- - - - - - -TOP - - - - -

-
- - WA E EAK CORREC ION- ~
- - - CAMAROS & FIREBIRDS--

22002.63-1
 FOREWORD
The reference information contained in this booklet does not constitute an endorsement by
GM of any single manufacturer's product or procedure.

Contained in this booklet is repair information based on the latest data available at the time
of publication approval. The right is reserved to make product or publication changes, at any
time, without notice. This booklet, or any portion thereof, may not be reproduced without
written consent of GM Product Service Training, General Motors Corporation.

INTRODUCTION
This booklet will serve as a ready reference with some available techniques and products
that can be utilized to diagnose and correct waterleak conditions encountered on those
Camaros and Firebirds GM series vehicles equipped with the T-Top Roof Option. It IS NOT
intended to replace any product manufacturer's label instructions or procedures.

This booklet is divided into seven main categories: General Information, Body Construction,
Headlining and Interior Garnish Moldings, Diagnosis Techniques, Sealers and Related
Product Usage, Waterleak Repair Operations, and Final Watertest. Each section contains
pertinent service information and applicable illustrations as required.

Copyright © 1987 General Motors Corporation

 TABLE OF CONTENTS
I. GENERAL INFORMATION 1
A. The Waterleak Condition 1
B. Material and Equipment List 1
C. Customer Comment Worksheet 3

II. BODY CONSTRUCTION :........................ 5

A. Roof Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5
B. Latch Rods 5
C. Latch Assembly 5
D. Lift-Off Panel Assembly 5
E. Lift-Off Panel Opening Center Upper Finishing Molding 5

III. HEADLINING AND INTERIOR GARNISH MOLDINGS...................... 7

A. Formed Headlining 7
B. Interior Garnish Moldings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7

IV. DIAGNOSIS TECHNIQUES.............................................. 9

A. Waterleak Diagnosis Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9
1. Visual Inspection 9
2. Spot Water Test 9
3. Overall Water Test 10
4. Air Hose and Soapy Water Test 10
5. Powder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12
6. Dollar Bill Test , 12
7. Chalk Test 13
B. Potential Waterleak Areas (Diagnosis Chart) . . . . . . . . .. 13
 TABLE OF CONTENTS (Cont'd)
V. SEALERS AND RELATED PRODUCT USAGE 15
A. Stationary Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15
B. Metal Joints, Seams and Small Pin Holes 15
C. Weatherstrip Retainers 15
D. Screws and Nuts 15
E. Weatherstrips 15
F. Release Agent 15
G. Tracing Powder 16
H. Adhesive Cleaner 16
I. Silicone Paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 16

VI. WATERLEAK REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17

A. Door and Body Lock Pillar Wedge Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17
B. Door Window Glass Adjustments 18
C. Lift-Off Glass Panel Channel 20
D. Side Roof Rail Lift-Off Panel on Glass Weatherstrip 22
E. Replacement of Side Roof Rail Lift-Off Panel Weatherstrips,
Retainers and Sealing Strips 23
F. Lift-Off Panel Adjustments 26
G. Lift-Off Panel Opening Center Upper Finishing Molding 31
H. Lift-Off Panel Opening Weatherstrip 33

VII. FINAL WATERTEST 45

GM vehicles are designed to operate under normal environmental conditions. The designed
criteria for sealing materials and components takes into consideration the sealing forces
required to withstand the natural elements. These specifications do not and cannot take into
consideration all artificial conditions such as may be encountered in some high pressure car
washes.

The Waterleak Condition

The source of waterleak entry is not always where the water appears. A careful inspection of
each reported leak is very important in order to make a satisfactory repair the first time.

To aid in the waterleak repair, the three "W's" should be covered with the customer
concerning the vehicle. The three "W's" are as follows:
1. What? - Waterleak.
2. Where? - Specific area(s) leak(s) are located.
3. When? - Under what condition(s) does the leak(s) occur.

A "Customer Comment Worksheet" similar to the one shown on page three (3), can be
very beneficial in obtaining helpful information necessary for all persons involved in the .
repair cycle.

Material and Equipment List

• Standard Complement of Hand Tools
• Tool J-23457 or BT-7107 Door Lock Striker Adjustment Tool
• Tool J-24595-B or BT-7323 Trim Removal Tool
• Tool J-9886 Window Crank Handle Removal Tool
• Urethane Adhesive Sealant GM #12345633
• Rubber Wedge Door Stop
• New 1986 Style Weatherstrips

Left Side Set:

- GM #20667535 - Lift-Off Panel Opening On Body
- GM #20680014 - Side Roof Rail On Lift-Off Glass
 GENERAL INFORMATION
Right Side Set:
- GM #20667534 - Lift-Off Panel Opening On Body
- GM #20680014 - Side Roof Rail On Lift-Off Glass
- GM #20329444 - Plate, Wedge Body Side
- GM #20329442 - Plate, Wedge Door Side
- GM #2032443-5 - Silencer, Wedge Plate Door Side
- Customer Comments Worksheet
- Chart of Available Adhesives, Sealers and Related Items
- Water Test Stand Unit
- Black Weatherstrip Adhesive 3M-8011
- Auto Bedding and Glazing Compound
- Liquid Soap
- Soft Chalk or Talc
- 3M Tape No. 969, Part 06493 Acrylic Adhesive
- Transfer Tape
- 3M-6375 Scotchfoam Black Vinyl Foam Tape
- General Purpose Adhesive Cleaner
- Release Agent
- Brushable Seam Sealer
- Strip Caulk
- Auto Joint & Seam Sealer (Flow Grade)
- GM #1042863 - Silicone Paste
- Heavy Drip-Check Sealant
- Window-Weld Primer
- Acid Brushes
- Drip Check Sealer
- Shop Cloths
- Blow Gun
- Putty Knife
- Hot Air Gun
- Waterproof Tape
- China Marking Pencil
- Protective Covers
- (2) Rules, 4"-6" in Length

