For 1990-2009 cars

# Water Leaks onto Headliner

Subject: | Water Leaks onto Headliner (Inspect and/or Repair Sunroof Module Drain Hoses, Open End of Front Drain Hose Grommets, and/or Reseal Various Locations on Sunroof Module) Due to changes under MODELS AFFECTED and PROCEDURE, this bulletin is being revised and supersedes bulletins 99-T- 35 and 98- T- 48, which should both be discarded.

Models: | 1996 -- 2001 Saturn S-Series Sedans and 1997 -- 2001 Saturn S-Series Coupes with sunroof option (RPO CF5)

### Condition

Water leaks onto headliner, causing possible water stain on headliner.

### Cause

1. Sunroof front and/or rear drain hose connections loose at sunroof module.
2. Front drain hose pinched by roof panel attachment bolts and/or rear drain hose kinked due to assembly of the grommet to the hose on vehicles built before and including VIN WZ246268.
3. Grommets at lower end of sunroof module front drain hoses may be obstructed by debris and/or be too restrictive on vehicles built before and including VIN XZ301802.
4. Void(s) in body seam sealer used at various locations on sunroof module.

### Correction

Follow the procedures in this bulletin to diagnose and repair water leak(s) as required.

### Procedures

General Diagnostic Information -- All Models

Important: Before removing any vehicle components, thoroughly water test vehicle to determine if leak is originating at any of the follow areas:

• | Front windshield

• | Rear glass

• | Door openings

Important: If customer reports vehicle is parked on an incline when water leak occurs, all water leak diagnosis should include raising end of vehicle that is "up" when customer parks on an incline. Raise one end of vehicle to simulate incline under which water leak occurs.

1. Refer to "Windows/Waterleak Customer Diagnosis Form," in the General Information section of the Body/Repair service manual (1996-1999) or Windnoise/Waterleaks/Apperance section of the Body/Electrical Volume I service manual (2000-2001) and fill out the Customer Comment Worksheet.
2. Remove headliner.

• | On 1996 -- 1999 model year vehicles, refer to "Headliner -- Coupe" or Headliner -- Sedan" remove procedure in the Vehicle Interior Systems section of the appropriate model year S-Series Body/Electrical Volume II Service Manual.

• | On 2000 -- 2001 model year vehicles, refer to "headliner -- Coupe" or Headliner -- Sedan" removal procedure in the Interior Trim section of the appropriate model year S-Series Body/Electrical Volume II Service Manual.

3. Water test vehicle in the water leak location described by the customer. (Refer to "Waterleaks in the General Information section of the appropriate model year Body/Repair service manual [1996-1999] or Windnoise/Waterleaks/Apperance section of Body/Electrical Vol. I service manual [2000-2001].

• | If water leak occurs in front area of sunroof module, refer to "Sunroof Drain Hose Clamps," "Sunroof Housing Front Drain Hoses," Sunroof Module Front Drain Hose Grommets," and Reseal Front of Sunroof Module" in this bulletin.

• | If water leak occurs in rear area of sunroof module, refer to "Sunroof Drain Hose Clamps," "Sunroof Housing Rear Drain Hoses," and Reseal Rear of Sunroof Module" in this bulletin.

• | If water leak occurs in any area(s) other that the headliner, refer to "Diagnosis and Repair" under Water Leaks in the General Information section of the appropriate model year Body/Repair service manual.

4. Once water leak had been repaired, install headliner.

• | On 1996 -- 1999 model year vehicle, refer to "Headliner -- Coupe" or "Headliner -- Sedan" installation procedure in the Vehicle Interior Systems section of the appropriate model year Body/Repair service manual.

• | On 2000 -- 2001 model year vehicles, refer to "Headliner -- Coupe" or Headliner -- Sedan" installation procedure in the Interior Trim section of the appropriate model year S-Series Body/Electrical Volume II Service Manual.

### Sunroof Module Drain Hose Clamps -- All Models

A water leak at sunroof module drain hose locations where they attach to sunroof module can be identified by watching around edges of sunroof module from inside vehicle while water test stand is running. Allow ample time when water testing for water leak to occur.

• | If water leaks between the hose and sunroof module drain, refer to the following procedure.

