Water Test

Figure 90:

Figure 91:

Before the vehicle is water tested, inspect the weatherstrips and make sure the door glass is properly adjusted.

Two water test methods are used. In the door glass area a spray bottle is used around the weatherstrips. In the hatch area the "flood" method is used to simulate larger volumes of water. The method used will depend on the leak location.

In any leak test - spray or flood - start low and work slowly upward allowing the water to flow downward across the weatherstrip. In the hatch area allow enough time for the water to follow possible leak paths into the vehicle.

Never use high pressure spray equipment. The results are often misleading and may result in unnecessary repairs.
If a water leak is found, refer to the Water Test - Leak Repairs (page 36).

NOTE: During the water test, ALWAYS be alert to other sources of waterleaks such as the windshield, cowl area and other body seams.

Figure 92:

1 Center Bar 2 T-Roof Frame 3 Butt Joints 4 Weatherstrips and Door Glass Adjustments 5 Front and Rear Door Glass Guide Weatherstrips 6 Striker Areas 7 Water Coming Through Glass/Rail

NOTE: Do not water test until Silicone dries.
WATER TEST - LEAK REPAIRS

Center Bar

1. Clean the edge between the center bar to roof frame mating surface.

Figure 93:

Figure 11:

2. Apply a 1/8 inch bead of Silicone Rubber Adhesive/Sealant, D6AZ-19562-B (or equivalent), along the edge of the center bar to roof mating surface.

3. Smooth and contour the sealer.

4. Install the hatches and repeat the water test.

Figure 94:

Figure 11:

WATER TEST - LEAK REPAIRS

T-Roof Frame

1. Clean the drain trough areas around the hatch weatherstrip channel.

2. Apply a 1/8 inch bead of Silicone Rubber Adhesive/Sealant, D6AZ-19562-B (or equivalent), around the base of the weatherstrip channel.

3. Smooth and contour the sealer.

4. Repeat the water test.

5. If the leak persists, proceed to Step 6.
6. Remove the hatch felt and roof moulding attaching rivets using a 1/3 inch drill.

7. Clean the edge around the roof frame to roof moulding mating surface.

8. Apply a 1/8 inch bead of Silicone Rubber Adhesive/Sealant, D6AZ-19562-B (or equivalent), along the edge of the frame to roof mating surface.

9. Position the roof moulding, roof felt and install 1/8 inch attaching rivets.

10. Repeat the water test.

11. If the water leak persists, remove the headliner to expose all possible hatch leak points and repeat the water test.
WATER LEAKS - LEAK REPAIRS

Striker Area

1. Inspect the weatherstrip tab in the drain trough (front and/or rear).

- If any voids or gaps are visible in the sealant, the tab requires resealing.

- If the trough is plugged with sealant, remove the excess sealant and reseal the tabs.

2. Remove the striker plate cover(s).

3. Remove all sealant from the drain trough area.

Figure 95:

4. Clean the drain trough sealing area.

5. Apply a 1/8 inch of Silicone Rubber Adhesive/ Sealant, D6AZ-19562-B (or equivalent), around the drain trough tab.

NOTE: Use only enough sealer to cover the tab edge. Excessive amounts of sealer can plug the drain trough creating a damming effect. The water backing up behind this dam may cause leaks in other areas.

6. Repeat the water test.
WATER TEST - LEAK REPAIRS

Hatch Weatherstrip

1. For 6 inches either side of the suspected leak area, pull the weatherstrip out of the hatch channel.

2. Install a layer of 1/2 inch x 1-1/6 inch butyl tape along the bottom of the weatherstrip channel.

Figure 96:

3. Apply a 1/4 inch bead of Weatherstrip Adhesive, COAZ-19552-A, along the center of the butyl tape.

4. Seat the weatherstrip in the channel.

5. Install the hatches.

6. Repeat the water test.