBLE WINDNOISE AND WATER LEAK DIAGNOSIS AND ALIGNMENT".

THE VEHICLE SHOULD BE VISUALLY INSPECTED AND WATERTESTED WITH WATER TEST STANDS AS DESCRIBED IN SECTION 10-1 OF THE APPROPRIATE SERVICE MANUAL.

CHECK AND ADJUST QUARTER GLASS ALIGNMENT IF NECESSARY. REFER TO SECTION 10-7 OF THE APPROPRIATE SERVICE MANUAL.

CHECK AND ADJUST DOOR GLASS TO QUARTER GLASS ALIGNMENT IF NECESSARY. REFER TO SECTIONS 10-6 AND 10-7 OF THE APPROPRIATE SERVICE MANUAL.

CHECK AND ADJUST CONVERTIBLE TOP ALIGNMENT IF NECESSARY. REFER TO SECTION 10-9 OF THE APPROPRIATE SERVICE MANUAL.

#### CONDITION:

1. PERMANENT DAMAGE TO WEATHERSTRIPS AT A-PILLAR, FRONT RAIL, CENTER RAIL AND/OR REAR RAIL SUCH AS:

- HOLE IN WEATHERSTRIP (REFER TO FIGURE 1). - EXTENSIVELY DEFORMED (REFER TO FIGURE 1). - TORN OR BADLY DISTORTED (REFER TO FIGURE 1).

2. WATERLEAK FOUND BETWEEN WEATHERSTRIP RETAINER AND A-PILLAR, FRONT RAIL, CENTER RAIL OR REAR RAIL.

3. WATERLEAK FOUND BETWEEN A-PILLAR WEATHERSTRIP TO FOLDING TOP FRONT SEAL ASSEMBLY HAS TWO POTENTIAL CONDITIONS IDENTIFIED:

- GAPING (REFER TO FIGURE 2). - PUCKERING (REFER TO FIGURE 2).

4. WATERLEAK FOUND BETWEEN FRONT RAIL WEATHERSTRIP TO CENTER RAIL WEATHERSTRIP HAS TWO POTENTIAL CONDITIONS IDENTIFIED:

- GAPING (REFER TO FIGURE 3). - PUCKERING (REFER TO FIGURE 3).

5. WATERLEAK FOUND BETWEEN CENTER RAIL WEATHERSTRIP TO REAR RAIL WEATHERSTRIP HAS THREE POTENTIAL CONDITIONS IDENTIFIED:

- GAPING (REFER TO FIGURE 4). - PUCKERING (REFER TO FIGURE 4). - ROLLING (REFER TO FIGURE 4).

#### CORRECTION:

#### NOTE: WHEN CORRECTION PROCEDURES ARE COMPLETE, APPLY A THIN COAT OF PETROLEUM JELLY OR SILICONE TO SIDES OF CENTER RAIL WEATHERSTRIP AND REAR RAIL WEATHERSTRIP TO REDUCE WEATHERSTRIP ROLLING. REFER TO FIGURE 5.

1. DAMAGED WEATHERSTRIPS TO BE REPLACED. REFER TO PROCEDURES IN SECTION 10-9 OF THE APPROPRIATE SERVICE MANUAL.

2. REPAIR WEATHERSTRIP RETAINER. REFER TO PROCEDURES IN SECTION 10-9 OF THE APPROPRIATE SERVICE MANUAL.

3. TO CORRECT A-PILLAR WEATHERSTRIP TO FRONT RAIL WEATHERSTRIP GAPING, USE THE FOLLOWING PROCEDURE:

1. REMOVE APPROXIMATELY 100MM (4.0 INCH) OF WEATHERSTRIP FROM TOP OF A-PILLAR RETAINER. 2. USING BLACK WEATHERSTRIP ADHESIVE, P/N 12345097, OR EQUIVALENT, INSTALL WEATHERSTRIP INTO A-PILLAR RETAINER WHILE PULLING WEATHERSTRIP UPWARD UNTIL CONTACTING FRONT RAIL WEATHERSTRIP END. REFER TO FIGURE 6.

3A. TO CORRECT A-PILLAR WEATHERSTRIP TO FOLDING TOP FRONT SEAL ASSEMBLY PUCKERING, USE THE FOLLOWING PROCEDURE:

1. LOWER CONVERTIBLE TOP ABOUT HALFWAY. 2. REMOVE APPROXIMATELY 100MM (4.0 INCH) OF WEATHERSTRIP FROM TOP OF A-PILLAR RETAINER. 3. REMOVE APPROXIMATELY 100MM (4.0 INCH) OF FOLDING TOP FRONT SEAL ASSEMBLY FROM ACROSS NO. 1 BOW AND DOWN FRONT SIDE RAIL RETAINER. 4. INSTALL STUFFERS (TWO EACH END) INTO THE CUT-AWAY IN BACK OF WEATHERSTRIPS. REFER TO FIGURE 7. THIS WILL PUSH THE WEATHERSTRIP SURFACE BACK TO ITS ORIGINAL SHAPE. 5. USING BLACK WEATHERSTRIP ADHESIVE, P/N 12345097, OR EQUIVALENT, INSTALL WEATHERSTRIP INTO A-PILLAR RETAINER. 6. USING BLACK WEATHERSTRIP ADHESIVE, P/N 12345097, OR EQUIVALENT, INSTALL FOLDING TOP FRONT SEAL ASSEMBLY. 7. RAISE CONVERTIBLE TOP AND LOCK.