• | If water is not leaking between hose and sunroof module drain, refer to the other procedure in this bulletin.

1. Inspect for clamps on all drain hoses of sunroof module.

• | If sunroof module drain hose clamps are present, tighten clamps and retest for water leak.

• | If sunroof module drain hose clamps are not present, continue to next step.

2. Remove all drain hoses from sunroof module.
3. Fed sunroof module drain hose clamps (P/N 01626260) onto hoses.
4. Push hoses back onto sunroof module so that they fully seat.
5. Tighten clamps. Left front shown. Others similar.
6. Water test vehicle in sunroof module area.

### Sunroof Module Front Drain Hoses -- All Models

Most likely cause of an obstruction may be the front sunroof housing drain hose(s) pinched by the cockpit attachment bolts during assembly.

1. Open sunroof glass to the full open position.
2. Using a standard measuring cup, pour two cups of water directly into the sunroof housing front drain hole. The water should be able to be poured into the sunroof housing front drain hole in under 60 -- 80 seconds without water collecting along the sunroof using drain channel and spilling over into the vehicle. Repeat this procedure for the other sunroof housing front drain hole.

• | If waters pours through each sunroof housing front drain hole in under 60 -- 80 seconds, refer to the other procedures in this bulletin.

• | If water does not pour through each sunroof housing drain hole in under 60 -- 80 seconds, proceed to the next step.

3. Using a standard air gun, limited to 207kPa (30 psi), blow into the sunroof housing front drain hole(s) with the obstruction and attempt to clear the obstruction.
4. Water test again, using a standard measuring cup, pour two cups of water directly into the sunroof housing front drain hole that was obstructed. The water should be able to be poured into the sunroof housing front drain hole in under 60 -- 80 seconds without water collecting along the sunroof housing drain channel and spilling over into the vehicle. Repeat this procedure for the other sunroof housing front drain hole if it was also obstructed.

• | If water pours through the sunroof housing front drain hole(s) in under 60 -- 80 seconds, obstruction has been removed.

• | If water still does not pour through each sunroof housing front drain hole in under 60 -- 80 seconds, proceed to the next step.

5. Replace sunroof housing front drain hose(s) with new sunroof housing front drain hose(s) and new sunroof housing drain hose clamp(s).

• | On 1996 -- 1999 model year vehicles, refer to "Front Drain Hose Grommet" in the Vehicle Interior Systems section of the appropriate model year Body/Repair Service Manual.

• | For 2000 -- 2001 model year vehicles, refer to "Front Drain Hose Grommet" om the Sunroof section of the appropriate model year S-Series Body/Electrical Volume II Service Manual.

6. Water test vehicle in sunroof module area.

### Sunroof Module Front Drain Hose Grommets -- All Models

The grommets at bottom ends of sunroof module front drain hoses can be obstructed by debris, or they may be too restrictive to allow water to pass freely through them. To open up ends of sunroof module front drain hose grommets, use the following procedure.

1. Remove hinge pillar garnish/sill molding.

• | Starting at the rear of molding, pull firmly at clip locations.

• | Use a large flat blade screwdriver to reach top clip location and release clip.

2. Partially remove insulators in hinge pillar to expose lower end of sunroof module front drain hose grommet.
3. Pull lower end of sunroof module drain hose with grommet attached through lower access hole in hinge pillar.
4. Pull grommet off end of sunroof module drain hose. Do not pull on the drain hose. Right side shown. Left side similar.
5. Once grommet is removed, extend side slits on end of grommet all the way through the bottom as show is illustration. Do not remove any material from grommet.
6. Install grommet to end of drain hose, seat grommet and drain hose in rocker panel through hole in hinge pillar.
7. Install hinge pillar garnish/sill molding.

• | Start at the top clip and work towards the rear of the vehicle.

• | Install garnish molding by snapping molding and clips into clip locations.

8. Water test vehicle in sunroof module area.

### Reseal Front of Sunroof Module -- All Models

Important: Forcing butyl sealer through the drive cable tube holes in the module will restrict the water drainage system of the sunroof module.

