Club Touareg Forum banner

DIY Roof/Headliner Water Leak Repair 7L

9.7K views 19 replies 6 participants last post by  casioqv  
#1 ·
Do you have water dripping from your roof compass/Webasto control/sunglassses cubby area when it rains or when you wash your beast?

237750


That's water dripping from the headliner onto the sat nav!

Have you checked the sunroof and other drains lower down to ensure there is no trapped water in those drains that could be backed up and spilling over?

If you had little or no water or blockages in those drains then the source of the water ingress must be higher up.

For me, once the other drains have been ruled out, the likely culprit has to be the seals under the aluminum slider rails that the factory roof bars slide along.

Having done the repair I can speak from experience and say that after 15 years, the rubber seals between the slider rails and the screw holes in the roof were perished and next to useless.

It doesn't help that the rubbers are very thin and fragile. Almost like it was designed not to last!

The rubber items for each side of the mk1 Treg consist of 2 lengths of rubber seals (think flimsy windshield wiper) and 6 rectangular rubber pieces for the bolt holes.

The long wiper type seals are there to keep as much water out of the channel as possible, which is recessed flush into the roof. The rectangular seals are there to stop what water does get in the recessed channel from entering the roof via the bolt holes.

Parts required:

Long rubber seals (ÂŁ38 for one pack of two seals from the dealer)

237751


2 packs required if you plan on doing both sides

6 rectanglular seals:

237753


12 required if you are doing both sides

Outdoor silicone sealant (optional)

237754


Tools required:

T25 Torx bit on a ratchet/screwdriver
Brush
Cloths or Paper Towel
Pick tool
Household cleaner ie glass/tile

Steps:

1. Remove roof bars.

2. Remove 6 x T25 bolts that secure the recessed aluminum slider rail to the roof.

237755


If you watch the bolt heads as you start loosening them you may see moisture rise up from the threads as you press down.

Also, if the threads are dry, you should hear a satisfying crack when the bolt comes loose. If it loosens without a murmur, then this may also be a sign that it is wet underneath. I had one watertight bolt seal out of six on the driver's side alone.

3. Reach in the groove with a finger and gently lift the aluminum rail up and out of the recess.

237757


4. Check all rubbers for damage, kinked edges and that all six rectangular rubbers came off with the rail.

237756


The above picture shows just how fragile the rubber seals are. This was one of three that had an epic fail around the bolt hole on the driver's side alone, letting water into my headliner and all the electrics up there. Not very robust considering how important their job is.

5. Set aside the rail and inspect the recess for pooled water, debris, damage, etc. basically anything that shouldn't be there that may cause you a problem once its all back together.

237758


6. Use the brush to remove the larger pieces of crap in the recess. Then use the spray cleaner and a cloth to wipe the rest away. Keep wiping until its just the paint and then let dry.

7. Remove the long seals from each side of the length of the rail. Take care with the rail ends as they are plastic. The ends will just pull off to make the job easier.

8. Remove the six rectangular seals from the underside of the rail. If you are doing this on a budget and will be reusing them with silicone, a quick soak in warm soapy water should get any buildup free from their nooks and crannies.

9. Clean all the mating surfaces with the spray cleaner. The entire length of the underside and the two grooves that hold the wiper seal in place. Use a pick tool, spray cleaner and the cloth to clean the wiper grooves well. Then let dry.

10 Insert the new wiper seals into their respective grooves then attach the plastic ends. Once both ends fitted and both grooves done, gently stretch the seals so they reach the plastic ends and secure them to the two clips that retain them in place at each end.

237759


11. Replace/fit new rectangular seals to underside of the rail. Consider bolstering the water repelling properties of the rubber with outdoor silicone if you wish.

12. Return cleaned rail with new/repaired seals to the cleaned roof recess and line up bolt holes carefully if you used silicone. If so, press down firmly so that some silicone pushes up the hole to form a watertight seal.

13. Put the 6 bolts back in and tighten.

14. Do the other side as required and replace the roof bars and you're done.

15. Check bolts a week later and snug up as necessary.

Tips:

If you plan on using silicone check your weather forecast so that it has adequate time to cure.

After spraying down the rail and cleaning the grooves, stand upright so that it drys quicker. Remove plastic ends before standing upright though.

If you live in a temperate climate and get your fair share of rain, definitely consider using outdoor rated silicone sealant to help the rubbers do their job better. They are just too delicate to hold up well under extreme temperature cycles.

You can either drop a blob of sealant around the bolt hole in the roof's recess or apply it to the rubber rectangles first to ensure the entire surface of the rubber is covered and the water has no way in.

If you don't want to use silicone but wish to maximise the life of your rubbers, take them off once a year and soak them overnight in Armor All or any liquid tyre cleaner. This will keep the rubber soft and flexible, extending its life.

You may be able to find the part numbers for the rubbers online and save massively compared to dealer prices. By doing this and doing the work yourself, you are saving approx ÂŁ350 and extending the life of your Treg.
 
