23-005-13

NUMBER:
GROUP:
DATE:
23-005-13
Body
February 27, 2013
This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retrieval system,
or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of Chrysler Group LLC.
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 23-016-10 REV. A, DATED
SEPTEMBER 25, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL
MODELS, NOTES OR EXPANDED STEPS TO THE PROCEDURE.
SUBJECT:
Water Leaks At The Front And/Or Rear Roof Area
OVERVIEW:
This bulletin involves inspecting the front and/or rear of the headliner for dampness. If
necessary add additional seam sealer to the roof ditch and replacing the front and/or rear
sunroof drain tubes or grommets.
MODELS:
2007 - 2010
(MK)
**Compass** / Patriot
NOTE: This bulletin applies to vehicles built before August 20,2010 (MDH0820XX).
SYMPTOM/CONDITION:
Water leaks from the roof ditch and sunroof area.
DIAGNOSIS:
The customer may experience dampness at the front and/or rear of the headliner.
PARTS REQUIRED:
Qty.
Part No.
Description
1(AR)
57010774AA
Tube, Right Front Sunroof Drain (Patriot)
1(AR)
57010773AA
Tube, Left Front Sunroof Drain (Patriot)
2(AR)
05160134AC
Tube, Rear Sunroof Drain (Patriot)
**1(AR)
68082597AB
Tube, Right Front Sunroof Drain (Compass)**
**1(AR)
68082598AB
Tube, Left Front Sunroof Drain (Compass)**
**2(AR)
05160043AB
Tube, Rear Sunroof Drain (Compass)**
2(AR)
05027191AA
Grommet, Front Sunroof Drain Tube
1(AR)
05116250AD
Molding, Right Roof Ditch
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Qty.
Part No.
Description
1(AR)
05116251AD
Molding, Left Roof Ditch
1(AR)
NPN
Kent Hi-Tech Clear Seam Sealer P10200 or
Equivalent (One 5oz. tube services one
vehicle)
1(AR)
NPN
3M 08984 General Purpose Adhesive
Cleaner or Equivalent (1oz. services one
vehicle)
INSPECTION PROCEDURE:
1. Inspect the headliner at the front and rear of the vehicle. Was there any dampness
and/or water stains on the headliner?
a. Yes>>> Proceed to Step #2.
b. No>>>This bulletin does not apply continue further diagnosis.
2. Lower the headliner. Perform a water flow test to the entire roof. Where there any
signs of water leaking?
a. Yes>>> Proceed to Step #3.
b. No>>> This bulletin does not apply continue further diagnosis.
3. If the water was leaking from the front and/or rear of the roof area and built before
12/10/2009 and is equipped with convoluted drain tubes (Fig. 1) proceed to Step #1 of
the repair procedure. If the vehicle was built after 12/10/2009 proceed to Step #1 of
roof seams and rear body plugs.
Fig. 1 Convoluted Drain Tube
1 - Convoluted Drain Tube
2 - Sunroof Module
REPAIR PROCEDURE:
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1. Remove the right and left front sunroof drain tubes. Refer to the detailed removal
procedures available in DealerConnect> TechCONNECT under: Service info> Body>
Sunroof> Tube, Sunroof Drain> Removal.
2. Is the vehicle equipped with a manual transmission or automatic transmission?
a. If the vehicle is equipped with a automatic transmission proceed to Step #1 install
left front drain tube for vehicles equipped with an automatic transmission only.
b. If the vehicle is equipped with a manual transmission proceed to Step #1 install left
front drain tube for vehicles equipped with a manual transmission only.
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INSTALL LEFT FRONT DRAIN TUBE FOR VEHICLES EQUIPPED WITH A
AUTOMATIC TRANSMISSION ONLY:
1. Remove the air cleaner body. Refer to the detailed removal procedures available in
DealerConnect> TechCONNECT under: Service info> Engine> Air Intake System>
Body, Air Cleaner> Removal.
2. Remove the two nuts retaining the master cylinder to the brake booster and move it
forward so the left front sunroof drain tube routing path can be accessed behind the
left front strut tower (Fig. 2).
NOTE: Do not disconnect any brake lines connected to the master cylinder.
