Interior - Various Interior Water Leaks
No: 76/16/03/NASRef:
Issue: 1
Date: 06/27/03
Rear Load Space Water Ingress
AFFECTED VEHICLE RANGE:
New Range Rover (LM) All
SITUATION:
SEALING FAULTS PERMIT WATER ENTRY PATHS
Inconsistent manufacturing sealing processes can permit water to enter the vehicle during inclement weather from a variety of potential ingress areas.
RESOLUTION:
IDENTIFY LEAK PATHS AND SEAL
When a customer complaint of water ingress into the passenger area is confirmed, identify the likely point of ingress based on testing, water accumulation and likely migration paths and perform the indicated operation in this TIB to resolve the problem. Some leak areas identified in this TIB may have had sealant applied during post-production inspections.
PARTS INFORMATION:
Locally Sourced Clear RTV silicon adhesive/sealant
WARRANTY CLAIMS:
NOTE:
Select applicable repair process and then only claim against appropriate repair SRO number(s) from below.
Normal warranty policy and procedures apply. Material allowance is included in labor operation.
REPAIR PROCEDURE
REPAIR 1 - ROOF RACK FITTINGS
1. Fully lower the suspension ride height.
2. Open the six access covers in the roof channel moldings. (Figure 1)
3. Inspect around the roof rack location fittings for pinholes. (Arrowed in Figure 1)
4. Ensure the fittings are clean and dry.
5. Fill any holes / gaps with sealant making sure not to fill the roof rack fitting opening.
6. Wipe off any excess sealant.
7. Close access covers.
8. Return the suspension to normal ride height.
REPAIR 2 - BODY SEAMS AROUND THE TOP CORNERS OF THE UPPER TAILGATE OPENING
1. Fully lower the suspension ride height.
2. Open the tailgate.
3. Inspect the full length of the body seams at the upper tailgate opening for pinholes / gaps.
(Arrowed in Figure 2)
4. Inspect the top corner body seams for pinholes / gaps. (Arrowed in Figure 3)
5. Ensure that the seams are clean and dry.
6. Fill any holes / gaps with sealant.
7. Wipe off any excess sealant.
8. Return the suspension to normal ride height.
REPAIR 3 - BODY SEAMS - REAR
1. Refer to RAVE section 76.22.74 and remove the rear bumper assembly.
2. Inspect the following body seams, brackets and grommets for pinholes / gaps:
^ The rear lower panel upper and lower seams behind the rear armature (Figure 4)
^ The rearquarter panel lower seams (Arrowed in Figure 5)
^ The rear bumper mounting brackets (Arrowed in Figure 6)
^ The body seam between the tail lamp and the tailgate aperture (Arrowed in Figure 7)
^ Ensure all the grommets behind the rear bumper are fully fitted to the body.
3. Ensure the seams are clean and dry.
4. Fill any holes / gaps with sealant.
5. Wipe off any excess sealant.
CAUTION:
Care must be exercised to avoid damage to the bumper plastic components.
6. Refer to RAVE and install rear bumper assembly.
REPAIR 4 - TAILGATE APERTURE SEAL
1. Open the tailgate.
2. Inspect the tailgate seal for damage.
CAUTION:
Use of pliers to crimp the tailgate seal to the body could damage the seal surface if care is not taken.
3. If no damage is present, use a clean pair of pliers to carefully squeeze all around to tighten the crimp of the tailgate seal carrier. (Figure 8)
4. If the seal is damaged, replace the tailgate aperture seal.
5. Ensure there are no gaps between the tailgate seal carrier and the body.
6. Close the tailgate.
REPAIR 5 - REAR WHEEL ARCH SEAM TO THE BODY SIDE
1. Raise the air suspension to its highest ride height setting.
2. Clean the rear wheel arch seam.
NOTE:
Pay particular attention to the rearward corner.
3. Inspect the full length of the rear wheel arch seam for pinholes / gaps. (Arrowed in Figure 9)
4. Ensure the seam is clean and dry.
5. Fill any holes / gaps with sealant.
6. Ensure the sealant is pushed fully into the holes / gaps.
7. Wipe off any excess sealant.
8. Repeat for alternate side of the vehicle.
9. Return the suspension to normal ride height.
REPAIR 6 - BODY SEAMS AND GROMMETS BEHIND THE TAIL LAMPS
1. Refer to RAVE section 86.40.70 and remove both tail lamps.
2. Inspect body seams behind the tail lamps for pinholes.
3. Ensure the seams are clean and dry.
4. Fill any holes I gaps with sealant.
5. Wipe off any excess sealant.
6. Ensure the grommets are fitted correctly to body. (Arrowed in Figure 10)
7. Position the tail lamps and start the fastener screws.
8. Apply sealant around the fastener openings. (Arrowed in Figure 11)
9. Install the tail lamp fastener and wipe off any excess sealant.