1. Inspect butyl sealer placed around copper drive cable tubes as they exit the front of the module for water leaks. If the eater leak occurs from this area, apply Kent Industries Seal n' Caulk (P/N 10310), or equivalent, as needed until the leak is corrected.
2. Inspect for leakage where the sides of the sunroof module are joined to the front of the module. Inspect for cracked module. If no cracks are present, apply a bead of Kent Industries HIGH TECH Seam Sealer (P/N 10070), or equivalent, as shown in the illustration. If cracks are present, replace module.
3. Water test vehicle in sunroof module area.

### Rear Sunroof Module Drain Hoses -- Sedan

1. Remove roof rear panel assemblies (rear roof appliques) from the left and right side of vehicle.

• | On 1996 -- 1999 model year vehicle, refer to "Panel -- Roof Rear Outer -- Sedan" in the Roof Rocker Panels and attaching Components section of the appropriate model year S-Series Body/Electrical Volume I Service Manual.

• | On 2000 -- 2001 model year vehicles, refer to "Panel -- Roof Rear Outer -- Sedan" in the Roof and Rockers section of the appropriate model year S-Series Body/Electrical Volume I Service Manual.

2. Remove the quarter outer panel hole plugs on the left and right side of the vehicle. (Quarter outer panel hole plugs are located under the rear of the roof rear panel assembly.)
3. Inspect both sunroof housing rear drain hoses through the quarter outer panel holes to determine if they are kinked. (The sunroof housing rear drain hose(s) may have been kinked by the installation of the sunroof housing rear drain hose grommet, which is located below body plug.)

• | If either of the sunroof housing rear drain hoses are kinked, remove the kinked sunroof housing rear drain hose(s) and replace with a new sunroof housing rear drain hose(s) and sunroof housing drain hose clamp(s).

• | On 1996 -- 1999 model year vehicles, refer to "Rear Drain Hose Grommet -- Sedan" in the Vehicle Interior Systems section of the appropriate model year Body/Repair Service Manual.

• | On 2000 -- 2001 model year vehicles, refer to "Rear Drain Hose/Grommet -- Sedan" in the Sunroof section of the appropriate model year S-Series Body/Electrical Volume II Service Manual

• | If neither of the sunroof housing rear drain hoses are kinked, remove each sunroof housing rear drain hose from the sunroof housing and proceed to the next step.

4. Using a standard air gun, limited to 207 kPa (30 psi), blow into the sunroof housing rear drain hole(s) with the obstruction and attempt to clear the obstruction.

• | If air flows freely through both sunroof housing rear drain hoses, there is no obstruction. Reattach sunroof housing rear drain hoses and refer to "Sunroof Module Sealer" in this bulletin.

• | If at first air does not flow freely through either of the sunroof housing rear drain hoses, then starts to flow freely, obstruction has been removed. Reattach sunroof housing rear drain hoses.

• | If air does not flow freely through either of the sunroof housing rear drain hoses and obstruction cannot be removed, replace sunroof housing rear drain hose(s) with new sunroof housing rear drain hose(s)

• | On 1996 -- 1999 vehicles, refer to "Rear Drain Hose Grommet -- Sedan" in the Vehicle Interior Systems section of the appropriate model year Body/Repair Service Manual.

• | On 2000 -- 2001 vehicles, refer to "Rear Drain Hose/Grommet -- Sedan" in the Sunroof section of the appropriate model year S-Series Body/Electrical Volume II Service Manual.

5. Water test vehicle in sunroof module area.

### Rear Sunroof Module Drain Hoses -- Coupe

1. Raise the front of the vehicle so all water flows to the rear of the sunroof housing .
2. Water test the vehicle with the sunroof closed.

On the 1996 - 1999 model year vehicles, refer to "Waterleaks" in the General Information section of the appropriate mode year Body/Repair Service Manual.

On 2000 -- 2001 model year vehicles, refer to "Waterleaks" in the Windnoise/Waterleaks/Appearance section of the appropriate model year S-Series Body/Electrical Volume I Service Manual.

• | If water runs over the rear portion of the sunroof module during the water test, remove the sunroof housing rear drain hoses from the vehicle and proceed to step 3.