Fig. 2 Brake Booster
1 - Nuts
3. Remove the lower left side cowl trim panel. Refer to the detailed removal procedures
available in DealerConnect> TechCONNECT under: Service info> Body> Interior>
Panel, Cowl Trim, Side> Removal.
4. Remove the kneeblocker. Refer to the detailed removal procedures available in
DealerConnect> TechCONNECT under: Service info> Body> Instrument Panel>
Kneeblocker> Removal.
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5. Route the new left front sunroof drain tube through the engine side of the bulkhead
(Fig. 3)
Fig. 3 Left Front Drain Tube
1 - Strut Tower
2 - Air Box
3 - Master Cylinder
4- Drain Tube Grommet
NOTE: From underneath the left side instrument panel, roll back the jute between
the bulk head and the instrument panel at the top left to verify drain tube
routing.
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6. Verify the grommet is correctly seated in the bulk head using a mirror and position it
behind the strut tower looking at the upper right corner (Fig. 4).
NOTE: **If the grommet is damaged or has a 90°elbow and is not a straight grommet,
replace it with new grommet PN 05027191AA.**
Fig. 4 Drain Tube Grommet Seated
1 - Drain Tube
2 - Bulk Head
7. Connect the drain tube to the sunroof drain spout and drain tube pass through
grommet.
8. Install the Kneeblocker. Refer to the detailed removal procedures available in
DealerConnect> TechCONNECT under: Service info> Body> Instrument Panel>
Kneeblocker> Installation.
9. Install the lower left side cowl trim panel. Refer to the detailed installation procedures
available in DealerConnect> TechCONNECT under: Service info> Body> Interior>
Panel, Cowl Trim, Side> Installation.
10. Re-secure the master cylinder to the brake booster with the two nuts previously
removed.
11. Install the air cleaner body. Refer to the detailed Installation procedures available in
DealerConnect> TechCONNECT under: Service info> Engine> Air Intake System>
Body, Air Cleaner> Installation.
12. Skip the next procedure for manual transmission only and proceed to Step #1 RIGHT
FRONT SUNROOF DRAIN TUBE.
INSTALL LEFT FRONT DRAIN TUBE FOR VEHICLES EQUIPPED WITH A MANUAL
TRANSMISSION ONLY:
1. Remove the air cleaner body. Refer to the detailed removal procedures available in
DealerConnect> TechCONNECT under: Service info> Engine> Air Intake System>
Body, Air Cleaner> Removal.
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2. Remove the master cylinder. Refer to the detailed removal procedures available in
DealerConnect> TechCONNECT under: Service info> Brakes> Hydraulic/Mechanical>
Master Cylinder, Brake> Removal.
3. Remove the lower left side cowl trim panel. Refer to the detailed removal procedures
available in DealerConnect> TechCONNECT under: Service info> Body> Interior>
Panel, Cowl Trim, Side> Removal.
4. Remove the clutch pedal for access to the bulk head where the drain tube will be
routed.
5. Route the new left side sunroof drain tube through the engine side of the bulkhead
(Fig. 5).
NOTE: From underneath the left side instrument panel, roll back the jute between
the bulk head and the instrument panel at the top left to verify drain tube
routing.
Fig. 5 Right Front Drain Tube
1 - Right Strut Tower
2 - Drain Tube Grommet
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6. Verify the grommet is correctly seated in the bulk head using a mirror and position it
behind the strut tower looking at the upper right corner (Fig. 6).
NOTE: **If the grommet is damaged or has a 90°elbow and is not a straight grommet,
replace it with new grommet PN 05027191AA.**
Fig. 6 Drain Tube Grommet Seated
1 - Drain Tube Grommet
2 - Bulk Head
7. Connect the drain tube to the sunroof drain spout and drain tube pass through
grommet.
8. Install the clutch pedal.
9. Install the lower left side cowl trim panel. Refer to the detailed installation procedures
available in DealerConnect> TechCONNECT under: Service info> Body> Interior>
Panel, Cowl Trim, Side> Installation.
10. Re-instal the master cylinder. Refer to the detailed Installation procedures available in
DealerConnect> TechCONNECT under: Service info> Brakes> Hydraulic/Mechanical>
Master Cylinder, Brake> Installation.
11. Install the air cleaner body. Refer to the detailed Installation procedures available in
DealerConnect> TechCONNECT under: Service info> Engine> Air Intake System>
Body, Air Cleaner> Installation.
