Fixing the infamous Saturn door leak?

[Morgan19]

Through my family and friends, I've managed to come up with 4 instances of early-90s Saturns leaking at the front doors when it rains. Does anyone know of a fix for this problem? I've heard mention of rain gutters you can install on cars, but looking online has produced no real results. I'd really appreciate any help anyone could give, because then I could make 4 other people very happy.

Thanks!
m19

[TrueWhiteBoy]

Well, unfortunately I'm going to have to add one to your case list.

Mine also leaks, I've tried a special sealent glue (twice), but that didn't help at all

[GetGetGo]

all right listen up and listen good, my friend got on alldata and checked out the T.S.B and found the door leak on there, what you have to do to fix it is bend very carefully the top part of the door in ward, start at the bottem by the mior and work your way up, if you bend it to much your screwed cuz your window wont shut but if you do it just enough than you wont have to worry about it ever leaking again.

[snugerud]

yup i had the same problem mine was the black plastic pieces at the top of your window that runs all along the top. looses adhesive and if you take it to the saturn dealer its only 20 -40 to get repaired. that or it may originate with your roof and rust out

[TrueWhiteBoy]

Alright, I've finally managed to somewhat fix this.

It IS the sealent of the sunroof, I dont really have a good way to fix it, but despite it seeming to come in from the doors, it's coming in from the sunroof, I'm trying to order a new seal to see if that will fix it, I've used a silicone caulk (sorry if I'm not very specific, I'm not quite sure what I used), but that has decreased the amount coming in by a significant amount.

Also, the rain completely rusted away the sunroof motor, which means I get to see if I can find a new one of those too. Fun Fun Fun.

[bowtiebandit]

these may help

SUNROOF LEAKS WHEN BRAKING & TURNING CORNERS-ADD FOAM SEAL #93-T-20-SATURN - (07/16/1993)
SUBJECT: Sunroof Leaks When Braking and Turning Corners (Add Foam Seal Along Top of Sunroof Module Assembly)

MODELS AFFECTED: 1993 Saturns equipped with sunroofs, built between VIN PZ166439 and PZ248368.

CONDITION: Customers may comment about a water leak in the sunroof when braking or turning the vehicle.

CAUSE: Under braking and turning conditions water runs over sunroof drain tray.

CORRECTION: Add foam seal along top of sunroof module assembly using Kent Industries 3/8" x 7/16" Adhesive-Backed Shim Stock (P/N 40120) or equivalent, according to the following procedure. Saturns built prior to VIN PZ166439 and after VIN PZ248368 already have the foam seal installed.

PROCEDURES:

---------- 1. Verify that vehicle is not equipped with a foam seal by retracting sunroof glass and inspecting front corners for foam seal between sunroof module assembly and roof panel.

a. If vehicle is equipped with a foam seal, check for proper drain hose attachment and drain hose operation. If vehicle is a Sedan, also refer to Technical Bulletin 92-T-39 (Front of Headliner Wet When Vehicle Has Been Parked Facing Down on an Incline) for possible cause of water leak.

b. If vehicle is not equipped with a foam seal, proceed to Step 2.

2. Remove sunroof module assembly according to the "Sunroof Module Assembly" removal procedures in the "Vehicle Interior Systems" section of the "Body/Collision Repair Service Manual."

3. Place sunroof module assembly on a clean workbench.

4. Starting at center rear of sunroof module assembly, apply Kent Industries 3/8" x 7/16" Adhesive-Backed Shim Stock (P/N 40120) or equivalent along outer edge of sunroof module assembly.

IMPORTANT: Do not stretch adhesive-backed shim stock around corners.

[bowtiebandit]

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Waterleak at the Front Upper Door Frame #481506r - (01/09/2003)
Waterleak at the Front Upper Door Frame (Adjust the Front Upper Door Frame and Apply Sealer to the Door Opening Joints) -- Due to random collation error by the printer in the previous printing of this bulletin, this bulletin supersedes bulletin 94-T-52A which should be discarded.
1991-1995 Saturns and 1996 Saturn Coupes

Condition:
The customer may comment of water dripping from the top of the door frame area.

Cause:
This condition may be caused by the seal between the front side door, primary, weatherstrip and space frame. There may also be a low spot in the sealer at the door opening joint.

Correction:
Adjust the top of the door frame inward to achieve a better seal between the front side door, primary, weatherstrip and the space frame. Also, if required, add sealer to the door frame joints.

Procedure:




With the aid of a helper, direct an unrestricted flow of water over the top of the door frame, one side of the vehicle at a time.
Inspect the top of the door from the inside of the vehicle:
If water is leaking between the front side door, primary, weatherstrip and the space frame, proceed to the next step.
If water is not present in the immediate area, refer to Waterleaks in the General Information section of the appropriate year Body/Collision Repair Service Manual for the vehicle being worked on.
Open the door and lower the door glass to the full-down position.

Notice
Care should be taken not to over bend the door frame which could impair door glass operation or door closing. It is better to adjust the door frame in small increments to achieve the required fit.


