Body - Water Leaks To Interior At Rear of Vehicle
No: 76/10/05/NASRef:
Issue: 1
Date: 01 June 2005
Water Ingress at Rear of Vehicle
AFFECTED VEHICLE RANGE:
Freelander (LN) All
SITUATION:
WATER LEAKS IN VARIOUS REAR BODY LOCATIONS
A number of locations in the vehicle may be susceptible to water ingress as the result of incomplete caulking, seal failure or other deterioration of the vehicle seals.
RESOLUTION:
INSPECT AND SEAL AFFECTED AREAS.
Upon confirmation of the customer complaint and determination of the leak source, the instructions provided in this TIB are to be followed to seal known problem areas on the vehicle.
PARTS INFORMATION:
DDW WARRANTY CLAIMS:
Select repair number and claim against SRO's from the tables below. Times claimed should reflect the work carried out and the job card should be endorsed with the repair procedure reference. For each repair a separate claim line will be required.
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 1A - TAILGATE SEAL UPPER SEALING ISSUES
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LN
Freelander/2004 > Workshop Manuals > Service
Procedures > Bookmark "INTERIOR TRIM
COMPONENTS 76-3-1" > TOC "Trim casing - rear
quarter - upper - 5 door" link to 76.13.13
1. Confirm symptoms of dampness or stained rear edge of the headlining.
2. Refer to GTR Workshop Manual section 76.13.13. and remove left and right- rear quarter interior upper trim casing. (Figure 1)
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LN
Freelander/2004 > Workshop Manuals > Service
Procedures > Bookmark "DOORS > REPAIRS" >
"Finisher, rear screen"
3. Refer to Freelander 2001 MY section 76.43.81 and remove the rear exterior window side trim. (Figure 2)
4. Remove the rear exterior window upper trim as follows:
(Figure 3)
^ Release 5 clips securing finisher to bracket.
^ Remove tail door glass upper finisher. Remove and discard clips from finisher or bracket
5. Inspect the tailgate sealant for correct and complete application coverage.
6. Ensure no gaps are visible.
7. If gaps exist in sealant, apply polyurethane sealant to fill the spaces. (Figure 4)
8. Clean away any visible excess polyurethane sealant.
PROCEDURE 1B - TAILGATE GLASS UPPER FINISHER PLASTIC ATTACHMENT NUTS (LOKUTS).
1. Confirm the symptom of wet or stained rear edge of headlining. (Figure 5)
2. If not previously performed, remove trim as follows:
^ Refer to GTR Workshop Manual section 76.43.81 and remove tailgate glass side trim.
^ Carefully release tailgate upper finisher from fasteners.
3. Remove five screws securing tailgate upper finisher bracket to body.
4. Inspect and verify that the lokuts are pushed fully home to the panel.
5. If "lokuts" are damaged or fail to locate correctly, perform the following:
^ Cut defective "lokuts" with a sharp blade to remove, taking care not to damage the panel.
^ Replace removed "lokuts" with new parts (DYH100980).
^ When satisfied that the lokuts are secure, apply waterproof tape over them.
NOTE:
When the finishers are refitted the securing screws will penetrate the tape.
6. Install the tailgate upper finisher using new retailing clips.
7. Install glass side finishers using new retainers (DCE1OO56O) if required.
8. Apply water to the former leak area to ensure seal is complete. (Figure 6)
PROCEDURE 2 - ROOF CHANNEL SEAMS -5 DOOR
1. Confirm the symptoms or a wet or stained headlining.
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LN
Freelander/2004 > Workshop Manuals > Service Procedures
> Bookmark "EXTERIOR FITTINGS > REPAIRS" > "Moulding roof 5-door"
2. If leak symptoms are present, seal the roof channel seams as follows:
^ Refer to GTR Workshop Manual section 76.43.68 and remove the roof molding. (Figure 7)
^ Inspect full length of roof channel seams for pin-holes.
^ Fill any holes with polyurethane sealant.
3. Apply water to the former leak area to ensure seal is complete.
4. Install roof moulding.
PROCEDURE 3 - TAILGATE SHEDDER
1. Confirm the symptom or water ingress from bottom of tailgate.
2. If leak symptoms are present, verify the source of the tailgate leaks as follows:
^ Open the tailgate
^ Apply water to the exterior surface of the glass.
