Sunroof - Leaks
89volvo02Reference Bulletins: Subject: Product
SB 81-102; SUNROOF CARS
Aug. 1988
200 Group
ALL 83
Date: No.
AUGUST 1989 201
THIS BULLETIN APPLIES TO THE U.S. AND CANADA
REFERENCE: TP 31120/1 (ENGLISH); BODY
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Leakage from the left and right guide rails, and the two front rails, can be corrected using the following procedure. (To remedy the situation, the sunroof and guide rails must be removed.) The sealers to be used are butyl tape (P/N 1277872-6), plastic filler (P/N 1161123-3), and body filler (P/N 277253-1).
Preparation:
Remove sun visor (2 screws), if applicable
Open sunroof halfway
Remove wind deflector (4 screws)
Unhook clips at front edge of sunroof lining
Push lining back to expose sunroof mounts
Removing Sunroof
Close sunroof Push leaf spring (1) to side. Remove screws for front and rear sunroof mounts (4 screws on each side).
Note: Carefully note position of rear mount reinforcing plates (2). This will simplify installation.
Remove:
- Crank and gear assembly for sunroof
- Cover molding and intermediate sections on guide rails (10 screws - arrows)
Remove front reinforcing plate for cable guide rails
Lift out cables and put to one side
Remove cable guide rails (4 screws)
Clean guide rails thoroughly
Remove nut plates for gear assembly (under guide rails)
Pull out sunroof liner
Remove guide rails on both sides
Pull guide rails straight out
Note: Guide rails may be stuck in place due to butyl tape in drain channel.
Important: Carefully remove all butyl tape remaining in guide rails
Installation
Important: make sure no butyl tape remains on base plate. Thoroughly clean as necessary.
Apply butyl tape, P/N 1277872-6, to guide rails and plastic filler, P/N 1161123-3, on rear mounts
Place a strip of tape (180 mm) diagonally over guide rail. Fold tape up at rear and side, see illustration.
Apply soap solution to butyl tape.
Install:
- guide rails on both sides.
Note: Make sure rails are correctly positioned under rear brackets on base plate. See illustration.
- sunroof lining
- intermediate sections
Check that no leakage occurs at splash guards
Plug holes for both front drain holes. Clamp both rear drain hoses. Pour water in channels on base plate. Check that no water runs past rear section of guide rails and into car.
Unplug all drains.
Apply body filler P/N 277253-1 in space between sunroof channel and cable guide rail. See both illustrations above.
Install:
- nut plates for gear assembly
- guide rails for cables
- reinforcing plates for cable guide rails
Adjust sunroof mount (10 mm)
Install cover molding for cables
Install:
- gear assembly
- cover molding
- crank
Note: Before installing crank, be sure gear assembly is in start position.
Install sunroof
Make sure reinforcing plates (2) for rear mounts are correctly positioned.
Put leaf spring (1) into position
Reattach front edge of sunroof lining
Install:
^ wind deflector
^ sun visor, if applicable
Note:
make sure wind deflector connecting arms (arrow) are correctly positioned between roof and base plate.
Water leakage could result if arms contact roof or base plate.
Check sunroof function.
During the New Car Warranty period, claims must be submitted under:
Operation Number Labor Description Time Allowance
336 353 Sunroof repair 2.1 hr
according to SB 83-201