•
2
 CUSTOMER COMMENT WORKSHEET
Repair Order No.: Date: _ CONDffiON: WEATHER CONDmON:
Customer Name: _ o Water Leak 0 Dust Leak DRain 0 Light 0 Heavy
o Wind Noise 0 Rattle DOry
Telephone No.: Bus. No.: _
VIN: License No.: _ ROAD TYPE WHEN NOnCED:
Make: Series: Body Type: _
o Paved 0 Other, Specify: _
o Gravel
'"a:w '"a:w POsmON OF VEHICLE WHEN CONDmON NonCED:
~
05
AREA(S) OF i~ ~
05
AREA(S) OF i~ o In Motion/Speed 0 Parked 0 Level 0 Incline
LEAK OR NOISE ~itj LEAK OR NOISE ~Ol o In Car Wash 0 Automatic 0 Wand 0 Hand
f f
Grille Parcel Shelf
CIRCLE TROUBLE AREA IN VEHICLE SHOWN BELOW:
Hood Quarter Glass

~~
Front I IFront
Fender Rear I Wheelhouse !Rear
(.,)
Windshield Rear Window

Windshield Pillar TailgatelWindow

~~
Upr. I I Upr.
Lwr. I Shroud (Cowl) I Lwr. Rear Compartment (Trunk)
Front I IFront
Instrument Panel Rear I
Bumper I R&ar
Heater-NCModule Tail Lamp

Gl~
Side Roof Rail Other, Specify:

Front Door/Glass

Rear Door/Glass
Remarks:

ai~
Sun RoofNista Vent

Hatch RooflT-Top
Front I IFront
Rear I
Floor/Carpet I Rear
Side Trim Panels
NOTES _

4
 BODY CONSTRUCTION
To provide the background for effective and reliable service repair procedures, a thorough
understanding of how the unit is designed and installed is necessary.

Roof Assembly
The roof inner consists of ribbed reinforcements welded together. This reinforcements
assembly ties into the windshield pillars and sail panels and forms the windshield and back
light headers.

Latch Rod Strikers

Two steel latch rod strikers with elongated holes are screw-retained at the upper ends of the
windshield and body lock pillars in the panel opening.

Latch Assembly
The latch assembly consists of the following components which are riveted into a single
serviceable unit: a mounting bracket, detent spring, two sector links, two steel tubular rods
and a keyed driver stud.

The outboard ends of the steel tubular rods are coated with a black nylon material which
serves as an antisqueak feature. The rods pass through the screw retained latch rod
strikers. This arrangement permits a range of up/down and in/out adjustments.

Lift-Off Panel Assembly

Commonly called the liT-Top," the lift-off panel assembly consists of a tempered glass panel
contoured to match the roof outer panel surface, glass support, latch mechanism, weath-
erstrip and sealing strip.

The glass support panel is constructed of plastic. It is bonded along the outboard edge of the
glass panel and along the area of the support adjacent to the glass with urethane adhesive.

Each glass panel is secured into the body opening with a latch assembly that is mounted to
the glass panel support with screws.

On some earlier style vehicles with the T-Top option, a three-piece, formed, black poly-
carbonate plastic channel is bonded to the glass panel around three sides with urethane
adhesive. The plastic channel is a serviceable unit and is available through GM Service
Parts Organization.

Lift-Off Panel Opening Center Upper Finishing Molding

The center upper finishing molding provides inboard retention of the left and right glass
panels and the center inboard weatherstrip retainers. It is held in position with sheet metal
screws.

5
NOTES _

6
Formed Headlining
The headlining is a one-piece fiberglass substrate covered with a foam cloth facing. The
construction of the fiberglass substrate does not allow for replacement of the cloth facing
and requires that the headlining be serviced as a complete assembly. Cut-out sections are
provided for the lift-off panel openings.

Final attachment is accomplished when the interior molejings and attaching screws that
retain the sunshade brackets, dome lamp base and coat hooks are installed.

Interior Garnish Moldings

Interior garnish moldings are constructed of plastic or metal and color impregnated or are
painted to match the interior of the vehicle. Retention is accomplished with sheet metal
screws and/or plastic clips.

The follOWing are the garnish moldings used in "F" style vehicles with the Twin Lift-Off Panel
option:
1. Windshield Side Upper Garnish Moldings
2. Lift-Off Panel Trim Cover Garnish
3. Body Lock Pillar Trim Panel Garnish

7
NOTES _

8
 DIAGNOSIS TECHNIQUES
Proper diagnosis of a waterleak condition is most important and can vary depending on the
type and location of the leak. The repair procedure, however, is determined by the type of
seal regardless of condition.

Waterleak Diagnosis Methods

1. VISUAL INSPECTION

WATERLEAK D AGNOSIS

INSPECT SUSPECTED AREAS OF LEAK FOR:

• MISALIGNED COMPONENTS

• TORN WEATHERSTRIPS

• BROKEN WELD JOINTS

• SEALER AND/OR ADHESIVE SKIPS

• EVIDENCE OF WATER, DIRT AND

RUST STAINS ACCUMULATION OF WATER
CLEAR WATER IS PROBABLY RAIN WATER

2. SPOT WATER TEST (WITH WATER HOSE)

If area of the leak(s) are known, a spot water test check with a water hose test may be used.
The hose test should always start at the base of the suspected leak area with a small stream
of water. As the hose is moved up, water will not enter the vehicle until the leak area has
been reached. This method can be utilized on any area of the body.