^ Observe the bottom of the door for signs of water emerging from under the trim casing.
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LN Freelander/2004 > Workshop Manuals > Service Procedures > Bookmark "DOORS > REPAIRS" > "Trim casing - tail door"
3. If water emerges from underthe trim casing, refer to GTR Workshop Manual section 76.34.10 and remove door trim.
4. Remove and discard the four "lokuts" from lower left hand side of tailgate panel.
5. Replace with new "lokuts" (EYH100420).
6. Inspect shedder for damage and for gaps in sealant between shedder sheet and the door.
CAUTION:
When installing a new shedder the following precautions must be observed:
^ Shedder and surface of vehicle must be between 18° and 30°C (65° to 86°F).
^ Creases in the shedder may not be present.
^ Adhesive contact areas must be pushed fully down onto clean surfaces.
^ A suitable roller must be used to ensure plastic sheet is fully sealed to the tailgate.
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LN Freelander/2004 > Workshop Manuals > Service Procedures > Bookmark "DOORS > REPAIRS" > "Plastic sheet - tail door"
7. If the shedder is damaged, refer to GTR Workshop Manual section 76.34.25 and replace the shedder with a new part.
8. If sealant gaps are found, repair gaps using polyurethane sealant.
9. When shedder repairs are complete, refer to GTR Worship Manual section 76.34.10 and install the trim casing.
PROCEDURE 4A - TAILGATE ADJUSTMENT
1. Determine poor seal contact with the door body as follows:
^ Inspect for water ingress at the point in Figure 8.
^ Inspect the contact of the seal/lower tailgate from within the vehicle.
2. Refer to GTR and adjust the tailgate striker and/or tailgate hinges as required to achieve full contact between the seal and lower tailgate.
PROCEDURE 4B - TAILGATE GLASS ADJUSTMENT
1. Confirm the symptom of water ingress from tailgate glass to the seal or interior.
2. Inspect that the tailgate glass slides into position underneath the seal to prevent water ingress. (Figure 9)
NOTE:
GTR lookup sequence is as follows:
GTR Home> NAS > Service Information/ LN
Freelander/2004 > Workshop Manuals > Service
Procedures > Bookmark "DOORS > REPAIRS" >
"Glass - Tail door"
3. If door glass does not move into the correct position when closing, refer to GTR Workshop Manual section 76.31.20 and perform glass adjustment procedure.
PROCEDURE 4C - TAILGATE GLASS SEAL CONTACT
1. With the tailgate closed, visually inspect for leaks between the seal and the tailgate glass.
NOTE:
Contact should exist and can be verified by applying light pressure to the glass, while carefully observing the seal for movement and contact.
2. Press against the tailgate glass and verify contact between the seal and the glass.
CAUTION:
Extreme care must be taken to avoid damage to the plastic trim if the body adjustment is undertaken.
3. If window contact with the seal is poor but the tailgate striker adjustment is acceptable, open the tailgate and lightly tap the area of poor contact outwards with a rubber mallet to move the seal and flange closer to the tailgate glass. (Figure 10)
4. Verify the contact between seal and glass has improved.
PROCEDURE 4A - TAILGATE ADJUSTMENT
1. Determine poor seal contact with the door body as follows:
^ Inspect for water ingress at the point in Figure 8.
^ Inspect the contact of the seal/lower tailgate from within the vehicle.
2. Refer to GTR and adjust the tailgate striker and/or tailgate hinges as required to achieve full contact between the seal and lower tailgate.
PROCEDURE 4B - TAILGATE GLASS ADJUSTMENT
1. Confirm the symptom of water ingress from tailgate glass to the seal or interior.
2. Inspect that the tailgate glass slides into position underneath the seal to prevent water ingress. (Figure 9)
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LN
Freelander/2004 > Workshop Manuals > Service
Procedures> Bookmark "DOORS > REPAIRS" >
"Glass - Tail door"
3. If door glass does not move into the correct position when closing, refer to GTR Workshop Manual section 76.31.20 and perform glass adjustment procedure.