4. TO CORRECT FRONT RAIL WEATHERSTRIP TO CENTER RAIL WEATHERSTRIP GAPING, USE THE FOLLOWING PROCEDURE:

1. REMOVE CENTER RAIL WEATHERSTRIP RETAINING SCREW. REFER TO FIGURE 8. 2. REMOVE FRONT RAIL WEATHERSTRIP RETAINING SCREW. REFER TO FIGURE 8. 3. REMOVE APPROXIMATELY 100MM (4.0 INCH) OF WEATHERSTRIP FROM REAR TO CENTER OF FRONT RETAINER. 4. REMOVE APPROXIMATELY 100MM (4.0 INCH) OF WEATHERSTRIP FROM FRONT TO CENTER OF CENTER RETAINER. 5. USING BLACK WEATHERSTRIP ADHESIVE, P/N 12345097, OR EQUIVALENT, INSTALL FRONT AND CENTER RAIL WEATHERSTRIPS INTO RETAINER, PULLING ENDS TOGETHER UNTIL CONTACTING. REFER TO FIGURE 8. 6. INSTALL FRONT AND CENTER RAIL WEATHERSTRIP RETAINING SCREWS. REFER TO FIGURE 8.

4A. TO CORRECT FRONT RAIL WEATHERSTRIP TO CENTER RAIL WEATHERSTRIP PUCKERING, USE THE FOLLOWING PROCEDURE.

1. LOWER CONVERTIBLE TOP ABOUT HALFWAY. 2. REMOVE CENTER RAIL WEATHERSTRIP RETAINING SCREW. REFER TO FIGURE 8. 3. REMOVE FRONT RAIL WEATHERSTRIP RETAINING SCREW. REFER TO FIGURE 8. 4. REMOVE APPROXIMATELY 100MM (4.0 INCH) OF WEATHERSTRIP FROM REAR TO CENTER OF FRONT RETAINER. 5. REMOVE APPROXIMATELY 100MM (4.0 INCH) OF WEATHERSTRIP FROM FRONT TO CENTER OF CENTER RETAINER. 6. INSTALL STUFFERS (TWO EACH END) INTO THE CUT-AWAY IN BACK OF WEATHERSTRIPS. REFER TO FIGURE 7. THIS WILL PUSH THE WEATHERSTRIP SURFACE BACK TO ITS ORIGINAL SHAPE. 7. RAISE CONVERTIBLE TOP AND LOCK. 8. USING BLACK WEATHERSTRIP ADHESIVE, P/N 12345097, OR EQUIVALENT, INSTALL FRONT AND CENTER RAIL WEATHERSTRIPS INTO RETAINER, PULLING ENDS TOGETHER UNTIL CONTACTING. REFER TO FIGURE 8. 9. INSTALL FRONT AND CENTER RAIL WEATHERSTRIP RETAINING SCREWS. REFER TO FIGURE 8.

5. TO CORRECT CENTER RAIL WEATHERSTRIP TO REAR RAIL WEATHERSTRIP GAPING, USE THE FOLLOWING PROCEDURE:

1. LOWER CONVERTIBLE TOP ABOUT HALFWAY. 2. LOWER QUARTER WINDOW. 3. REMOVE CENTER RAIL WEATHERSTRIP RETAINING SCREW. 4. REMOVE APPROXIMATELY 100MM (4.0 INCH) OF WEATHERSTRIP FROM FRONT TO CENTER OF RETAINER. 5. RELOCATE CENTER RAIL WEATHERSTRIP RETAINING SCREW HOLE FORWARD 4 - 5MM (0.156 - 0.203 INCH). REFER TO FIGURE 9. 6. USING BLACK WEATHERSTRIP ADHESIVE, P/N 12345097, OR EQUIVALENT, INSTALL CENTER RAIL WEATHERSTRIP FORWARD IN RETAINER. 7. INSTALL CENTER RAIL WEATHERSTRIP RETAINING SCREW INTO NEW HOLE. REFER TO FIGURE 9. 8. PERFORM WATERTEST. IF WATERLEAK IS STILL EXISTING, PROCEED TO STEP 9. 9. REMOVE CENTER PORTION OF CENTER RAIL WEATHERSTRIP, APPROXIMATELY 25MM (1.0 INCH) FROM RETAINER ENDS. REFER TO FIGURE 10. 10. APPLY BLACK WEATHERSTRIP ADHESIVE, P/N 12345097, OR EQUIVALENT, IN RETAINER. 11. INSTALL CENTER RAIL WEATHERSTRIP INTO RETAINER WHILE PUSHING WEATHERSTRIP REARWARD. REFER TO FIGURE 10.