RIGHT FRONT SUNROOF DRAIN TUBE:
1. Remove the lower right side cowl trim panel. Refer to the detailed removal procedures
available in DealerConnect> TechCONNECT under: Service info> Body> Interior>
Panel, Cowl Trim, Side.
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2. Route the new right side sunroof drain tube through the engine side of the bulkhead
(Fig. 7).
Fig. 7 Right Front Drain Tube
1 - Right Strut Tower
2 - Drain Tube Grommet
NOTE: From underneath the left side instrument panel, roll back the jute between
the bulk head and the instrument panel at the top left to verify drain tube
routing.
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3. Position a mirror behind the right strut tower and verify the grommet is properly seated
against the bulkhead(Fig. 8).
Fig. 8 Drain Tube Grommet Seated
1 - Drain Tube Grommet
2 - Bulk Head
NOTE: **If the grommet is damaged or has a 90°elbow and is not a straight grommet,
replace it with new grommet PN 05027191AA.**
4. Connect the drain tube to the sunroof drain spout and drain tube pass through
grommet.
5. Install the lower right side cowl trim panel. Refer to the detailed installation procedures
available in DealerConnect> TechCONNECT under: Service info> Body> Interior>
Panel, Cowl Trim, Side> Installation.
REAR DRAIN TUBES:
1. Remove the right and left rear drain tubes. Refer to the detailed removal procedures
available in DealerConnect> TechCONNECT under: Service info> Body> Sunroof>
Tube, Sunroof Drain> Removal.
2. Install the new rear sunroof drain tubes. Refer to the detailed installation procedures
available in DealerConnect> TechCONNECT under: Service info> Body> Sunroof>
Tube, Sunroof Drain> installation.
3. Proceed to Step #1 of the verification procedure.
ROOF SEAMS AND REAR BODY PLUGS:
1. Using a trim stick remove the right and left roof ditch moldings.
2. Remove all adhesive residue in the roof ditch with 3M General Purpose Adhesive
Cleaner 08984 or Equivalent with a general purpose cloth.
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3. Apply a clear paintable seam sealer such as Kent Hi-Tech Seam Sealer P10200 or
equivalent along both sides of the roof ditch seam as shown in (Fig. 9).
Fig. 9 Roof Ditch
1 - Clear Seam Sealer
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4. At the rear check all body plugs and grommets (Fig. 10) and verify they are properly
seated.
Fig. 10 Grommets And Plugs
1 - Grommets And Plugs
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5. At the rear roof panel apply Kent Hi-Tech Seam Sealer P10200 or equivalent around
the patch shown in (Fig. 11) on the right and left side.
Fig. 11 Roof Seam
1 - Side Aperture
2 - Sealer
3 - Tailgate
6. Allow the sealer to fully cure per adhesive manufacturers recommendations.
7. Install the right an/or left roof ditch molding(s).
NOTE: When installing the roof ditch molding apply firm pressure to the molding so
proper wet is achieved to insure proper adhesion.
VERIFICATION PROCEDURE:
1. Perform a water flow test and verify there are no water leaks.
2. Return the vehicle to the customer.
POLICY:
Reimbursable within the provisions of the warranty.
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TIME ALLOWANCE:
Labor Operation No:
Description
Amount
23-50-57-93
Inspect and water test (1 Semi-Skilled)
0.3 Hrs.
23-50-57-94
Inspect and Water Test, Repair
One Roof Seam (1 Semi-Skilled)
1.8 Hrs.
23-50-57-95
Inspect and Water Test, Repair
Both Roof Seams (1 Semi-Skilled)
2.2 Hrs.
23-30-63-96
Inspect and Water Test,
Replace Sunroof Drain Tubes
With (Auto Trans) Only (1 Semi-Skilled)
2.4 Hrs.
23-30-63-97
Inspect and Water Test,
Replace Sunroof Drain Tubes
with (Manual Trans) Only (1 Semi-Skilled)
3.2 Hrs.
23-30-63-98
Inspect and Water Test,
Replace Sunroof Drain Tubes
,Repair Both Roof Seams Only
(1 - Semi-Skilled)
3.3 Hrs.
FAILURE CODE:
ZZ
Service Action