Diagnosis and Repair Procedures

The following illustrated charts are designed to ease locating and eliminating water leaks from various body areas. Leak condition, possible causes, repair method, and repair materials (sealers) are described. Water test methods are also described where applicable.


NOTE: A more detailed description of water test methods plus additional diagnosis procedures are outlined in M.R. 171 I.S. Note 8E.

FIGURE 1:

Condition:
^ Water on front floor apparently coming from under instrument panel (Fig. 1).

FIGURE 2:

Possible Causes:
^ Fresh air box (1) improperly sealed (Fig. 2).
^ Heater motor area (2) improperly sealed (Fig. 2).
^ Dash seams (M) not sealed (Fig. 2).
Test:
^ Spray the cowl-windshield-wheel house areas (use fine spray).


Repair:
^ Seal the air box, heater and dash seams with 3M 08646.

FIGURE 3:

Condition:
^ Water on front floor near and/or dripping down front pillar (Fig. 3).

FIGURE 4:

Possible Causes:
^ Water coming in past front fender mounts (1) (Fig. 4).
^ Windshield frame-to-dash seam (2) not sealed (Fig. 4).
^ Gaps in sealer at welded seam (3) (Fig. 4).
Test:
^ Spray the front wheel well area.

FIGURE 5:

Repair:
^ Spray seams (1), (2), and (3) with underbody sealers, such as Kent Ind. DN BRU-50005, or equivalent (Fig. 5).

NOTE: If large voids, remove fender and seal with 3M 08646 or equivalent.
Condition:
^ Water on floor near kick panel or rocker panel.

FIGURE 6:

Possible Causes:
^ Door frame (1) and window frame (2) form step at (A) causing gap between seal (J) and door frame (1) (Fig. 6).
Test:
^ Spray the forward door-to-body seam joint.

FIGURE 7:

Repair:

^ Adjust seal (J) and body flange that seal is attached to for proper fit.

^ Cut a 90~ notch in the door seal as shown in Figure 7 to form a runoff for any water remaining on the seal.

FIGURE 8:

Condition:
^ Water on floor near pillars and rocker panels (Fig. 8).

FIGURE 9:

Possible Causes:
^ Vinyl water dam sheet (V) improperly installed or loose (Fig. 9).
Test:
^ Press door glass inward and spray water into the door between rubbing strip and glass.

FIGURE 10:

Repair:
^ Remove the trim panel (W) and install the water dam sheet correctly (Fig. 10). Use adhesive tape (R) to keep tabs on water dam sheets in door slots (Fig. 10) and use 3M 08044 adhesive/sealer to reglue the sheet if necessary.

FIGURE 11:

Condition:
^ Water dripping from fixed or swing-out rear quarter windows and collecting on floor (Fig. 11).

FIGURE 12:

Possible Causes:
^ Water seeping in between window seal and body or between seal and glass (Fig. 12).
Repair:
^ Seal area (1) with 3M 08509
^ Seal area (2) with 3M 08513

NOTE: On urethane installed windows use 3M 08609 or equivalent.

^ On swing-out windows, replace seal (3) if damaged, or bend flange (4) to obtain tight fit between glass (5) and seal (3).

FIGURE 13:

Condition:
^ Water on rear floor apparently coming from side of vehicle or from under seats (Fig. 13).

FIGURE 14:

Possible Causes:
^ Water enters air vent (1), runs down rear quarter behind stiffener (2) in section A (Fig. 14) then runs out between the rear pillar and trim onto the floor.
Test:
^ Apply a fine spray directly at and into the air vents.


Repair:
^ Remove the air vents and rear lamp assemblies.
^ Clean and dry the entire rear quarter area.
^ Use a sprayable sealer such as Kent Ind. BFG-80 405 along Joint (4). Be sure area (5) is completely sealed.

FIGURE 15:

Condition:
^ Water in the luggage compartment, under the seat and on the rear floor (Fig. 15). Appears after driving in rain and through water puddles.

FIGURE 16:

Possible Causes:
^ Incomplete sealing at joints (1), (2), and (3) (Fig. 16).
^ Seat belt bolt holes (4), (5) not sealed (Fig. 16).
^ Hose/wire grommets or clips (7) out of position or loose (Fig. 16).
Test:
^ Spray the rear wheelhouses and rear floor area.

FIGURE 16:

FIGURE 17:

Repair:
^ Clean and dry areas (1) through (7) (Fig. 16).

^ Seal interior area (1) through (7) with 3M 08646.

^ Seal exterior area (1) through (7) with Kent Ind. BRU-50005 sprayable sealer (Fig 17).

FIGURE 18:

Condition:
^ Water on luggage compartment floor (Fig. 18) and in liftgate.

FIGURE 19:

Possible Causes:
^ Liftgate seal (1) misaligned, loose, damaged (Fig. 19).
^ Water leaking between liftgate seal and body flange (1) (Fig. 19).
^ Water leaking between rear window glass and seal (2) or between seal (2) and body (Fig. 19).


Test:
^ Spray entire liftgate area.

FIGURE 19:

FIGURE 20:

Repair:
^ Clear drain holes (3) if blocked (Fig. 20).
^ Seal rear window glass with 3M 08511 or 08509 (refer to standard sealer chart).
^ Seal liftgate seal to body flange (1) (Fig. 19) with 3M 08509.