5A. TO CORRECT CENTER RAIL WEATHERSTRIP TO REAR RAIL WEATHERSTRIP PUCKERING, USE THE FOLLOWING PROCEDURE:

1. LOWER CONVERTIBLE TOP ABOUT HALFWAY. 2. LOWER QUARTER WINDOW. 3. REMOVE CENTER RAIL WEATHERSTRIP APPROXIMATELY 100MM (4.0 INCH) FROM THE REAR JOINT END BY DISCONNECTING CLIP. 4. INSTALL STUFFERS (TWO) INTO THE CUT-AWAY IN BACK OF CENTER RAIL WEATHERSTRIP. REFER TO FIGURE 7. THIS WILL PUSH THE WEATHERSTRIP SURFACE BACK TO ITS ORIGINAL SHAPE. 5. APPLY BLACK WEATHERSTRIP ADHESIVE, P/N 12345097, OR EQUIVALENT, IN RETAINER. 6. INSTALL CENTER RAIL WEATHERSTRIP INTO RETAINER.

5B. TO CORRECT CENTER RAIL WEATHERSTRIP TO REAR RAIL WEATHERSTRIP ROLLING, USE THE FOLLOWING PROCEDURE:

1. LOWER CONVERTIBLE TOP ABOUT HALFWAY. 2. LOWER QUARTER WINDOW. 3. REMOVE CENTER RAIL WEATHERSTRIP RETAINING SCREW. REFER TO FIGURE 11. 4. REMOVE APPROXIMATELY 100MM (4.0 INCH) OF WEATHERSTRIP FROM FRONT TO CENTER OF RETAINER. 5. APPLY BLACK WEATHERSTRIP ADHESIVE, P/N 12345097, OR EQUIVALENT, IN RETAINER. 6. INSTALL CENTER RAIL WEATHERSTRIP INTO RETAINER WHILE PUSHING WEATHERSTRIP REARWARD 3 - 4MM (0.118 - 0.157 INCH). REFER TO FIGURE 11. 7. INSTALL CENTER RAIL WEATHERSTRIP RETAINING SCREW. 8. PERFORM WATERTEST. IF WATERLEAK IS STILL EXISTING, PROCEED TO STEP 9. 9. REMOVE CENTER PORTION OF CENTER RAIL WEATHERSTRIP APPROXIMATELY 25MM (1.0 INCH) FROM RETAINER ENDS. REFER TO FIGURE 10. 10. APPLY BLACK WEATHERSTRIP ADHESIVE, P/N 12345097, OR EQUIVALENT, IN RETAINER. 11. INSTALL CENTER RAIL WEATHERSTRIP INTO RETAINER WHILE PUSHING WEATHERSTRIP REARWARD. REFER TO FIGURE 10.

#### PARTS AVAILABILITY:

PARTS ARE CURRENTLY AVAILABLE FROM GMSPO.

#### WARRANTY INFORMATION:

FOR VEHICLES REPAIRED UNDER WARRANTY, USE:

SEAL, CENTER TO REAR RAIL - LABOR OPERATION NUMBER: B3110 (RIGHT) B3111 (LEFT) LABOR TIME: 0.3 HR.

SEAL, SIDE RAIL WEATHERSTRIP - LABOR OPERATION NUMBER: B3140 (RIGHT) B3141 (LEFT) LABOR TIME: 0.3 HR.

SEAL, REAR RAIL (REAR ROOF RAIL WEATHERSTRIP) - LABOR OPERATION NUMBER: B3150 (RIGHT) B3151 (LEFT) LABOR TIME: 0.3 HR.

FIGURES: 11

GENERAL MOTORS BULLETINS ARE INTENDED FOR USE BY PROFESSIONAL TECHNICIANS, NOT A "DO-IT-YOURSELFER". THEY ARE WRITTEN TO INFORM THOSE TECHNICIANS OF CONDITIONS THAT MAY OCCUR ON SOME VEHICLES, OR TO PROVIDE INFORMATION THAT COULD ASSIST IN THE PROPER SERVICE OF A VEHICLE. PROPERLY TRAINED TECHNICIANS HAVE THE EQUIPMENT, TOOLS, SAFETY INSTRUCTIONS AND KNOW-HOW TO DO A JOB PROPERLY AND SAFELY. IF A CONDITION IS DESCRIBED, DO NOT ASSUME THAT THE BULLETIN APPLIES TO YOUR VEHICLE, OR THAT YOUR VEHICLE WILL HAVE THAT CONDITION. SEE A GENERAL MOTORS DEALER SERVICING YOUR BRAND OF GENERAL MOTORS VEHICLE FOR INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THE INFORMATION.

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