Body - Water Leak At Headliner
No: 76/04/04/NASRef:
Issue: 1
Date: April 30, 2004
Water Ingress to Headliner
AFFECTED VEHICLE RANGE:
Discovery Series II (TL) All
SITUATION:
WATER ENTERS NEAR "A" PILLAR
The customer may complain that water is appearing along the upper edge of the windshield and may dampen the headliner. The entry point is most likely near the top of the "A" pillar. Incomplete sealing operations during assembly may permit water ingress in this area.
RESOLUTION:
SEAL THE AFFECTED AREA
Using the specified sealant, seal the possible entry paths for water as described in this bulletin.
^ A gap in the sealant along the drip rail
^ Pin holes in the sealant around the joints of the A-pillar, roof panel and drip rail
PARTS INFORMATION
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
REPAIR PROCEDURE
INSPECTION FOR DRIP RAIL VOIDS
1. Carefully lift the clip securing the drip rail corner trim to the drip rail. (Arrowed in Figure 1)
2. Inspect the drip rail seam joint for a gap or void.
CORRECTION OF DRIP RAIL VOIDS
1. If a gap or void is present, perform the following drip rail rectification procedure:
^ Refer to RAVE section 76.43.39 and remove the windshield side trim moulding.
^ Release and remove the drip rail corner trim from the drip rail.
^ Clean the drip rail.
^ Fill the gap / void with sealant (see Figure 2).
NOTE:
The sealant must be applied evenly to the drip rail. Ensure the sealant does not prevent satisfactory installation of the drip rail corner finisher.
2. Position but do not install the windshield side finisher to the "A" post.
3. Apply water to the drip rail and check for leaks.
4. Rectify any remaining leaks as necessary.
5. Install the windscreen side trim moulding using new plastic rivets.
6. Install the drip rail corner trim to the drip rail.
INSPECTION FOR CRACKED ROOF SEALANT
CAUTION:
Extremely care must be taken to avoid deforming the windshield trim moulding.
1. Carefully pull back the corner of the windscreen upper seal and use tape to secure the trim moulding to the windshield glass. (Figure 3).
2. Inspect for pin-holes or cracks around the "A" post-to-roof joint, and the drip rail sealed joints (Arrowed in Figure 4).
3. Refer to RAVE/GTR section 76.64.15.21 and carefully remove interior A-post trim and sun visor assembly.
4. Spray soap water into the affected area outside and test the corner of the windscreen upper seal with low-pressure air nozzle directing the air stream through the sun visor and/or the A-post mounting hole.
5. If no pin-holes, cracks, or air bubbles are found, remove tape securing the windshield upper moulding to the windshield and push the trim moulding back into position.
CORRECTION FOR CRACKED ROOF SEALANT
1. If pin-holes, cracks, or air bubbles are found; perform the following:
^ Clean the area completely of dirt, debris, or oil.
NOTE:
The sealant must be applied evenly. Care must be taken to ensure that the sealant does not prevent satisfactory installation of the upper windshield trim moulding.
^ Fill any pin holes or cracks with sealant. (Area shown in Figure 5).
^ Make sure to let the sealant dry completely and reexamine for any porosity within the fill sealant.
^ Apply water to the windshield upper corner and check for leaks.
^ Remove tape securing the windshield moulding to the windshield and push the upper moulding back into position.
^ Refer to RAVE/GTR section 76.64.15.21 and install A-post trim and sun visor.
2. Rectify any remaining leaks as necessary.