Water Ingress Bulkhead, Plenum Chamber & Front Door Trim Information

FIGURE 1:

1. Water Ingress via Bulkhead Plenum Chamber - Series III & XJ-S (Fig. 1)

If the seams in this chamber are inadequately sealed, water can enter the footwells whenever the vehicle is exposed to heavy rainfall.

NOTE: If any water lies in the chamber, the drain tube should be checked for distortion or blockage.

Rectification

1. Remove plenum grille (Series III Workshop Manual Operation 80.15.29, XJ-S Workshop Manual Operation 84.15.12 - Items 1-7).

2. Apply sealant, such as 3M Drip Check Sealer, by brush into all seams inside the chamber (Fig .1).

3. Replace grille.
Also check windshield wiper wheel box seals for secure fit.

FIGURE 2:

2. Water Ingress on to Front Door Trim CasingsSeries III Only


This problem may be caused by any or all of the following:

A. Poor sealing of finisher BAC-1668 or BAC-1669 (Fig. 2A)

B. Tears in the polythene water curtain.

C. Water running along door warning light harness and seeping on to the trim pad.

Rectification

A i. Lower window fully and remove outer weather
strip. ii. Remove finisher BAC-1668 and/or BAC-1669.

iii. Apply non-silicone body sealer into the door
channel (Fig. 2A), refit finisher and apply around the edge. Wipe off surplus and refit weather strip.

B i. Examine the water curtain and repair any tears,

ensure that the curtain is hanging correctly.
ii. Check all securing bolts regulator mountings,
etc., for seepage. Dry off any doubtful bolts

and apply sealant around the heads.

C i. Remove the clip securing the wires to the door
at "X" (Fig. 2B), fit clip BD-25772 at "Y" and attach the harness so that it is secured below the orifice "Z".