Body - Water Leaks To The Interior
NO.: LTB00168ISSUE: 1
DATE: 07 OCT 2008
SECTION: 501
Water Ingress into Cabin Area - Diagnostic Procedure
AFFECTED VEHICLE RANGE
CONDITION SUMMARY:
Situation:
Water may enter the cabin area in one or more of the following scenarios: Through the headliner in the proximity of the driver's or front passenger's head, possibly dripping onto the top of the instrument panel. Behind the A-pillar trim, through the fascia and possibly into the front footwell. Removing the fascia end closing panel, water ingress in this area can be identified by rust-colored marks on the instrument panel reinforcement. Through the headliner around the rear of the roof opening panel. Into the left and right-hand-side rear footwell. Water ingress from the above may be caused by poorly routed / blocked / kinked / twisted front roof opening panel drain tubes or a badly fitted front or rear door water shedder.
Action:
In the event of a customer concern of any of the above, refer to the Diagnostic Procedure outlined below to inspect and rectify the source(s) of the water ingress.
PARTS
TOOLS:
Refer to Workshop Manual (GTR) for any required special tools
WARRANTY
DIAGNOSTIC PROCEDURE:
NOTE:
Global Technical Reference (GTR) lookup sequence is as follows:
GTR Home > NAS > LM - New Range Rover > Service Information > Model Year > Workshop Manuals > 1: General Information > 100-00: General Information Solvents, Sealants, and Adhesives
CAUTION:
Refer to Workshop Manual (GTR) Section 100-00: General Information to ensure all safe use of sealer and adhesive.
WATER INGRESS INTO FRONT FOOTWELL AREA
NOTE:
Global Technical Reference (GTR) lookup sequence is as follows:
GTR Home > NAS > LM - New Range Rover > Service Information > Model Year > Workshop Manuals > 76-3 - Interior Fittings
1. Refer to Workshop Manual (GTR) Section 76.34.01, Trim Casing - Front Door, to remove the appropriate front door trim casing.
2. Inspect the door water shedder for signs of poor adhesion.
^ If poor adhesion is evident, replace the door water shedder.
^ If poor adhesion is not evident, replace the trim casing and proceed to INSPECT ROOF OPENING PANEL DRAIN TUBES below.
WATER INGRESS INTO REAR FOOTWELL AREA
NOTE:
Global Technical Reference (GTR) lookup sequence is as follows:
GTR Home > NAS > LM - New Range Rover > Service Information > Model Year > Workshop Manuals > 76-3 - Interior Fittings
1. Refer to Workshop Manual (GTR) Section 76.34.04, Trim Casing - Rear Door, to remove the appropriate rear door trim casing.
2. Inspect the door water shedder for signs of poor adhesion.
^ If poor adhesion is evident, replace the door water shedder.
^ If poor adhesion is not evident, replace the trim casing and proceed to INSPECT ROOF OPENING PANEL DRAIN TUBES below.
INSPECT ROOF OPENING PANEL DRAIN TUBES
1. Ensure vehicle is parked on dry level ground.
2. Fully open roof opening panel to access roof opening panel frame and drain tubes.
3. One corner at a time, pour a small amount of water into each drain hole / tube.
4. Verify water has pooled on the ground at all four drain tube exit points.
5. If no water found at drain tube exit point(s), release the grommet at the bottom of the affected drain tube(s) from the sill.
6. Inspect for twists in the lower section of the affected drain tube(s).
^ If the tube is twisted, releasing it from the sill will allow it to untwist.
7. Install the grommet at the bottom of the drain tube to the sill.
8. Pour a small amount of water into the affected drain hole / tube.
9. Verify water has pooled on the ground at the affected drain hole / tube.
NOTE:
Global Technical Reference (GTR) lookup sequence is as follows:
GTR Home > NAS > LM - New Range Rover > Service Information > Model Year > Workshop Manuals > 76.64.15
10. Refer to Workshop Manual (GTR) Section 76.64.15 to remove the headlining to gain access to the top section of the drain tube.
11. Inspect the affected drain tube(s) for kinks or twists.
^ If the tube(s) is kinked or twisted, release and re-route the drain tube(s) from the roof opening panel.
^ If no kinks or twists are found, proceed to step 16.
12. Connect the drain tube(s).
13. Pour a small amount of water into the affected drain hole / tube(s).
14. Verify water has pooled on the ground at the affected drain hole / tube(s).
15. Release the affected drain tube(s) from the roof opening panel.
16. Inspect the drain tube(s) for damage (hole, tear, etc).
^ If no damage is found, use compressed air to blow out the affected drain tube(s).
^ Pour a small amount of water into the repaired drain hole / tube(s).
^ Verify water has pooled on the ground at the repaired drain hole / tube(s).
^ If damage is found, proceed to REPLACE DAMAGED SECTION OF DRAIN TUBE(S) below.