9
 DIAGNOSIS TECHNIQUES
WATERTEST STANDS

3. OVERALL WATER EST

Can be easily done using a watertest stand. This allows the technician to set up the
watertest equipment, turn the water on and drive the vehicle under the stands, permitting a
one man watertest. The duration of the overall watertest should be at least four (4) minutes.
Use only if owner did not know where vehicle leaked.

4. AIR HOSE AND SOAPY WATER TEST

Using a mixture of liquid soap and water, spray the area of the suspected leak with the
solution, then apply air pressure to the suspected area from inside of the vehicle (205
kPa-30 p.s.i.). The result will be large bubbles at the exact leak point.

10
 DIAGNOSIS TECHNIQUES
WATERTEST STAND COMPONENTS
1/2" COUPLING
"FULL-JET" SPRAY NOZZLE
NO. 1/2GG·25 OR EQUIVALENT _-,,!7'
NOZZLE HEIGHT-54" TO FLOOR

1/2" COUPLING (LEFT ONLY)

WATER PRESSURE GAGE
(RIGHT SIDE ONLY)
1/2" X 1/2" X 1/4" REDUCING TEE
(RIGHT ONLY)

1/2" CROSS (RIGHT ONLY)

1/2" X 30" PIPE (STRAIGHT) _ _~ I
1/2" TEE (LEFT ONLY)
1/2" PIPE TO HOSE NIPPLE
HOSE QUICK CONNECT 1/2" PIPE TO HOSE NIPPLE (RIGHT ONLY)

12' CROSS HOSE (5/8" DIA.) 5/8" FEMALE HOSE

COUPLING

5/8" FEMALE HOSE - L . : : ' - - -

COUPLING 2' INPUT HOSE (5/8" DIA.) (RIGHT ONLY)
1/2" CROSS WITH WELD·ON 1/2" CAP
1/2" CLOSE NIPPLE
RIGHT SIDE SHOWN (LEFT SIDE SIMILAR)

WATERTEST STAND SPECIFICA IONS

Type of Nozzle - Full cone spray with 60° Included angle - "Full Jet" Spray Nozzle No. 1/2 GG·25
or eqUivalent.
Nozzle Height - Approximately 1 600 mm (63") from floor.
Volume of Flow - 14 liters (3.7 gallons) per minute.
Pressure - 155 kPa (22 psi) measured at nozzle.
Windshield and Front Body Pillar - approximately 30 degrees down, 45 degrees toward rear and
aimed at corner of windshield.
Side - approximately 30 degrees down, 45 degrees toward rear and aimed at center of rear door
or rear quarter.
Back Window and Rear Compartment Lid - approximately 30 degrees down, 30 degrees toward
front and aimed approximately 600 mm (24") from corner of back window.

Center Line of Body

~~--------

1600 mm
(63')

Windshield &
Front Body Pillar
Side Back Glass &
Deck Lid
1 1351

11
 DIAGNOSIS TECHNIQUES
5. POWDER TEST
Best suited for checking weatherstrip contact of door, door glass, and lift-off panel areas.
Powder is also available in an aerosol can which is one of the most convenient methods of
use. Spray weatherstrip contact surface with powder and close. When you reopen, those
areas of the weatherstrip which are properly contacting the surface will have traces of
powder on them.

DOLLAR BILL TEST

~_~ DOLLAR BILL OR SIMILAR

SIZE PIECE OF PAPER

6. DOLLAR BILL TEST

Place a dollar bill or similar size piece of paper between weatherstrip and contact surface,
then close door.

Slowly withdraw the bill or paper after door is closed to check the amount of pressure on the
weatherstrip. There should be some resistance as the bill or paper is withdrawn. If little or no
resistance is noted, it indicates that there is insufficient contact between weatherstrip and
surface.

12
 DIAGNOSIS TECHNIQUES
7. CHALK TEST
Apply soft chalk to surface of the weatherstrip around the perimeter of the door or hatch roof
panel. Be sure the chalk line is unbroken and that surrounding areas are free of chalk.

Close the door or panel completely, without slamming, to firmly compress the weatherstrip
against its mating surface, and then reopen.

The chalk line on the weatherstrip will be marred where it has good contact. There will be a
corresponding imprint left where weatherstrip touched its mating surface. Any irregularities
in chalk line on either surface indicate a poor seal.

Potential Waterleak Areas (Diagnosis Chart)

To assist you in the diagnosis and correction of T-Top waterleaks, a chart has been
developed and is included in your handouts. Use as help aid if you so desire.

The Chart Includes:

Possible water entry points, probable causes and possible repair solutions.

The conditions and corrections on the chart were developed from in-plant and field
watertests.

Appropriate corrections have been instituted at the plant level to control build and sealing
operations.

Design changes have also been made and will continue to be made where necessary to
improve and simplify sealing operations.

Items listed on this chart should not be misconstrued as the only possible waterleak areas
but rather as a guide in locating the types of waterleaks that can be encountered.

In addition, there may be a combination of causes which contribute to the same leak
condition; therefore, it is advantageous to eliminate all known conditions in that general
area.

