I still have a leak on the drivers side it is a tiny leak I removed the kick but panel and it is a leak running down the side of the body but I cannot see where from I can see far enough up to see the ground wire but can't see past it

any ideas?

 

found this tsb on disco web about water intrusion

DISCOVERY (U) ALL


* indicates updated information

SITUATION:

WATER LEAKS INTO FRONT FOOTWELLS

There have been cases of customers complaining of water entering the vehicle. Some of the following conditions may exist:

^ Water is seen leaking into the footwells and the HVAC intake (the material covered in *TIB # 80/01/97/NAS*) is not the cause.

^ Floor materials (carpets, mats, and insulation) are wet or damp for unknown reason.

^ A musty smell in the vehicle that is traced to moisture in the floor covering materials.

^ Difficult to clear condensation continually accumulating on the inside windows (A/C must be used. Wet floor materials are believed to be the cause).


RESOLUTION:

SEAL LEAKING BODY AREAS AND CLEAR RESTRICTED DRAINS

If it is determined that these conditions were not caused by customer actions (windows and/or doors left open, etc.); use the following procedure to resolve the complaints.

Thoroughly examine the passenger compartment to determine the source of the leakage. Remove the sill plate treads and raise the carpet and insulation for inspection of both sides of the vehicle. Note the presence of water or moisture.

If water is present on either front floor, perform the plenum/bulkhead repair procedure. Perform the lower A-pillar repair procedure on any side where water is present (left, right or both).

NOTE: The repairs outlined in this TIB are to be performed to resolve customer complaint of the symptoms described.

PARTS INFORMATION:

338018 Plastic Plug Qty 1
LRN2274-006 Washer Tube Grommet Qty 1
MUC4177 Fender seal Qty 2
LRNA10570 Sealant
LRN50087 Kent Leak Chek
LRNKS-E Leak Chek Extension Wand

WARRANTY CLAIMS:

NOTE: If hood and fender removal is required, standard remove and refit times apply.

76.10.8952 Time 0.55 hrs.
Plenum/Bulkhead Repair

76.10.8953 Time 0.65 hrs.
Lower A-pillar Repair (per side)
COMP CODE: 9K3P

Normal warranty policy and procedures apply

REPAIR PROCEDURE:

PLENUM AND BULKHEAD REPAIR

NOTE: Water entry into the plenum area is normal. The water must exit through the drain holes at the ends of the plenum cavity. If the drains are clogged or restricted water can leak into the engine compartment area and may leak into the passenger compartment through bulkhead panel seams, harness grommets and other bulkhead openings. The primary object of this procedure is to ensure the proper management of the water entering the plenum. As a secondary precaution, possible leak paths through the bulkhead will be sealed to prevent water entry into the passenger compartment.

1. Following procedures outlined in WSM section 76.16.01 and 76.11.08, remove the hood, engine compartment seal and wiper valence.

2. Refer to TIB 86/03/97/NAS to determine if the HVAC air intake needs to be modified.








3. Install a new windshield washer hose grommet where it passes through the forward plenum wall (Figure 1).

4. Remove adhesive dot on the unused washer hose hole on left-hand side of the forward plenum wall.

5. Install plastic plug (338018) in place of adhesive dot.

6. Locate all unused holes covered with black adhesive dots in the forward plenum wall.

7. Using Kent sealant (LRNA10570) or equivalent, seal all holes. Place sealer on plenum side.








8. On vehicles with front mounted crash sensors (before VIN TA198222 and TA528977), apply LRNA10570 sealant to seal all holes in the plenum floor created by the SRS harness retainers (Figure 2).

9. Seal any other holes between the plenum and the engine compartment.

10. Closely inspect the drain holes at both ends of the plenum.








11. Using a knife or other sharp instrument, carefully remove any excess seam sealer that may be restricting the drain (the drain is a circular hole approximately 25 mm (1 inch) in diameter, see Figure 3). Treat any exposed metal with paint or Dinitrol (RTC7769/25).

NOTE: Clogged or restricted drain holes, particularly on the right-hand side can cause water to build-up in the plenum cavity under certain conditions such as a torrential rainfall or a car wash. If the water level is high enough, it can leak into the HVAC air intake.

CAUTION: Whenever using spray sealant, care must be taken to protect the other vehicle surfaces from overspray.

1. Seal the wiper mounting plate to the body and seal all wiper-mounting points with Kent Leak Chek (LRN50087).

NOTE: Spray sealer directly into the seam. If sealer is applied perpendicular to the joint, the joint will not be covered.

2. Seal between the HVAC air intake and body with Leak Chek spray sealant.

3. Seal around the body to hood hinge mountings with Leak Chek.

4. Apply Leak Chek using an extension tube to seal the following areas of the bulkhead:

^ Pedal box to bulkhead.

^ Right-hand closeout panel to bulkhead.

^ Main harness grommet to bulkhead (right and left sides).

^ Hood release cable pass through.

^ Cruise control vacuum hose pass through.


5. Complete the lower A-pillar repair procedure on the side where water is detected.


LOWER A-PILLAR REPAIR PROCEDURE

1. Remove fender of the affected side of the vehicle using directions found in WSM 76.10.24.

2. Seal the plastic grommet just below the drain for the plenum with windshield sealant LRNA10570 (Figure 3).

3. If the left side is affected, seal the back of the bolt that retains the hood release cable and the cup sack for the lower trim, using windshield sealant LRNA10570 (Figure 4).








4. Locate and drill 25-mm access hole in side of the inner fender stiffener over the A-pillar seams (Figure 4).

5. Drill a 19-mm hole, 50-mm forward of the 25-mm hole, in the bottom of the stiffener for drainage.

6. Clean all dirt and metal particles from the inside of the stiffener and treat any exposed metal with paint or Dinitrol.

7. Apply spray sealant through the access hole drilled in the inner fender stiffener to the A-pillar seam located inside the stiffener. Apply two coats of sealer.








8. Seal the plastic grommet at the base of the A-pillar using Leak Chek (Figure 5).








9. Inspect the entire A-pillar seam, seal large gaps with windshield sealant LRNA10570 (Figure 6).

10. Use Leak Chek sealant to seal entire A-pillar seam and all other grommets, cupsacks, and bolts located in the inner fender that may leak into the passenger compartment.

11. Reinstall fender(s).

12. Reinstall the hood, seal and wiper valence.

13. Install two seals MUC4177, one for each side, along each fender seam to seal fender to hood. (see TIB 19/10/97/NAS GEMS Water Degradation).

14. Reassemble vehicle.

15. Recheck vehicles for leaks.
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