Repair Procedure For Windshield Header Seal

This repair procedure is applicable when water is evident on the: 

Fig 1: Door Trim Panel & Instrument panel / A-pillar

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• Door trim panel (1)
• Instrument panel / A-pillar (2)

Fig 2: Header Seal

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1. Remove Header Seal (1).
   Fig 3: Butyl & Tape Residue

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   NOTE:

   A rubber wheel bit may be used to aid in residue removal

2. Remove all butyl (1) and tape residue (2).
3. Clean surface with general adhesive cleaner.
4. Alcohol wipe entire surface and allow to dry.
   Fig 4: 4mm Butyl

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   NOTE:

   This operation is only applicable for vehicles built before 6/1/2008. Vehicles built after this date, should already have sealer present in this area

5. Install 4mm butyl (1) in a pattern, as shown.
   Fig 5: Center With Butyl

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6. Fill in the center with butyl (1) and make certain to fill in all holes, wrinkles and step offs to allow for a smooth surface to bond the tape / butyl to the new seal.
   NOTE:

   Excessive amount of butyl (1) can cause transition voids/leaks. Make sure to smooth out butyl (1)

   Fig 6: New Seal

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7. Locate and install the new seal.
8. Line seal up at end points (2) on both the left and right side of header.
   CAUTION:

   THIS STEP IS CRITICAL, if not done correctly leak will return

   NOTE:

   It is also critical to pressurize the area at the ends of the seals as indicated in corner areas (1)

   NOTE:

   A small roller or firm finger pressure should be used to be certain the tape is adhered completely from side to side

9. Remove release tape and pressurize seal firmly in contact with header sheet metal to smooth out adhesive tape and butyl, starting at the ends and working toward the center.