13
 DIAGNOSIS TECHNIQUES
T·TOP WATERLEAK DIAGNOS S CHART
POINT OF WATER PROBABLE CAUSE(S)
CORRECTION
ENTRY OF LEAK
Headliner - between Skips or voids In the Remove upper finishing molding, raise
twin 11ft-off roof panels sealing of body seams sealing pads and apply sealer along front
or at rear of roof panel underneath twin 11ft-off and rear cutout seams, also, check front
opening. panel center upper and rear foam pads.
finishing molding.
Outboard corners of Skips or voids In the Remove weatherstrip and existing sealer
weatherstrip between sealing or bridge material from front and rear upper
roof sheet metal and material between the corners of roof panel to windshield and
weatherstrip. weatherstrip and the center pillars. Apply strip-caulk and
roof sheet metal. smooth material in area to be bridged.
Any area between roof Skips or voids in Apply a smooth continuous 3/15" bead of
portion of weatherstrip weatherstrip adhesive. adhesive in the Inboard lip of retainer
and retainers or at around total body opening.
outboard ends of
retainers.
Skips or voids in Apply a secondary sealing bead of
secondary sealing. adhesive at front and rear portion of
weatherstrip In body opening.
Twin 11ft-off panel Skips or voids in Apply a bead of adhesive sealing material
between glass and outer urethane adhesive. the entire length of weatherstrip retainer.
plastic support panel.
Twin 11ft-off panel Skips, voids or 1. Apply double adhesive backed tape to
between outer plastic improperly sealed under surface of sealing strip.
support panel and the weatherstrips or sealing 2. Install retainer over sealing strip and
sealing strip, strips. loosely drive screws.
weatherstrip and/or 3. Apply a bead of strip caulk to ends of
weatherstrip retainer. retainer.
4. Place lift-off panel in opening, align
weatherstrip retainer with body
opening weatherstrip butt joint and
tighten screws.
5. Smooth sealer flush at front and rear
of retainer.
6. Apply a bead of adhesive the entire
length of the weatherstrip retainer.
Door glass to side Misaligned, misadjusted 1. Position weatherstrip Into weatherstrip
weatherstrlps (especially twin lift-off panel retainer Inserting retainer tabs through
at the butt joint areas). weatherstrip at butt slots in retainer.
joints. 2. Roll outboard edge of weatherstrip into
Misaligned, misadjL!sted retainer.
door glass. 3. Insert both Inboard and outboard
edges of weatherstrip Into retainer.
4. Push side roof rail weatherstrip lightly
to opening weatherstrip butt joint and
drive retainer tab screws. Increase slot
size in retainer if additional
adjustments are required.

14
Before sealing any leaks, it is important to know which sealer to use to repair the various
areas where a leak may be encountered.

Stationary Glass
Urethane Sealant (GMWWD #12345633) is the only GM recommended sealant for:
1. Windshield to body opening
2. Lift-off panel glass to support
3. Panel glass to three piece poly-carbonate channel

Metal Joints, Seams and Smal Pin Holes

1. Paintable body sealers such as: Heavy Drip Check Sealer, Leak Stop Sealer, Wet/Dry
Leak Check Sealer, etc.

Weatherstrip Retainers
1. 3M 6375 Scotchfoam Black Vinyl Foam Tape
2. Bedding and glazing compound

Screws and Nuts

1. Thumb grade type sealers such as:
a. Bulk-caulk
b. Strip caulk

Weatherstrips
1. Black weatherstrip adhesive such as:
a. 3M 08011

Release Agent
A special blend of solvents that quickly softens adhesive bonds between weatherstrips and
metals to aid in weatherstrip removal. Will not harm paint finish.
1. Kent 30125 - Special Release Agent SR-A
2. 3M 08971 - Release Agent
3. American Sure Seal SRI - Release It

15
SEAL
Tracing Powder
Used to check weatherstrip contact to a mating surface.
1. American Sure Seal STP - Tracing Powder
2. Kent 20065 - Tracing Powder STP

Adhesive Cleaner
A special blended cleaning solvent that will not harm the paint finish, vinyl or plastics.
1. Kent 60070 - Acrysol Body Solvent
2. American Sure Seal BSS - General Purpose Sure Solve
3. 3M 08984 - General Purpose Adhesive Cleaner

Silicone Paste
A paste material. When applied on the weatherstrips, deposits a thin protective film coating
over the outer surface.
1. GM part number 1042863

16
 BODY LOCK PILLAR WEDGE PLATE

1. WEDGE PLATE
2. MASKING TAPE

Door and Body Lock Pillar Wedge Plates

Before adjusting the lift-oft panel or door glass make sure that the door to lock pillar makes
contact.

The door side of wedge plate is a plastic material, and the lock pillar side of wedge plate is
stamped metal.

To check wedge plate contact, proceed as follows:

Open door and apply a piece of masking tape over the body lock pillar wedge plate. Close
door and reopen. Then, check tape.

If tape IS NOT torn, add additional shims as required. Shims are available for door and
body side wedge plates.

Perform the check again, if the tape IS torn, alignment is correct.

17
A common repair for most waterleak conditions is adjusting the components that form the
seal.

Before attempting to seal any leak it is important to know what sealers and/or related
products to use on the different areas of the vehicle.

DOOR W NDOW GLASS ADdUSTMENTS

1. BOLT-FILLER ASSEMBLY TO SUPPORT

2. NUT-UP STOP ON SUPPORT
3. BOLT-SUPPORT TO INNER PANEL
4. RIVET·SASH CHANNEL TO GLASS
5. BOLT-GLASS STABILIZER
6. BOLT-REAR UP STOP
7. BOLT·REAR GUIDE CHANNEL
8. BOLT-GUIDE CHANNEL TO SUPPORT
9. BOLT-CAM CHANNEL
10. RIVET-REGULATOR
11. ADJUSTING STUD AND NUT-FILLER ASSEMBLY

Door Window Glass Adjustments

Any work performed on window system hardware requires removal of the door trim and
inner panel water deflector.

After making adjustments, tighten all loosened attachments to 10 to 14 Nom (90 to 125 in-Ibs)
torque.

18
To seat it more firmly against its weatherstrip, the door window glass may need to be tipped
forward, tipped rearward, or raised SLIGHTLY. To do this:

1. Remove door interior trim panels and hardware, including the water deflector.
2. Determine the needed adjustment, and follow appropriate procedure.

Window Rotated - Loosen up-stop bolts (2 and 6); and inner panel cam bolts (9).
Adjust window as required and tighten attaching screws.

