For 1990-2009 cars

# Water Leaks onto Headliner (Replace Sunroof Housing Drain Hoses or Seal Sunroof Module)

Subject: | Water Leaks Onto Headliner (Replace Sunroof Housing Drain Hoses or Seal Sunroof Module)

Models: | 1996 -- 1997 Saturn Sedans, 1997 Saturn Coupes, and 1998 Saturn Sedans and Coupes built up to and including VIN WZ246268, equipped with factory installed sunroof (CF option).

### Condition

Water leaks onto headliner, causing possible water stain.

### Cause

During assembly:

• | The sunroof housing rear drain hoses kinked.

• | The sunroof housing front drain hoses pinched.

• | Skips in sealer between sides and front of sunroof module.

| Stiffer sunroof housing drain hoses were added to vehicles built after and including VIN WZ246269

### Correction

Follow the procedures in this bulletin to diagnose and repair.

### Procedure

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

• | Front windshield

• | Rear window

• | Door openings

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

1. Refer to the "Waterleak Customer Diagnosis Form," in the General Information" section of the appropriate year Body/Repair Service Manual and fill out the "Customer Comment Worksheet"
2. Water test the vehicle in the waterleak location described by the customer. (Refer to "Waterleaks" in the "General Information" section of the appropriate year Body/Repair Service Manual.)

• | If water leaks onto front of headliner, refer to "Sunroof Housing Front Drain Hoses -- All Models" in this bulletin.

• | If water leaks onto rear of headliner, refer to either "Sunroof Housing Front Drain Hoses -- Sedan " or Sunroof Housing Rear Drain Hoses -- Coupe" in this bulletin.

• | If water leaks occur in any area(s) other than the headliner, refer to "Diagnosis and Repair" under "Waterleaks" in the General Information" section of the appropriate year Body/Repair Service Manual, and repair waterleak.

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

Most likely cause of an obstruction ma 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 housing drain channel and spilling over into the vehicle. Repeat this procedure for the other sunroof housing front drain hole.

• | If water pours through each sunroof housing front drain hole in under 60 -- 80 seconds, refer to either "Repeat Sunroof Housing Drain Hoses -- Sedan," "Rear Sunroof Housing Drain Hoses -- Coupe" or "Sunroof Module Dealer" 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 207 kPa (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 each 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 grain hole in under 60- 80 seconds, proceed to the next step.

### Rear Sunroof Housing Drain Hoses -- Sedans

1. Remove the roof rear panel assemblies (rear roof appliques) from the left and right side of the vehicle. (Refer to "Panel -- Roof Rear Outer -- Sedan" in the "Roof, Rocker Panels and Attaching Components" section of the appropriate year Body/Repair 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 (s), which are 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 replace with a new sunroof housing rear drain hose (s) (P/N 21052849) and sunroof housing drain hose clamp(s) (P/N 01626260). (Refer to "Rear Drain Hose Grommet -- Sedan" in the "Vehicle Interior Systems" section of the appropriate year Body/Repair Service Manual.)

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

4. Using a standard air gun, limited to 207kPa (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) (P/N 21052849). (Refer to "Rear Drain Hose Grommet -- Sedan" in the "Vehicle Interior Systems" section of the appropriate year Body/Repair Service Manual.)

### Rear Sunroof Housing Drain Hoses -- Coupes

1. Remove headliner from vehicle. (Refer to "Headliner" removal procedure in the "Vehicle Interior System" section of the appropriate year Body/Repair Service Manual.)
2. Raise the front of the vehicle so all water flows to the rear of the sunroof housing.
3. Water test the vehicle with the sunroof closed. (Refer to "Waterleaks" in the "General Information" section of the appropriate year Body/Repair 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 4.

• | If water does not run over the rear portion of the sunroof housing during the water test, proceed to "Sunroof Module Sealer" in this bulletin.

4. Using a standard air gun, limited to 207 kPa (30 psi), blow into the sunroof housing rear drain hoses to dislodge any possible obstructions.
5. 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 6.

• | If water does not run over the rear portion of the sunroof housing during the eater test, the obstruction has been removed. Install headliner to vehicle. (Refer to "Headliner" installation procedure in the "Vehicle Interior Systems" section of the appropriate year Body/Repair Service Manual.)

6. Replace the sunroof housing rear drain hoses with new sunroof housing rear drain hoses (P/N 21052828) and sunroof housing drain hose clamp(s) (P/N 01626260). (Refer to "Rear Drain Hose Grommet -- Coupe" in the Vehicle Interior System" section of the appropriate year Body/Repair Service Manual.)

### Sunroof Module Sealer -- 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. With headliner removed from previous leak detection, inspect butyl sealer that is placed around copper drive cable tubes as they exit the front of the module for water leaks. If the water leak occurs from this area, use a thumb -- grade butyl to add to the area 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 fro cracked module. If no cracks are present, apply a bead of Kent Industries Quik Leak Check, P/N 10510 (or equivalent) as shown in the illustration. If cracks are present, replace module.

#### Parts Requirements

21052828 | Hose--Sun Rf Hsg Frt Drn
01626260 | Clamp--Sun Rf Hsg Frt Drn Hose
10510 | Kent Industries Quik Leak Check (or equivalent)
Kent Products Tele Marketing 1-800654-6333 (USA) 1-800-663-2800 (Canada)

### Claim Information

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for B2852 (replace front sunroof drain hose), or B2853 (replace rear sunroof drain hose), or if another procedure is performed, refer to the appropriate Electronic Labor Time Guide for the correct Labor Operation Code and Time.