Sunroof - Water Leak
2/6/9576/08/95/US
SUBJECT
Sunroof - Water Ingress
MODEL
Discovery with Sunroofs
AFFECTED VEHICLES
LP
LH
LJ 081991 to 148332
LD
DETAIL
There are two possible causes of water leaks through both front and rear sunroofs:
1) Water drips from the water dam and appears to drip from the sunroof handle/motor and headlining. This may be due to the absence of the water dam gasket.
The water dam gasket will be fitted to all sunroofs from VIN 148332
2) Water appears from between the sunroof glass and the seal along the front edge of the sunroof. This is due to excessive spacer thickness. These spacers should be replaced by the thinner type detailed below.
ACTION REQUIRED
Upon customer complaint, ensure sunroof is fully closed and water test the affected sunroof to identify the source of the leak. Once identified follow the appropriate action detailed below.
PARTS INFORMATION
STO 1684 Glass panel assembly for repair # 1
STC 2991 Spacer (Thin) 2 required for repair # 2
PROCEDURE
Process for Repair # 1. Gasket missing from the water dam: (Refer to the workshop manual section 76 Sunroof Electric/Manual.)
1. Remove front inner sunroof catch cover and check for water ingress
2. Remove 2 Torx head screws (size TX 20) and remove the sunroof catch body.
3. Using a flash light and probe check for the presence of the water dam gasket. See illustration A. (The gasket can be identified by the cross hatching on the surface, or a probe can be inserted inside the catch. If glass contact is made the gasket is missing).
4. If the gasket is missing replace the glass panel with a new assembly. See parts information.
5. If the gasket is present re-fit the catch. Re-tighten catch screws to 1.5 lb.ft (2 Nm).
6. Ensure a 3/16" (5 mm) gap exists between the front edge of the sunroof and inside edge of the upper frame.
7. When the new sunroof assembly is fitted, check the sunroof operation, and re-test for water ingress.
Process for Repair # 2, Leaks from sunroof glass seal:
(Refer to workshop manual section 76 Sunroof Electric/Manual.)
1. Tilt and open the sunroof. Stretch a piece of tape across the 2 capnuts that fit through the glass sun roof, to prevent movement.
2. Remove the front glass screws using a TX 20 Torx bit, (see illustration B).
3. Carefully lift the glass enough to remove the existing spacers Replace the spacers with the thinner type spacers, part number STC 2991.
4. Re-tighten the screws to 2.1 - 2.2 lb.ft (2.9 - 3.0 Nm), remove tape.
5. Check sunroof operation and recheck for water ingress.
WARRANTY
Normal warranty policy and procedure apply.
COMP. CODE
8G5N Glass Panels - Renew
9D6N Gasket and Spacers
SRO
76.82.64 - Glass Panel - Front - Renew - 0.50 hr.
76.82.65 - Glass Panel - Rear - Renew - 0.50 hr.
76.82.89/27 - Check water dam gasket - 00.05 hr.
76.82.89/28 - Fit new type spacers - 00.25 hr.