Window Upper Edge Too Far Inboard or Outboard - Loosen the following:

a. Filler at belt (1 and 11)

b. Rear guide upper support lower bolts (8)
c. Adjust rear guide as needed and tighten bolts. Adjust and tighten filler assembly.

Window Too Far Forward or Rearward - Loosen filler assembly bolts (3 and 11).

With the window partially down, loosen bolts on rear guide channel (7). Position glass to
opening as needed and tighten bolts. Position filler to glass and opening as needed and
tighten bolts.

Window Too High or Too Low in Up Position - Loosen up-stop bolts (5). Adjust up-
stops as needed and tighten bolts.

3. Check the window seal for proper adjustment.

4. Install water deflector, and door interior trim panels and hardware.

19
 LIFT-OFF GLASS PANEL CHANNEL

10
o 0_

5 9
SECTION A-A

1. SINGLE EDGE RAZOR BLADE

2. SIDE CHANNEL VIEW B
3. CENTER CHANNEL
4. CHANNEL LIP
5. LIFT-OFF GLASS PANEL CHANNEL
6. URETHANE SEALANT
7. CHANNEL
8. URETHANE SEALANT
9. GLASS TOP SURFACE
10. GLASS BOTTOM SURFACE

Lift-Off Glass Panel Channel

On some earlier style vehicles with the T-Top option, a three-piece, formed, black poly-
carbonate plastic channel is bonded to the glass around three sides with urethane sealant.

DISASSEMBLY

1. Place lift-off glass assembly on a clean, protected surface.

2. With a single edge razor blade, cut the urethane adhesive between the glass and glass
channel.
3. Place glass aS~9mbly upside down on the work surface. With a single edge razor blade,
cut the channel next to the channel lip.
4. Grasp edge or end of channel and pull upward and/or outward to disengage channel
from glass.
5. Remove excess urethane from glass with razor blade and clean surfaces with a glass
cleaner.

20
REASSEMBLY

1. Apply the clear glass primer to edges of the glass and interior sides of channel.
2. Position new channel on glass and remove any excess material in the area of the glass
and metal frame.
3. Remove channels and apply a small bead of Urethane Sealant (GMWDD #12345633)
into the interior of the channels.
4. Install long, center channel over edge of glass (Section A) and press firmly in position.
5. Install side channels by first placing the end of each channel against the end of the center
channel, then over the edge of the glass making certain that channel is under the metal
frame before pressing channel in position.
6. Place cloth-backed tape over channels to hold firmly in place. To reduce urethane cure
time, warm water may be applied to channel installation.
7. Allow sufficient time for urethane to cure, trim off excess urethane and then install lift-off
panel.

21
 LIFT-OFF PANEL WEATHERSTRIP RETA ER
AND SEALING STRIP INSTALLATION

ADHESIVE TAPE

SEALING STRIP
(AWNING) TAPE
SECTION A-A

L1FT·OFF PANEL AT
WEATHERSTRIP SEALING STRIP

STRIP CAULK
MATERIAL

WEATHERSTRIP SIDE ROOF

RAIL RETAINER

VIEW B

Side Roof Rail Lift-Off on Glass Panel Weatherstrip

The side rail lift-off panel weatherstrip is of hollow tubular construction with slotted integral
reinforced tabs at each end. The weatherstrip ends are mitered to mate with the body side
weatherstrip at the side roof rail to windshield and body lock pillar joints.

The edges are tucked into a retainer which is attached by screws to the glass panel support.
The retainer is sealed to the support assembly with a foam (nitrile) tape.

Black weatherstrip adhesive is applied to the inboard edge of the retainer.

The slotted tabs of the weatherstrip permit it to be positioned for a uniform fit to the mating
mitered joints of the panel opening weatherstrip before the tab screws are tightened.

Sealer skips and voids can cause waterleaks between the outer plastic support panel and
sealing strip, weatherstrip and/or weatherstrip retainer.

22
 BODY OPEN NG SEALING

-- --=--::::::: -

~ B
VIEW B
VIEW OF RIGHT FRONT CORNER OF THE VIEW OF THE RIGHT FRONT CORNER OF
ROOF ASSEMBLY AT LIFT OFF PANEL THE ROOF ASSEMBLY SHOWING THE
OPENING. BRIDGING OF THE SEALING MATERIAL.

VIEWC VIEW D

VIEW OF THE RIGHT REAR CORNER OF ROOF VIEW OF THE UPPER FRONT CORNER
OPENING SHOWING SMOOTH MATERIAL BRIDGE FORMED BY THE ROOF PANEL AND
BETWEEN ROOF AND PILLAR WEATHERSTRIP WINDSHIELD INNER UPPER FRAME.
RETAINERS.

Replacement of Side Roof Rail Lift-Off Panel Weatherstrip

Retainers and Sealing Strips:
1. Remove lift-off panel and place upside down on a clean protected work surface.
2. Remove handle and lift-off panel trim cover.
3. Remove screws holding tabs at each end of lift-off panel weatherstrip.
4. Begin to remove weatherstrip from weatherstrip retainer by carefully pulling on weath-
erstrip while breaking sealer bond between weatherstrip and retainer with a flat-bladed
tool. A suitable release agent (Kent Special Release Agent, 3M Release Agent or
equivalent) or a heat gun will aid in breaking the weatherstrip adhesive bond. Remove
plastic tabs on weatherstrip through retainer slots.
5. Remove screws located along retainer and carefully lift up retainer using a flat-bladed
tool.

NOTE
If sealing strip displays a wavy or rippling effect prior to the removal of the
lift-off panel from the roof opening, it should be replaced.
6. Remove sealing strip (awning) by pulling upward.
7. Scrape excess sealer from weatherstrip retainer.