PROCEDURE 4C - TAILGATE GLASS SEAL CONTACT
1. With the tailgate closed, visually inspect for leaks between the seal and the tailgate glass.
NOTE:
Contact should exist and can be verified by applying light pressure to the glass, while carefully observing the seal for movement and contact.
2. Press against the tailgate glass and verify contact between the seal and the glass.
CAUTION:
Extreme care must be taken to avoid damage to the plastic trim if the body adjustment is undertaken.
3. If window contact with the seal is poor but the tailgate striker adjustment is acceptable, open the tailgate and lightly tap the area of poor contact outwards with a rubber mallet to move the seal and flange closer to the tailgate glass. (Figure 10)
4. Verify the contact between seal and glass has improved.
PROCEDURE 5A - TAILGATE APERTURE SEAL RETENTION
1. Confirm the symptom of water ingress past the tailgate seal.
2. Pull gently on the lower part of the seal to verify that the tailgate aperture seal is located onto the flange with sufficient clamping force to prevent leakage.
3. If the aperture seal releases from the flange easily, perform the following:
^ Disengage the seal from the flange.
^ Crimp the metal carrier on the seal (Arrowed in Figure 11) using a pair of pliers to increase the clamping force on the flange.
4. Install the seal to the flange.
5. Verify that the seal is now secure.
PROCEDURE 5B - TAILGATE APERTURE SEAL INSERT
1. Confirm the symptom of Water ingress past the tailgate seal and determine that Procedure 5A has been completed.
2. Look through the left and right hand rear quarter glass and inspect for a visible gap between the tailgate aperture seal and the tailgate. (Arrowed in Figure 12)
3. If a gap can be seen, check that the tailgate is correctly set and aligned to the body. (Procedure 4A)
4. Open the tailgate and inspect the aperture seal at waist line height to see if the rubber insert is at its highest position within its retaining rubber membrane.
5. If the rubber insert is not at its highest position perform the following repair:
^ Cut a piece of 7 mm (1/4 in) plastic tube to a length of approximately 75 mm (3 in).
^ Inset the tube into the seal membrane just below the mid door joint and behind the "flap" in the seal to increase the seal contact to the door. (Figure 13)
6. Glue the inserted tube into the seal membrane to retain it in place.
PROCEDURE 6: TAILGATE SEAL (LOWER SECTION) INSTALLATION ISSUES.
NOTE:
Tailgate seal replacement is not required unless the seal is split, torn or damaged.
NOTE:
Additional information is found on GTR i Workshop Manual, section 76.22.74. Bookmark "EXTERIOR FITTING > REPAIRS" > "Bumper valance - rear"
1. Ensure waist molding is correctly located as follows:
^ Inspect for correct location at interior trim waist line. (Figure 14)
^ Visually inspect the tailgate seal to ensure correct installation and that there are no kinks. (Figure 15)
^ Remove rear tread-plate (luggage compartment carpet retainer).
^ Ensure that the yellow seal timing mark is correctly aligned with the tread-plate centre attachment insert. (Arrowed in Figure 16)
2. If the seal is kinked or the seal timing mark is not aligned, carefully remove the lower section of the seal from the bodywork taking care not to damage the seal.
3. Ensure mid section clip is correctly located onto the flange.
4. Starting from waist molding clip area, push the seal onto the vertical body flanges (some crimping of the seal may be required if seal retention is poor).
5. Ensure seal is free from kinks by working seal excess onto straight section of flange and away from corners.
PROCEDURE 7A - REAR QUARTER INTERIOR PANEL DAMPNESS RH SIDE
NOTE:
GTR lookup sequence is as follows:
GTR Home> NAS > Service Information/ LN
Freelander/2004 > Workshop Manuals > Service
Procedures > Bookmark "INTERIOR TRIM
COMPONENTS > REPAIR"> "Trim casing - rear
quarter- lower"
1. Refer to GTR Workshop Manual section 76.13.12 and remove the RH lower rear quarter trim casing.
2. Inspect for fuel filler area water ingress as follows:
Apply water to the fuel filler area. (Arrowed in Figure 17)
NOTE:
If there is a water leak from the filler cap area, the water will run down the wheel arch seam and into the body box section.
