Golf III L4-1984cc 2.0L SOHC (1993)
Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins
Sunroof - Water Leaks
GROUP: 60
NUMBER: 94-01
DATE: Oct 1, 1994
SUBJECT:
Troubleshooting Water Leaks from Sunroof Area
MODEL(s):
Golf III /Jetta III from 1993 Model Year
File this Technical Bulletin in Repair Manual No.: W42 011 294 114
CONDITION
Water pours over the lip of the sunroof drain tray into the passenger compartment, or the headliner develops visible water stains in the sunroof drain
area.
PRODUCTION
Corrections to assembly procedure have been implemented in production.
SERVICE
First, check that the sliding roof panel seal makes adequate contact all the way around the perimeter of the roof opening. Too much water entering past
the seal will overload the capacity of the drain system. If the seal contact is not adequate, it may be adjusted. See Technical Bulletin # 93-01, Group 60,
for details.
Next you should always pour water into each corner of the drain tray and observe that all of the water flows into, through, and out of the bottom of each
drain hose without obstruction. If the water flows noticeably more slowly out of one hose than the others, or doesn't flow through at all, check this hose
for possible obstructions per the Golf III/Jetta III Repair Manual, pages 60-14 and 60-15. If less water exits from the hose than the amount poured in or if
you have visible water stains in the drain hose area of the headliner, check the hose and fitting for leaks. Water could also be trapped in low areas of the
hose if it is improperly routed, especially a rear hose.
Some other potential problem areas which have been identified are:
Improper slope of a rear drain hose. To ensure proper drainage, the hoses must be straight and sloping gradually downward as in the illustration above. If
a hose is bowed upward or downward, you may have to pull some of the excess length through from the bottom to straighten the bowed area. Ensure the
hose is reasonably taut and secured by all retaining clips.
Excessive heat radiation from the roof panel in extremely hot areas may also cause the hose to bow upward in this area. To prevent this, glue a block of
foam approximately 5O mm square by 4O mm thick (2" square by 1-9/16" thick) to the roof panel directly above the bowed area of the hose.
Acoustic foam (arrow 5 above) exerts excessive pressure against the hose. Although the primary purpose of this foam is noise reduction, it is also used to
retain the hose in a properly sloped position as it curves downward into the "C" pillar. If the foam exerts too much pressure on the hose, it will crush,
impeding or stopping the flow of drain water.
On early production Jetta III's the hose was routed into the "C" pillar through the hole. To improve the slope angle of the hose, later Jetta III's have the
hose routed directly into the "C" pillar, bypassing this hole. If necessary, reposition the hoses on an older vehicle to follow the new routing.
If the bottom (exit end) of a rear hose is in contact with the bumper cover, the hose may pinch shut, clog with debris, or bend and crimp somewhere in
the "C" pillar. If you must shorten the hose cut the end off diagonally, with the opening facing the rear of the vehicle to take advantage of any scavenging
effect created by airflow past the hose end.
Leaks from the hose fitting area could be due to a cracked or loose fitting hose end, or the plastic drain fitting itself could be cracked underneath the hose
end. A loose fitting hose end can be secured with silicone sealant. Also ensure the rubber end cap for the frame channel is in place and sealed at the rear
of the frame.
The plastic drain fittings are bonded in place at each corner of the metal sunroof frame. Ensure no water is leaking from around the perimeter. Leaks can
be eliminated using silicone sealant applied from above and/or below.