23
 LIFT-OFF PANEL WEATHERSTRIP RETAINER AND
SEALING STRIP INSTAL ATION

BUTT JOINT
(FLUSH TO 1.5 MM
AT LOWER EDGE OF PLASTIC SUPPT.
TO ROOF OTR. PNL.)

-d1-FLUSH
SECTION B-B VIEW A

INSTALLATION PROCEDURES
1. If original sealing strip is to be replaced, apply 3M's 969 High Tack 1/2" Acrylic Adhesive
or equivalent to the under surface of the sealing strip. Then, press strip to support.
2. Apply 3M's 6375 Scotchfoam 1/2" Black Vinyl Foam Tape or its equivalent to the bottom
surface of retainer.
3. Install retainer over sealing strip and drive screws loosely.
4. Place lift-off panel in the opening, align weatherstrip retainer with body opening weath-
erstrip butt joint for in and out alignment.
5. If aligned properly, tighten screws securely.
6. Remove lift-off panel and place upside-down on a clean protected work surface.
7. Apply a bead of strip caulk to each end of the weatherstrip retainer.

24
 MATING OF LIFT·OFF PANEL AND BODY OPENING
WEATHERSTRIPS MITERED JOINTS

PROPER MATING OF FRONT

MITERED BUTT JOINTS

8. Apply a 3/16" bead of sealing material (3M's 8011 or Sure Seal BSG-B) the entire length
of weatherstrip retainer.
9. Position weatherstrip into weatherstrip retainer inserting retainer tabs through slots in
retainer.
10. Roll outboard edge of weatherstrip into retainer.
11. Insert both inboard and outboard edges of weatherstrip into retainer.
12. Place lift-off panel in the opening, align weatherstrip with body opening weatherstrip
butt joint.
13. Push side roof rail weatherstrip lightly to opening weatherstrip butt joint and drive
retainer tab screws. Increase slot size in retainer if additional adjustments are required.
14. Remove unit and replace all previously removed hardware and trim panel.
15. Remove and replace unit several times to check alignment then, test the assembly for
leaks.

25
Lift-Off Panel Adjustments
Proper lift-off panel adjustments are important to prevent waterleaks. If it is determined that
the panel requires adjusting, make sure that the condition is not caused by another
component such as the door glass and/or door to lock pillar without making proper contact.

LIFT-OFF PANEL UP/DOWN HEIGHT CHECK

To check and align up/down height of lift-off panel:

1. Place a straight edge, horizontally across the front lower edge of the lift-off panel plastic
support and front roof header panel.
2. Hold a second scale or ruler vertically against the horizontally placed straight edge,
directly above and touching front roof header panel.
3. Notice how much of the vertical scale or ruler extends below the bottom of the horizontal
placed one. It should read not more than 1/16", or one-and-a-half millimeters.

26
The rear of the lift-off panel can be checked in the same manner by placing the vertical scale
or ruler across the horizontal straight edge directly above and touching the roof at the lock
pillar.

NOTE
If lift-off panel is high in the opening, you would place the vertical straight
edge or ruler above the front roof header or the roof panel at the lock pillar.
To be considered properly aligned, it should be flush to not more than
1.5mm (1/16").

4. Disengage lift-off panel from roof.

LIFT-OFF PANEL UP/DOWN ADJUSTMENT

STRIKER ASSEMBLY
(FRONT SHOWN
REAR SIMILAR)

5. If front, left, or right side of panel needs adjusting, remove windshield pillar trim to
adjust.
6. If rear needs adjusting, remove body lock pillar upper trim panel.
7. Loosen the striker assembly attaching bolts.
8. Adjust up or down travel of lift-off panel assembly as required.
9. Retighten bolts to 5 to 7 l'Jom (4 to 5 ft./lbs.).
10. Install lift-off panel assembly and check for proper fit.
11. If properly aligned, replace previously removed garnish molding or trim panel.

27
 LIFT-OFF PA EL IN/OUT ALIG MENT CHECK

,"", C USING RULER OR STRAIGHTEDGE TO

~K IN/OUT ALIGNMENT OF LIFT-OFF PANEL

\
"

To check and adjust in/out alignment of lift-off panel:

1. Place the flat side of a straight edge against the curved radius at the front leading edge of
the lift-off panel outer plastic support and the upper outboard corner of the windshield
header panel.

NOTE
Adjust front of lift-off panel flush before attempting to adjust the rear of the
panel.

28
 LIFT-OFF PANEL IN/OUT ADJUSTMEN
ADJUSTING SUPPORT PLATE
ATTACHING NUTS

FRONT SHOWN REAR SIMILAR

To adjust the front of lift-off panel, perform the following:

a. Remove lift-off panel from the opening.

b. Remove windshield pillar upper garnish molding.
c. Loosen nuts securing front support plate.
d. Adjust front striker fore or aft as required.
e. Retighten nuts to 6-8 Nom (4.5-6 ft./lbs.).
f. Install panel and check curved radius again.

If straight edge lies flat with no voids between it and the curved radius, proceed to step
number two (2).

29
 EDGE OF GLASS TO UPPER FINISH MOLDING
ALIGNMENT C ECK

OF FRONT AND REAR OF EDGES ACROSS

T·BAR AND L1FT·OFF PANEL
------
MASKING TAPE APPLIED 1"·2" INBOARD

2. With lift-off panel latched in the opening, apply a piece of masking tape across the glass
panel and the center upper finishing molding (T-Bar) approximately 1"-2" inboard of the
front and rear edges of the lift-off panel.
3. Cut the masking tape along the side of the center upper finishing molding.
4. Disengage and remove lift-off panel assembly.
5. With a ruler, measure the distance from the applied masking tape to the edge of the
glass.

NOTE
The distance from edge of masking tape to edge of glass at both front and
rear of panel should be identical.