^ Inspect for water entering the box section around the ventilation flaps.
3. If water is present in the fuel filler water test, perform the following:
^ Remove fuel filler cap
^ Seal the fuel filler aperture seam using clear polyurethane sealant.
^ Install the trim casing and fuel filler cap.
PROCEDURE 7B - REAR QUARTER INTERIOR PANEL
DAMPNESS LH SIDE
1. If the symptom is dampness on the LH interior quarter panel trim, remove the LH lower rear quarter trim casing.
2. Inspect for body vent water ingress as follows:
^ Apply a continuous flow of water between the rear bumper and side panel on the affected side. (Arrowed in Figure 18).
Inspect for water at the box section below the body vents.
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LN Freelander/2004 > Workshop Manuals > Service Procedures > Bookmark "EXTERIOR FITTING > REPAIRS" > "Bumper valance - rear"
3. Refer to GTR Workshop Manual section 76.22.74 and remove the bumper valance.
4. If no water ingress is found from the water test, go to Procedure 7C.
5. If water is present from the test, seal the rear body vents to prevent water ingress as follows:
^ Apply Polyurethane sealant around edge of body the vent sealing it to the body. (Arrowed in Figure 19)
^ Clean area above the body vent where shedder will be applied.
^ Remove backing paper from shedder (EBS100030).
^ Place shedder over vent with adhesive strip along shaded area (Figure 20).
^ Verify that the shedder covers the body vent.
PROCEDURE 7C - REAR QUARTER INTERIOR PANEL DAMPNESS RH OR LH SIDE
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LN
Freelander/2004 > Workshop Manuals > Service
Procedures> Bookmark "EXTERIOR FITTING >
REPAIRS" > "Liner - rear wheel arch"
1. When Procedure 7A and Procedure 7B are complete, inspect wheel arch seams for water ingress as follows:
^ Refer to GTR Workshop Manual section 76.10.49 and remove rear wheel arch liner from affected side.
^ Apply a continuous flow of water to the seam. (Arrowed in Figure 12)
^ Inspect to determine if water is present in the box section.
2. If water is present in the box section, seal the rear wheel arch seam using polyurethane sealant. (Figure 21)
3. Install removed wheel arch liner, bumper valance and trim casing.
PROCEDURE 8 - TAILGATE APERTURE SEALANT
1. Confirm the symptom of a wet "E" post trim and inspect for door aperture water ingress as follows:
^ Remove 6 Torx screws securing luggage compartment carpet retainer.
^ Remove carpet retainer.
^ Apply a continuous flow of water to the tailgate aperture seal sealant, slowly working up each side from waist level. (Figure 22)
^ While applying water, check if water is present where the carpet retainer is normally fitted.
2. If a leak is detected in the sealant, fill the gap with polyurethane sealant.
3. Close tailgate.
4. Apply a continuous flow of water to the upper tailgate finisher. (Figure 23)
5. If water is present where the carpet retainer is normally fitted carefully release tailgate upper finisher from fixings.
6. Remove the five screws securing the tailgate upper finisher bracket to body.
7. Fill gap in the sealant with polyurethane sealant.
8. Ensure that the "lokuts" are pushed fully home to the panel.
9. If "lokuts" are damaged or fail to locate correctly perform the following:
^ Cut defective "lokuts" with a sharp blade to remove, taking care not to damage the panel.
^ Replace removed "lokuts" with new parts (DYH100980).
10. Re-test and repeat above process as necessary.
11. Install removed components.
PROCEDURE 9 - STOWAGE BOX GROMMETS
1. Confirm the symptom of water in the stowage box.
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LN
Freelander/2004 > Workshop Manuals > Service
Procedures > Bookmark "INTERIOR TRIM
COMPONENTS > REPAIRS" > "Carpet - luggage
compartment"
2. Verify that the bungs in the lockable storage box are sealed correctly as follows:
^ Refer to GTR section 76.49.04 and remove the luggage compartment carpet.
^ Inspect the two fused bungs to confirm that they are located securely in the floor. (Arrowed in Figure 24).
^ Seal around the grommets with polyurethane sealant.
3. Install the removed carpet.