Body - Water Leaks To The Interior
No: 76/09/05/NASRef:
Issue: 1
Date: 01 June 2005
Water Ingress at Front of Vehicle
AFFECTED VEHICLE RANGE:
Freelander (LN) All
SITUATION:
WATER ENTERS PASSENGER COMPARTMENT
Various body sealing and chassis seam voids can permit water to enter the vehicle interior.
RESOLUTION:
INSPECT FOR WATER SOURCE AND REPAIR
Upon customer complaint of water ingress into the vehicle, refer to the following procedures to identify sources of ingress and the required rectification.
PARTS INFORMATION:
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
NOTE:
Various repair procedures are described in this Technical Information Bulletin. Use and claim only those procedures that match the symptoms described by the customer.
Normal warranty policy and procedures apply.
Material allowance included in repair times for miscellaneous shop supplies.
REPAIR PROCEDURE
PROCEDURE 1 - ROOF CHANNEL SEAMS - 3 AND 5 DOOR
1. Confirm the wet "A" pillar trim symptom.
2. If the vehicle is a 5 door, ensure that roof channel seams are fully sealed as follows:
^ Refer to GTR Workshop Manual section 76.43.68 and remove the roof moulding.
^ Inspect full length of roof channel seams for pin holes.
^ Fill any holes with polyurethane sealant.
^ Apply water to the suspected entry area to ensure leak has been cured.
^ Install the roof moldings.
3. If the vehicle is a 3 door, ensure that roof channel seams are fully sealed as follows:
^ If a roof rack is installed, refer to GTR Workshop Manual section 76.11.30 and remove the rack.
^ Release the clips and remove the finishers from roof.
^ Inspect full length of roof channel seams for pinholes.
^ Fill any holes with polyurethane sealant.
^ Install removed components.
PROCEDURE 2 - SEALANT AT TOP AND SIDES OF WINDSHIELD
1. Confirm wetness around sealant at top or sides of windshield symptom:
2. Ensure that windshield is fully sealed to the body as follows:
^ Refer to GTR Workshop Manual section 76.13.26 and remove "A" pillar interior upper trim finishers. (Figure 2)
^ Refer to GTR Workshop Manual, section 76.10.47 and remove sun visor.
^ Remove lens from interior lamp.
^ Remove two fasteners securing front interior lamp to body and release from headlining.
^ Disconnect multi plug and remove the lamp.
^ Remove screw covers and screws from grab handles and remove handles.
NOTE:
It may be necessary to support the headliner during the following process.
^ Remove grab handle blanking plugs. If necessary support headliner.
^ Apply water to the top and side edges of windshield, while checking from inside the vehicle for water entering through the sealant.
^ Fill any holes between aperture and windshield with polyurethane sealant. (Figure 3)
3. Installed removed components.
PROCEDURE 3 - "A" PILLAR AND FOOTWELL WATER INGRESS
1. Confirm wetness at base of "A" pillars and in foot well symptom:
2. Refer to GTR Workshop Manual section 84.15.11 and remove air intake plenum cover and wiper motor.
3. Remove scrivet and 5 Torx screws securing front carpet retainer and remove carpet retainer.
4. Remove 2 nuts securing footrest, if fitted.
5. Release and fold carpet back for access.
6. Remove foam plugs from "A" pillar.
7. If wetness is observed at the base of "A" pillars, apply sealant to areas arrowed in Figure 4 and Figure 5 to ensure that windshield aperture and hinge seams are fully sealed.
8. Ensure that the plenum seams are fully sealed as follows:
^ Apply polyurethane sealant around seam under plenum cover. (Figure 6)
^ Access the seam using the aperture at side of the plenum and apply sealant to the seam, (Figure 7).
9. Verify that lower edge of windshield is fully sealed as follows:
^ Apply water along lower edge of windshield while checking for water under fascia in "A" pillar area.
^ If water ingress point is identified, fill gaps in sealant with polyurethane sealant.
10. To ensure bulkhead to "A" pillar seam is fully sealed perform the following:
^ Release harness retainers from studs and move harness to one side.
^ Seal along the seam including bottom corner with polyurethane sealant. (Figure 8)
PROCEDURE 4 - BULKHEAD SPOT WELD BLOW HOLE REPAIR
1. Confirm the symptom of wetness under dashboard in the foot-well.
2. Ensure any bulkhead spot weld blow holes are fully sealed as follows:
Remove scrivet and 5 Torx screws securing front carpet retainer and remove carpet retainer.
^ If installed remove the 2 nuts securing the footrest.
^ Refer to GTR Workshop Manual section 80.20.01 and remove the heater unit.
^ Refer to GTR Workshop Manual section 80.25.20 and remove the Air Conditioning unit.
^ Release carpet retainers and roll carpet back for access.
^ Release harness retainers from studs.
NOTE:
In the following water test, the water will soak through the NVH cover on the bulkhead and run into the foot well.
^ Lift the hood and apply water to the bulkhead in the engine compartment while checking for water in the vehicle foot well.
^ If water is present in the foot well, cut the NVH cover to reveal the water ingress point and seal the spot-weld blowhole with polyurethane sealant.
^ Apply tape where the NVH has been cut.
3. Carry out Procedure 5, "Heater Pipe Grommet Installation Check," to ensure the grommet is correctly located.
4. Install removed components.
PROCEDURE 5 - HEATER PIPE GROMMET
1. Confirm the symptom of wetness under fascia in the foot-well.
NOTE:
In the following water test, the water will soak through the NVH cover on the bulkhead and run into the foot well.
2. Verify that the heater pipe grommet is properly located as follows:
^ Lift the hood and apply water to the heater pipes in the engine bay while checking for water in the foot well.
^ If water is present in the foot well, refer to GTR Workshop Manual section 26.10.01 and perform coolant drain procedure.
^ Release 2 clamps securing heater hoses to heater and disconnect hoses. (Figure 10).
^ Push grommet into position so it locates correctly onto heater pipes and bulkhead. (Figure 11)
^ Connect heater hoses to heater and secure with clamps.
^ Refer to GTR Workshop Manual section 26.10.01 and refill coolant system.
PROCEDURE 6 - SUNROOF - THREE DOOR, SEALANT
1. Confirm the symptom of wetness from the sunroof.
2. Perform the following to ensure there is sufficient seal around sunroof opening:
^ Apply water to sunroof while looking for water ingress around the sunroof opening. (Figure 12)
^ Refer to the GTR Workshop Manual section 76.64.15 and remove the headlining.
^ Seal water ingress point with polyurethane sealant.
^ Install removed headlining.
PROCEDURE 7 - ANTENNA REPLACEMENT
1. Confirm the symptom of wetness under the aerial on the headlining.
2. Refer to GTR Workshop Manual section 86.50.18 and replace the antenna to ensure there is a watertight seal around the roof antenna opening.