6. If not the same, the rear of the panel must be adjusted.

7. After all adjustments are made, install glass and check for proper fit.
8. Reinstall all previously removed trim.

30
 Lift-Off Panel Opening Center Upper Finishing Molding
The center upper finishing molding provides inboard retention of both right glass panels and
the center inboard weatherstrip retainer and is retained with sheet metal screws.

L T-OFF PANEL OPENING CENTER UPPER

FINISH MO DING SEALrNG A D
INSTALLATION

C ~B SEALING PAD

~
A
REAR AREA CUT-OUT
SHOWN, 'FRONT SIMILAR
/

~.
/
"-,-.;or./'oJ" y./
VIEW A
SEALING PAD

SCREWS

SECTION A-A VIEWC

VIEW B

To prevent water from entering into the passenger compartment at the lift-off panel upper
finishing molding, perform the following:

1. Remove lift-off panel from vehicle.

2. Remove both body opening weatherstrips in the area of the Upper Finishing Molding (T-
Bar) utilizing a flat-bladed tool and/or a suitable weatherstrip release agent.
3. Remove attaching screws.
4. Raise sealing pads and apply continuous beads of bedding and glazing compound, such
as Sure Seal LSW or 3M 08531, along front and rear weatherstrip retainer cutouts.

• 5. Reinstall sealing pads over retainer cutouts.

31
 FOAM SEALING PADS

TYP. BOTH ENDS

BEFORE MLDG.
INSTALLATION

VIEW B

6. Inspect and replace as required, front and rear foam sealing blocks.
7. Reinstall finishing panel molding and attaching screws.

32
Lift-Off Panel Opening Weatherstrip
The body opening is a one-piece tubular construction. It includes the windshield and the
body lock pillar sections as well as the perimeter of the lift-off panel opening.

The section of the weatherstrip around the perimeter of the lift-off panel opening incorpo-
rates a double tubular section. The area along the lock pillar has a raised lip. Both serve as
channels for water drainage. The opening butt joints are mitered to insure a uniform fit to the
lift-off glass weatherstrip.

The inner lip of the weatherstrip closest to opening serves to seal the glass of the lift-off
panel from water entry into the vehicle. The outer lip, (furthest from opening), serves to seal
against the lift-off panel edge thereby creating a double seal.

NOTE
It will not be necessary to replace the weatherstrips in all cases. However, in
those cases where it is necessary, current weatherstrips are the only parts to be
used and MUST BE REPLACED IN SETS (roof opening and lift-off panel) on the
affected side.

CURRENT WEATHERSTRIP PART NUMBERS ARE:

Left Side Set:

• Weatherstrip, Lift-Off Panel Opening On Body - 20667535

• Weatherstrip, Side Roof Rail On Lift-Off Glass - 20680014

Right Side Set:

• Weatherstrip, Lift-Off Panel Opening On Body - 20667534

• Weatherstrip, Side Roof Rail On Lift-Off Glass - 20680014

33
 L T OFF PANEL OPENING WEAT ERSTRIP
STALLATION

FINISHING
MOLDING

SECTION A-A

VIEW D VIEW C VIEW B

REMOVAL PROCEDURES
1. Remove lift-off panel.
2. Remove plastic fasteners located at rear end of lift-off panel opening weatherstrip using
tool J-21104 or equivalent.

NOTE
The following o,peration must be performed carefully to prevent damage to the
weatherstrip.

3. Remove retaining screws from upper front and rear corners of weatherstrip opening.
4. Grasp weatherstrip and pull upward gently while inserting a flat-bladed tool between
weatherstrip retainer and weatherstrip to break cement bond.

Using a suitable release agent, (Kent Special Release Agent or equivalent) or heat gun
will aid in breaking the weatherstrip adhesive bond.

34
 SEALING LOCATIONS AND PATTERNS FOR
BODY OPENING WEATHERSTRIP

BLACK BLACK
WEATHERSTRIP o B o o WEATHERSTRIP
ADHESIVE ADHESIVE
T-BAR
SECONOARV~
SE: I PRIMARY
~ SEALING

SECTION A-A SECTION B-B SECTION C-C

C C

STRIP CAULK TO FORM

MATERIAL "BRIDGE"

WINDSHIELD PILLAR LOCK PILLAR

WEATHERSTRIP RETAINER WEATHERSTRIP RETAINER

INSTALLATION PROCEDURES
1. Remove excess sealer from weatherstrip retainer.
2. Apply a coat of 3M 08643 - Window Weld Primer as a corrosion protection barrier in
areas where paint damage was done during clean up operations.

35
 SEALI G 0 TBOAR EDGES - ROOF ETAINER AREA

1/8" CONTINUOUS BEAD

ADHESIVE APPLICATION

3. Apply a smooth, continuous bead (1/8") of 3M 08011 or Sure Seal BSG-B adhesive in
the outboard edges of the roof area retainer.

FRONT AND REAR OU BOARD EDGES ADHESIVE BEAD

APPL CAT ON
APPLYING A QUARTER-SIZED
AMOUNT OF ADHESIVE

36
4. Apply a quarter-sized amount of 3M 08011 or Sure Seal BSG-B adhesive in the front
and rear inboard corners of the roof opening weatherstrip retainer.
5. Apply a smooth, continuous bead (1/8") of 3M 08011 or Sure Seal BSG-B adhesive in
the outboard edges of the windshield pillar and body lock pillar weatherstrip retainers.

OUTBOARD EDGE ADHESIVE BEAD APPLICATION

BODY OPENING TO SUPPORT ATTACHMENT

VIEW A VIEWS

37
6. Position weatherstrip at both outboard corners of lift-off panel opening. Align holes in
weatherstrip to supports and install screws.

POSITIONING WEATHERSTRIP AT LEFT OUTBOARD

CORNER

7. Continue to position weatherstrip from outboard corners following roof opening to

center upper finishing molding (front and rear).