• | If water does not run over the rear portion of the sunroof housing during the water test, refer to the other procedures in this bulletin.

3. Using a standard air gun, limited to 207kPa (30 psi), blow into the sunroof housing rear drain hoses to dislodged any possible obstructions.
4. Reattach sunroof housing rear drain hoses to sunroof housing and water test the vehicle again.

• | If water runs over the rear portion of the sunroof module during the water test, proceed to step 5.

• | If water does not run over the rear portion of the sunroof housing during the water test, the obstruction has been removed.

5. Replace the sunroof housing rear drain hoses with new sunroof housing rear drain hoses and sunroof housing drain hose clamp(s).

On 1996 -- 1999 model year vehicle, refer to "Rear Drain Hose Grommet -- Coupe" in the Vehicle Interior Systems section of the appropriate model year Body/Repair Service Manual.

On 2000 -- 2001 model year vehicle, refer to "Rear Drain Hose/Grommet -- Coupe" in the Sunroof section of the appropriate model year S-Series Body/Electrical Volume II Service Manual.

6. Water test vehicle in sunroof module area.

### Reseal Rear of Sunroof Module -- All Models

A water leak from the rear of the sunroof module may result from a void in body sealer between sunroof module side rail and end piece that drain hose attaches to. Before attempting this repair, be certain water leak is not present due to missing hose clamps on sunroof module drain hoses.

1. Remove sunroof module from vehicle.
2. From the top side, seal end piece in areas shown in illustration using Kent Industries HIGH TECH Seam Sealer (P/N 10070), or equivalent.
3. From bottom side, seal end piece in areas shown in the illustration using Kent Industries HIGH TECH Seam Sealer (P/N 10070), or equivalent.
4. Install sunroof module in vehicle.
5. Water test vehicle in sunroof module area.

#### Parts Requirements

0162620 | Clamp - Sun Rf Hsg Frt Drn Hose
21302069 | Hose - Sun Rf Hsg Frt Drn (1996 Sedan)
21302069 | Hose - Sun Rf Hsg Frt Drn (1997-2000 Coupe and Sedan)
21302069 | Hose - Sun Rf Hsg Frt Drn (2001 Coupe)
21302099 | Hose - Sun Rf Hsg Rr Drn (1996-2000 Sedan)
21302508 | Hose - Sun Rf Hsg Rr Drn (1997-2001 Coupe)
--
10070 | Kent Industries HIGH TECH Seam Sealer * (Or Equivalent)
10310 | Kent Industries Seal n' Caulk Black * (Or Equivalent)
--
* Kent Product Telemarketing | 1-800-654-6333 USA 1-800-663-2800

### CLAIM INFORMATION

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System as Follows

Case Type | Description | Labor Operation Code | Time
--- | --- | --- | ---
VW | Water Test and Determine Leak | Z4031 | --
INC: Time to Install Hose Clamps on Front and Rear Drain Hoses Sedan | -- | 1.3hrs 1.5hrs
ADD | To Replace One Front Drain Hose | -- | 0.2hrs
To Replace Both Front Drain Hoses | -- | 0.3hrs
To Modify Ends of Both Front Drain Hose Grommets | -- | 0.5hrs
To Seal Front of Sunroof Module | -- | 0.1hrs
To Seal Rear of Sunroof Module | -- | 0.5hrs
To Replace One Rear Drain Hose-Coupe | -- | 0.2hrs
To Replace Both Rear Drain Hoses-Coupe | -- | 0.3hrs
To Replace One Rear Drain Hose-Sedan | -- | 0.6hrs
To Replace Both Rear Drain Hoses-Sedan | -- | 1.4hrs

Important: Claims for the specified sealing material will be reimbursed in the following amounts:

Seal Rear of Sunroof Module-Seam Sealer-Retailer Cost of $2.00 x 30% = $2.60 Seal Front of Sunroof Module-Seam Sealer-Retailer Cost of $2.00 x 30% =$2.60 Seal N' Caulk-Retailer Cost of $0.21 x 30%=$0.27

It will be necessary to sell sealer and caulk to the CSO as material, using net item code "M." Claims exceeding the above amounts will be returned to the Retailer with reason 143 - material amount greater than maximum allowed.