Sunroof water ingress

SUNROOF WATER INGRESS

Model

Discovery fitted with Electric / Manual Sunroof

Affected vehicles

Upto 174805 Upto 505712

Date

1995-11-16

Reference

16/11/95

Bulletin text

Sunroof -Water Ingress

MODEL

Discovery fitted with Electric / Manual Sunroof

DETAIL

A small number of reports have been received that identify water ingress through both front and rear sunroofs. The reports indicate 2 areas of concern, 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 by the manufacturers from Vin number 148332 2. Water ingress between the sunroof glass and glass seal Following recent improvements to the sunroof, which increases the glass seal crush to eliminate water going between the sunroof glass and seal, a spacer kit will be required to ensure interchangeability between the modified and pre-modified lower tray and guide tube assembly. NOTE: This bulletin replaces 76/13/95/EN, the information contained within this bulletin been amended to replace previous sunroof issues.

ACTION REQUIRED

Upon customer complaint, ensure sunroof is fully closed, water test the affected sunroof to identify the source of the leak, and follow the appropriate action detailed below.

PARTS INFORMATION

STC 1684 Glass panel assembly for fix No 1

STC 3194 Spacer kit (4 off spacers) for fix No 2

PROCEDURE

Process for fix No 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 off torque head bit fixings (size TX 20) and remove the sunroof catch body. 3. Using a torch and probe check if the water dam gasket is present (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 catch, re-tighten catch fixings to 2 Nm. 6. Ensure a 5mm 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.

Issue 2 16/11/95

76/13/95/EN

AFFECTED VEHICLES

LP LH LJ Upto 174805 LJ Upto 505712

WARRANTY

Normal warranty policy and procedure apply.

COMP. CODE

9D6N 8G5N 9S6N

SRO

.25 hour 76.82.64/65 Glass panel renew (electric) 00.35 hour. 76.83.05/06 Glass panel renew (manual) 00.35 hour 76.82.89/27 Check water dam gasket 00.05 hour 76.82.89.28 Fit new type spacers 00

Sunroof - water Ingress

MODEL

Discovery fitted with Electric/Manual Sunroof

Process for fix No 2 Following recent improvements to the sunroof lower tray STC 1686 and the guide tube assembly STC 1683, a spacer kit Part No STC 3194 (containing 4 white spacers) will be required if either the sunroof lower tray or the guide tube assembly are changed in vehicles prior to the Vins given.

MODIFIED GUIDE TUBE (ILLUSTRATION A)

Underside view between upper frame and guide tube.

GUIDE TUBE UNMODIFIED (ILLUSTRATION B)

Underside view between upper frame and guide tube.

When fitting a modified lower tray to an unmodified guide tube x 2 spacers must be fitted to the guide tube. Gently lift the guide tube assembly off the two locating pegs on the upper frame to gain enough clearance to insert the spacers over the two inboard holes as indicated then reseat the guide tube assembly.

Continued......................

16/11/95 76/13/95/EN

AFFECTED VEHICLES

LP LH Upto 174805 LJ Upto 505712 LJ

Sunroof - water Ingress

MODEL

Discovery fitted with Electric/Manual Sunroof

MODIFIED LOWER TRAY ILLUSTRATION ‘C’

Underside view look for ‘U’ shaped impression around corner hole as shown opposite.

LOWER TRAY UNMODIFIED ‘D’

Underside view no impression around hole as shown opposite.

ILLUSTRATION ‘E’

Fit x 4 spacers as indicated opposite to the inside of the lower tray.

When fitting a modified guide tube assembly to an unmodified lower tray x 4 spacers must be fitted to the inside of the lower tray as indicated opposite.

16/11/95 76/13/95/EN

AFFECTED VEHICLES

LP LH Upto 174805 LJ Upto 505712 LJ