POSITIONING WEATHERSTRIP AT RIGHT OUTBOARD

CORNER

38
 WATERLEAK REPAIR OPERATIONS
WEATHERSTRIP INSTALLATION UNDER T·BAR

FLAT-BLADED TOOL

BODY OPENING
WEATHERSTRIP

8. Complete installation of weatherstrip by positioning it under center upper finishing

molding.

NOTE
To assist in inserting weatherstrip into retainer in the area of the center upper
finishing molding (T-bar), use a flat-bladed tool to tuck in corners, ends and top
edges of weatherstrip.

9. Insert windshield pillar and body lock pillar ends of weatherstrip into retainer (outboard
edges first) starting at hatch opening and working downward. Roll inboard edges of
weatherstrips into retainer.
10. Remove protective liner from front end of weatherstrip and align front end of weath-
erstrip to hinge pillar and press firmly to secure.
11. Align holes in rear end of weatherstrip to pierce holes in body lock pillar and drive
fasteners to secure.

39
 BODY OPE ING WEATHERSTRIP POSITIONING CHECK
- FRONT UPPER CORNER

POSITION WEATHERSTRIP
WEATHERSTRIP 5·BMM (3/16"-5/16") INBOARD

. . -_ \::~_::__=___=_\
:__-. O_F_D_O-=O:R:O:P::EN::I~N~G __L1NE

--~----

. RULER

NOTE
To insure proper fit of weatherstrip at front upper corner, weatherstrip must be
positioned 5-8mm (3/16"-5/16") inboard of door opening line. At rear corner, it
must be positioned as far inboard as possible.

12. Two additional 5mm (3/16") beads of adhesive must be applied as follows:
a. Between the outer lip of opening weatherstrip and roof header panel.
b. Between the outer lip of opening weatherstrip and roof panel at rear of body opening.

The beads of weatherstrip adhesive should be continuous and extend the full length of
the weatherstrip at both front and rear weatherstrip outer lip to panel contact points.

40
• SECONDARY SEALING OF BODY OPENING
WEATHERSTRIP

o o o

APPLY SEALER APPLY SEALER

ENTIRE LENGTH A A B B ENTIRE LENGTH

WEATHERSTRIP WEATHERSTRIP

SECTION A-A SECTION B-B

13. Replace lift-off panel and remove several times to insure a proper fit. Make sure lift-off
panel weatherstrip mitered joint and body opening weatherstrip mitered joint are
properly mated.

LIFT-OFF PANEL AND BODY OPENING WEATHERSTRIP

1. MITERED JOINT -
LIFT-OFF PANEL
WEATHERSTRIP
2. MITERED JOINT -
BODY OPENING
WEATHERSTRIP

41
 MATING OF WEATHERSTRIP FRONT MITERED
BUTT JOINTS

PROPER MATING OF FRONT

MITERED BUTT JOINTS

MAT NG OF WEATHERSTRIP REAR MITERED

BUTT JOINTS

I II ~--
PROPER MATING OF
I REAR MITERED
BUTT JOINTS

\ Ii

14. Water test assembly to insure no leak exists.

42
 LEAKS BETWEEN LIFT-OFF PANEL AND OUTER PLASTIC SUPPORT PANEL
AND/OR WEATHERSTRIP RETAINER

Sealer skips and voids can cause waterleaks between the outer plastic support panel and
sealing strip, weatherstrip and/or weatherstrip retainer.

SIDE ROOF RA L ON LIFT·OFF GLASS WEATHERSTRIP

INSTALLATION

BUTT JOINT

To repair leak(s), perform the following operations:

1. Replace double adhesive backed tape to under surface of sealing strip.
2. Reinstall retainer over sealing strip and loosely drive screws.
3. Apply a bead of strip caulk to the ends of retainer.
4. Place lift-off panel in opening.
5. Align weatherstrip retainer with body opening weatherstrip butt joint and tighten screws.
6. Smooth sealer flush at front and rear of retainer.

•
7. Apply a bead of adhesive the entire length of the weatherstrip retainer.

43
 LIFT-OFF GLASS PANEL WEATHERSTRIP TO RETAINER
SEALING

URETHANE ADHESIVE

0. .-

<fSS"'-7~.........._ LIFT-OFF GLASS PANEL

WEATHERSTRIP

VIEW A

WEATHERSTRIP INSTALLATION

1. Position weatherstrip into weatherstrip retainer inserting retainer tabs through slots in
retainer.
2. Roll outboard edge of weatherstrip into retainer.
3. Insert both inboard and outboard edges of weatherstrip into retainer.
4. Push lift-off glass weatherstrip lightly to properly mate with body opening weatherstrip
mitered butt joint and drive retainer screws.

NOTE
Retainer screw slots will have to be increased in size if additional adjustments
are required.

44
 FINAL WATERTEST
Final Watertest
No vehicle should ever be returned to an owner after a waterleak correction without
retesting. You cannot be certain that the leak was corrected unless you give the vehicle a
final watertest.

After all necessary repairs are performed, the lift-off panel(s) should be removed and
replaced several times to determine if proper alignments .are maintained. Retest the unit
with the proper watertest equipment to insure a satisfactory repair.

Apply a light coating of paste silicone, GM part number 1042863, with a clean cloth to all
weatherstrip surfaces to prevent squeaks and prolong weatherstrip life.

45
 1:--
Service TecMology GIOUp

WE SUPPORT
VOLUNTARY TECHNICIAN
CERTIFICATION THROUGH
Nal,onai InstItute 10'
AUTOMOTIVE
SERVICE
EXCELLENCE
I /"'L
./
•

. ~. ;

December 1990

GENERAL MOTORS CORPORATION LITHO IN USA