Grasp the upper door frame at the top of the frame and carefully pull the door frame inboard along the entire top of the door frame.
After a slight adjustment has been made, proceed to the next step and perform the Dollar Bill test.



Dollar Bill Test
Place a dollar bill or similar size piece of paper between the front side door, primary, weatherstrip and the contact surface of the space frame, then close the door.

Important
Make sure to leave the window in the full-down position. This equalizes the pressure inside the vehicle when the door is closed and allows the dollar bill, or piece of paper, to stay in the correct position.


Slowly withdraw the dollar bill or piece of paper after the door is closed to check the amount of pressure on the front side door, primary, weatherstrip.
There should be a medium amount of resistance as the dollar bill, or piece of paper is slowly withdrawn, Continue around the entire door frame.
If there is little or no resistance, it indicates there is insufficient contact to form a good seal between the front side door, primary, weatherstrip and the space frame. Repeat step 3 through 6, until the door frame is correctly adjusted.
If there is a medium amount of resistance, proceed to the next step.
After the door is properly adjusted, check the door glass operation by raising and lowering the door glass. Also, check the door operation by opening and closing the door to make sure it operates correctly.
To verify that the waterleak has been repaired, apply an unrestricted flow of water over the door frame -- as described in step 1 of this bulletin.
If the waterleak has been repaired, return the vehicle to the customer.
If the waterleak is still present and the vehicle is a:
Coupe, built after and including VIN PZ317192, proceed to step 9.
Sedan or Wagon, built after and including VIN PZ317192, proceed to step 9.
If the waterleak is still present and the vehicle does not fall into the years or VIN ranges given in the previous step, repeat steps 3 through 7 until the waterleak is repaired.




On Coupes:
Make sure the door opening space frame lap joints are clean and dry.

Important
Some vehicles may have black tape over existing sealer. Remove and discard this tape before applying new sealer.


Using a seal sealer such as Kent Industries High Tech Leak Check Seam Sealer, Black P/N 10070 or equivalent, fill the 2 space frame lap joints until flush with the space frame using a flat-bladed tool to keep the seal smooth.
Allow the sealer to completely dry and water test to make sure the waterleak has been repaired.
If the waterleak is still present, repeat steps 3 through 7 until the waterleak is repaired.
If the waterleak has been repaired, return the vehicle to the customer.




On Sedan or Wagon
Make sure the door opening space frame lap joint is clean and dry.

Important
Some vehicles may have black tape over existing sealer. Remove and discard this tape before applying new sealer.


Using a seal sealer such as Kent Industries High Tech Leak Check Seam Sealer, Black P/N 10070 or equivalent, fill the 2 space frame lap joints until flush with the space frame using a flat-bladed tool to keep the seal smooth.
Allow the sealer to completely dry and water test to make sure the waterleak has been repaired.
If the waterleak is still present, repeat steps 3 through 7 until the waterleak is repaired.
If the waterleak has been repaired, return the vehicle to the customer.

[2fast4_ur_ass]

The Modifications and Quick Fixes found on this site were submitted by fellow Saturn owners. By entering this section you agree that the fault and liability of failures or malfunctions for any reasons when attempting these modifications or quick fixes are yours and yours alone. The SaturnSpot.com, nor the persons who submitted the instructions can, nor will be held liable.

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[ramdam]

Originally Posted by TrueWhiteBoy

Alright, I've finally managed to somewhat fix this.

It IS the sealent of the sunroof, I dont really have a good way to fix it, but despite it seeming to come in from the doors, it's coming in from the sunroof, I'm trying to order a new seal to see if that will fix it, I've used a silicone caulk (sorry if I'm not very specific, I'm not quite sure what I used), but that has decreased the amount coming in by a significant amount.

Also, the rain completely rusted away the sunroof motor, which means I get to see if I can find a new one of those too. Fun Fun Fun.

I have found my solution. I removed the 6 screws that hold the sunroof in place and removed the whole thing. Took it and cleaned it all up and used clear silicone on the inside and black on the outside. Put it back in and no more leaks. It was better than the $450.00 the dealer wanted for a new one. It seems that the glass and seal is one unit.

[sickcallawayc12]

I had a leak on the roof of the driver side sort of in front of the visor. I put a piece of electrical tape over the leak and its rained quite a bit, haven't had any problems since. Quite strange.

[farescb]

I found a company on the web @ "www.CarPartFinderUSA.com". He tracked one down in a junkyard for 135 dollars. My sunroof would leak and it would seem that it was coming from the doors but it was sitting in the sunroof frame and when I started moving and turning corners it would run out of the sunroof frame and behind the headliner to the doors. Since I have replaced this I have no leaks. I think he found one in Arizona junkyard. This seems to be a known issue since he had a problem finding one that was not rusted. I have also found a website that sells the seals and read that its best to replace the seal regularly and I mean every so many years. During the replacement you need to clean up any surface rust etc. That is my dealings with the sunroof leaking and I just need to get the headliner fixed now since all that moisture in the car has caused it to start falling.