Windshield/Cowl/`A' Pillar - Water Leak Diagnosis
NUMBER: 23-007-01GROUP: Body
DATE: April 20, 2001
SUBJECT:
Windshield - Cowl Water Leaks
OVERVIEW:
This bulletin involves inspecting the windshield frame to cowl seal, bulk head and plenum areas. It points out common areas where leaks can occur.
MODELS:
1999 - 2001 (TJ) Wrangler
SYMPTOM/CONDITION:
Water leaks may be present at the Windshield/Cowl/ "A" Pillar area. This bulletin provides additional assistance to diagnose water leaks in this area.
DIAGNOSIS/REPAIR PROCEDURES:
When diagnosing water leaks, it should be noted that these vehicles have a unique body construction. Many of the body panels have been designed using single sheet metal stampings with no inner and outer panels. Vehicles utilizing inner and outer panels are designed with drains between the inner and outer panels. This allows any water entering the area between the panels to exit out the drains and prevents leakage into the passenger compartment. This must be considered when water leak testing this vehicle. Water should be applied to all areas where any body seam exists, including the underside of the floor panel, the cowl plenum/heater air inlet areas and the bulkhead in the engine compartment. Running water over the exterior body panels with the hood closed, may not be sufficient to expose leaks. This bulletin assumes that a water test of the exterior of the vehicle did not reveal any water entry points and attempts to highlight specific areas to inspect.
1. Raise the hood and apply a steady stream of water to all areas of the bulkhead in the engine compartment. Use a hose and avoid high pressure spray nozzles. Inspect all grommets and gaskets to make sure they are seated securely. The seal between the heater A/C housing and the bulkhead must be in the correct position and be compressed. This is also true for the holes where the heater and A/C hoses go through the bulk head. If any doubt about these seals is present, clean the areas and apply an aerosol sealer to the areas, or seal them with RTV (Fig. 1)
2. Look carefully at the brake booster reinforcement panel. Apply a bead of RTV around this panel to assure no water can seep between the panel and the bulkhead.(Fig. 1)
3. Remove the cowl grille. Inspect the heater A/C air inlet cover. Make sure that the cover is securely fastened to the plenum and that a good seal is present.
4. Inspect all seams in the plenum area. Apply RTV to any seam that looks suspect.
5. The cowl grille attaching screws, plastic screw anchors and plastic spacer must also provide a good sealing joint. These screws must not be stripped, loose, or missing. Replace the plastic screw anchors it any problems exist.
6. Inspect the cable and harness grommets coming through the bulk head. Apply RTV to any suspect area (Fig. 3).
7. Using the procedure outlined in the appropriate Service or Owner manual, loosen or remove the top and fold the windshield down to gain access to the windshield to cowl area. Make sure to mark the sport bar supports to assure that the windshield returns to the original position after the repairs. Apply a 1/8 inch bead of RTV as shown, to both sides of the cowl. (Fig. 4).
8. Inspect the windshield to cowl gasket for any signs of damage. Replace if necessary.
9. Inspect the underside of the windshield frame. Look for loose sealing tape, weld splatter or any irregular surface which could cause interference and not allow the windshield frame to seat correctly on the cowl/cowl gasket.
POLICY:
Information Only