#2 ·
Onya !!! nice write up ... for others... glad i dont have a sunroof anymore to minimise extra probs ... although i do miss it in winter o well !
 
#4 ·
Good on you !... Oz slang.... can also mean well done which is how it was meant. But others use it in a crap way.

Ok thought you did with the drain issues.........
 
  • Like
Reactions: Barrychapman
#6 · (Edited)
Update

The repair to the roof rail seals has reduced the amount of water ingress but I found the headliner was still damp across the front above my head.

I found the front windscreen top seal wasn't even to the paintwork and the plastic side trim pieces weren't secured to the metal clips at the bottom of the A pillars.

The autoglass chap came yesterday to remove the windscreen and reseal.

Long story short the sealant was perished on all four sides. It was letting water in at the top and caused rust!

The previous glazier hadn't removed all of the original sealant so the mating surface wasn't even.

With old and new sealant expanding and contracting at different rates, it was just a matter of time before it started letting water in

237966


237967


So if you replace the rubber seals in the roof rail channels and you still have water ingress then it may be perished windscreen seals and/or a poor glass fitting.
 
#7 ·
I am bumping this thread as it was hard to find. I recently did the repair to harness in drivers footwell and cleaned all drains. I was so happy that I had no water this morning after heavy rain. Then after I come out to car at lunch A pillars are soaked. The difference is at home I parked uphill and at work I parked downhill. I am sure its the Roof Rack tray / rails.
Thanks @VW_lover_2001
 
#8 ·
A few points…VWPartvortex sent 2 gaskets instead of four. I assumed they would have included two per the schematic. The rear most screws are into fixed nuts and off center so were much tighter, take your time with these. A few of the nuts were off center relative to the holes which caused issue with seal. I haven’t installed so not sure if I can improve on that issue. Cleaning bolts and applying fresh threadlocker.
 
#9 ·
When you order the gaskets from a dealer make sure to tell them 2 gaskets should be included for the part number. Ask them to call warehouse or distributer or you will end up paying for 4 gaskets. It very well could be cheaper to order the rails instead as they come with all the gaskets and hardware. Vwpartsvortex.com has the rails listed at $160.
Dan
 
#10 ·
So after replacing the gaskets on the roof rails my treg still leaking at A pillars. If I park uphill it doesn’t leak. Should I remove headliner or redo the roof rails and use silicone at bolt holes? I am thinking theres a chance it could be the seal on the tray of the sunroof or one of the drain connections?? I do need to replace my hinge struts but that doesn’t require removal of the headliner…TIA -Dan


Sent from my iPhone using Tapatalk
 
#11 ·
Did you ever get your leak fixed? I see water spots on my headliner right at the passengers side grab handle and on the A Pillar after a heavy rain or a car wash. The sunroof drains appear to be clear and water is draining out of the ports in the wheel well as designed when poured down the drains. I think something is causing water to back up in sunroof before it can get to the drains and overflow.
 
#14 ·
In the rear there is a drain slot beneath the hinge covers that does need to be cleaned. On the front my assumption is it basically drains into A pillar. The rails are mounted with 6 bolts using a small plastic spacer that has a rubber seal. After installing new gaskets and seals and then removing the rails it’s obvious this is a poor design. The nuts beneath the roof can’t line up perfectly with the rail screw holes and therefore the screws are offset. That’s my take on it. My advise is use the silicone and forego new gaskets. Clean everything though before applying silicone. If you choose to replace gaskets I suggest buying new rails which will come with all gaskets and new screws.
 
#15 ·
Confirming that yes the water pools under those rails.I just removed the roof rails and there was 20 years of crud and soil under there, and vibration from my Rhino Rack had loosened a couple of the bolts and caused leaks. I ordered the replacement plastic seals and gaskets. The old gaskets are firmly embedded in the rail, I haven't figured out yet how to cleanely remove them, they are very brittle.
 
#19 ·
I tried to fix rail gaskets issue with new gaskets and silicone. This didn't not work for me. I would suggest you don't use silicone as not only did it not work but it's a pain to clean it off when you have to redo it with the butyl - I used butyl tape, two layers and this did work. I also used a sealant on the fittings on the rear sunroof drain hoses. I removed the headliner because I wanted to replace my struts and make absolutely sure I have fixed the leaks with rail and drain fixes. I was surprised to find the seam issue that I posted the TSB for above. I have yet to fix the seam but I will post pictures of the repair when complete.
 
#20 ·
I tried to fix rail gaskets issue with new gaskets and silicone. This didn't not work for me. I would suggest you don't use silicone as not only did it not work but it's a pain to clean it off when you have to redo it with the butyl - I used butyl tape, two layers and this did work.
I do a lot of sailboat repairs, and silicon is absolute garbage - never works and is really hard to clean the residue off, but good quality butyl tape is a permanent solution that will last 100 years and will even continue to seal if the fasteners become lose and have some movement.

Butyl tape quality varies, this 'bed it' brand is much much better than others I've tried: Bed-It Bed-It Tape