REPLACE DAMAGED SECTION OF DRAIN TUBE(S)
1. Ensuring a straight cut, remove the damaged section of drain tube(s).
2. Using the removed section as a template, cut a replacement section from a new drain tube (AKJ760042 or AKJ60030).
3. Using Loctite 401 (STC50546), bond the replacement section to the remaining section of drain tube.
CAUTION:
Follow the sealant's instructions to allow sufficient time for curing.
4. Cover the joint with Polyurethane sealant (Betafil - locally sourced) and allow sufficient time for curing.
5. Install the repaired drain tube.
6. Pour a small amount of water into the repaired drain hole / tube(s).
7. Verify water has pooled on the ground at the repaired drain hole / tube(s).
^ If water pools on the ground, refer to Workshop Manual (GTR) Section 76.64.15 to install the headlining.
^ If water does not pool on the ground, refer to REPLACE FRONT DRAIN TUBE / REPLACE REAR DRAIN TUBE as necessary below.
REPLACE FRONT DRAIN TUBE
CAUTION:
Care should be taken when cutting drain tube; water may have collected in the tube due to blockage.
1. Access the affected A-Pillar drain tube(s) through the body side from the inside of the vehicle.
2. Cut the affected front drain tube(s) as shown by 'X' in Figure 1.
3. Carefully pour a small amount of water into the bottom section of the drain tube(s).
^ If water pools on the ground, a blockage exists in the lower section of the tube; proceed to step 4.
^ If no water pools on the ground, a blockage exists in the upper section of the tube; proceed to step 18.
4. Push the plastic drain tube retaining clip into the bottom of the A-pillar.
5. Remove the drain tube grommet from the sill.
6. Attach a length of welding wire securely around the top of the lower section of drain tube:
^ Wrap wire around the drain tube and tap into place.
7. Remove the drain tube from the vehicle:
^ Carefully pull the bottom of the train tube downwards and outwards, ensuring the welding wire follows.
^ Stop pulling once the welding wire has taken the place of the drain tube.
^ Leaving the welding wire in place inside the A-pillar, remove the drain tube from the welding wire.
8. Using the removed section of drain tube as a template cut a 10 cm (2.5 in) longer replacement section of drain tube (AKJ760042).
9. Attach the bottom of the welding wire to the top 10 cm (2.5 in) of the replacement drain tube:
^ Wrap wire around the drain tube and tap into place.
10. Install the drain tube into the vehicle:
^ Carefully pull the top of the welding wire upwards, ensuring the replacement drain tube follows.
11. Once the replacement drain tube is in place, remove the top 10 cm (2.5 in) of tube.
12. Remove the welding wire.
13. Using Loctite 401 (STC50546), bond the replacement section to the remaining section of drain tube.
CAUTION:
Follow the sealant's instructions to allow sufficient time for curing.
14. Cover the joint with Polyurethane sealant (Betafil - locally sourced) and allow sufficient time for curing.
15. Pour a small amount of water into the repaired drain hole / tube(s).
16. Verify water has pooled on the ground at the repaired drain hole / tube(s).
17. If water pools on the ground, refer to Workshop Manual (GTR) Section 76.64.15 to install the headlining.
NOTE:
The existing section of the drain tube will remain encapsulated within the vehicle body.
18. Cut off the top visible section of the existing drain tube and the bottom grommet of the new drain tube.
19. Install the top of a new drain tube onto the roof opening panel.
20. Run the tube down the inside of the A-pillar behind the upper A-pillar trim finisher.
21. Feed the tube down through the fascia to meet the existing lower section of drain tube.
22. Cut off the excess length of the new drain tube.
23. Using Loctite 401 (STC50546), bond the replacement section to the remaining section of drain tube.
CAUTION:
Follow the sealant's instructions to allow sufficient time for curing.
24. Cover the joint with Polyurethane sealant (Betafil - locally sourced) and allow sufficient time for curing.
25. Pour a small amount of water into the repaired drain hole / tube(s).
26. Verify water has pooled on the ground at the repaired drain hole / tube(s).
27. Refer to Workshop Manual (GTR) Section 76.64.15 to install the headlining.
REPLACE REAR DRAIN TUBE
1. Release the drain tube from the roof opening panel.
2. Ensuring a straight cut, remove section of drain tube(s).
3. Using Loctite 401 (STC50546), bond the replacement section to the remaining section of drain tube.
CAUTION:
Follow the sealant's instructions to allow sufficient time for curing.
4. Cover the joint with Polyurethane sealant (Betafil - locally sourced) and allow sufficient time for curing.
5. Pour a small amount of water into the repaired drain hole / tube(s).
6. Verify water has pooled on the ground at the repaired drain hole / tube(s).
7. Refer to Workshop Manual (GTR) Section 76.64.15 to install the headlining.