Land Rover Body Repairs Water Leaks Water Leak Landrover Jlrext Com Manual

							Body Repairs - Water Leaks - Water Leak 
Diagnosis and Testing 
Inspection and Verification 
1.1. Verify the customer concern. 
2. 2. Visually inspect for obvious signs of mechanical or  electrical damage. 
3. 3. 
If an obvious cause for an observed or reported con cern is found, correct the cause (if possible) before proceeding to the next step. 
4. 4. If the cause is not visually evident, verify the sy mptom and refer to the Symptom Chart. 
Water Leak Diagnostic Procedure 
Introduction  
This procedure has been developed to aid diagnosis  and rectification of water ingress on Defender vehicles with the aim of 
providing a  right first time fix . 
The procedure provides suggested points of water in gress and guidelines for a recommended fix. 
Prerequisites  
It is assumed the technician working on the vehicle  will be at least level 3 trained  and normal vehicle service protection 
equipment will be used where appropriate i.e. seat  covers, wing covers etc. 
Water Leak Diagnosis  
There are certain basic tools required for effectiv e water leak detection the following are a few reco mmendations. 
There are several adaptations of tools that can be  used, for example a watering can rose attached to a  hosepipe to create a 
spray, or a new sealant tube nozzle attached to a hosepipe can be very effective to direct water into awkward corners, there are also several ready made hosepipe nozzles availa ble from DIY stores which can be switched through s everal different 
water patterns, and finally not forgetting a normal  car wash. With the exception of a car wash initial diagnosis is more 
accurate if carried out by  two people, one inside and one outside the vehicle, the perso n outside can direct the water onto 
the areas where the leak is suspected to be enterin g, and the person inside can inspect with a 12 volt hand lamp to confirm 
the entry point.  
It is worth bearing in mind that the location that  the water appears in the interior of the vehicle, m ay not be the leak 
source,  for example water lying in the passenger footwell c ould be entering on the drivers side and running 
across, behind the fascia . In order to find the water entry point, trim or c omponents may have to be removed. 
Staining  
Often when water has been entering over a period of  time, the water entry point can be located visually by following the 
stains or tracks left by the leak.  
Sealing Water Leaks 
Basic tools
Hosepipe
Water supply
Pressure Washer
Watering Can
Torch
Mirror (telescopic type)
Air supply
Boning tool (Nylon shaped block for trim removal)
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							There are different substances that can be used to seal water leaks, putty type sealant and wet/paste  sealant. Examples of 
these are bostic (dum-dum) 303 glasticon and bet afill 10210 which is a white paste and terostat 33 which is clear. 
 NOTE: Do not use silicon based sealers as these w ill cause problems if any subsequent paint operations are required. 
Careful consideration needs be given as to the subs tance used to seal a water leak, for example an external seam on a 
white vehicle would require white or clear sealant,  dum-dum is best used in concealed places to fill larger gaps. The sealant 
should be applied in a manner that it does not look  unsightly when finished, if used in a box section or under a carpet, 
applying and smoothing over should be ok, but on th e external panels or visible areas the sealant should be wiped into the gap and any excess removed with a suitable spirit t hat will not harm the vehicles paintwork 
Once the water entry point has been confirmed, the  suspect area must be sufficiently dried prior to the application of any 
sealing compound the use of a compressed air will a ssist 
Symptom Chart 
Water Ingress Paths And Recommended Repair Procedur e  NOTE: Carry out a water leak test and visual inspection of any suspect or wet areas once the water e ntry point has been 
determined refer to the symptom chart below. 
Symptom - Water CollectingPossible Water Entry  PointsAction - To Be Carried Out Once The 
Water Entry Point Has Been Confirmed
In footwell  (entry point - front area)Heater cable grommet Wiper grommet  Windscreen seal  Footwell seams  Floor seams  Hood release grommet Pedal box grommet  Blower box  Air intake duct to 
blower join  
Air intake  Clutch/brake pedal  box  
Windscreen surround  frame  
For heater cable grommet GO to  Pinpoint Test A.  For wiper grommet GO to Pinpoint  Test B.  For windscreen seal GO to Pinpoint  Test C.  For footwell seams GO to Pinpoint Test D.  For floor seams GO to Pinpoint Test E. For hood release grommet GO to Pinpoint Test F.  For pedal box grommet GO to Pinpoint Test G.  For blower box GO to Pinpoint Test I. Air intake duct to blower join GO to  Pinpoint Test H.  For air intake GO to Pinpoint Test J.  For clutch/brake pedal box GO to Pinpoint Test K.  For windscreen surround frame GO to Pinpoint Test L.  
In footwell  (entry point - front door area)Door seal  Water shedder  Door latch/door edge  Rear tub capping  Upper to lower body 
joint (waist side)  
Roof to A post joint  
For door seal GO to Pinpoint Test M.  For water shedder GO to Pinpoint Test N.  For door latch/door edge GO to  Pinpoint Test O.  For rear tub capping GO to Pinpoint  Test P.  For upper to lower body joint (waist side) GO to Pinpoint Test Q.  For roof to A post joint GO to  Pinpoint Test R.  
In footwell  (entry point - rear door area)Door seal  Water shedder  Door latch/door edge  Rear tub capping  Upper to lower body 
joint (waist side)  
Roof to upper body  side joint  
For door seal GO to Pinpoint Test M.  For water shedder GO to Pinpoint Test N.  For door latch/door edge GO to  Pinpoint Test O.  For rear tub capping GO to Pinpoint  Test P.  For upper to lower body joint (waist side)GO to Pinpoint Test Q.  For roof to upper body side joint GO  to Pinpoint Test S.  
In footwell  (entry point - A post area)Door seal  For door seal GO to Pinpoint Test M.  
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							Windscreen hinge  Main harness grommet Air-con pipe grommet 
For windscreen hinge GO to Pinpoint Test T.  For main harness grommet GO to Pinpoint Test U.  For air-con pipe grommet GO to Pinpoint Test V.  
In rear luggage compartment/seating area (entry point - lower body side/rear)Rivets in body side  Tail lights/rear end  capping  For rivets in body side GO to Pinpoint Test W.  For tail lights/rear end capping GO to Pinpoint Test X.  
In rear luggage compartment/seating area (entry point - upper body side/rear)Corners of upper body quarter panels  Upper to lower body  joint (waist rear)  
Corners of upper body quarter panels GO to Pinpoint Test Y.  For waist seal rear (waist rear)GO to  Pinpoint Test Z.  
In rear luggage compartment/seating area (entry point - tail door)Rear end door  Upper to lower body joint  
Roof to upper body joint  
Rear end doorGO to Pinpoint Test AA. For upper to lower body joint GO to  Pinpoint Test Q.  For roof to upper body joint GO to Pinpoint Test S.  
In rear luggage compartment/seating area  (entry point - roof)Roof seam  Alpine lights (if installed)  
Front corner seams  Drain channel crack  
For roof seam GO to Pinpoint Test AB. For alpine lights (if installed) GO to  Pinpoint Test AC.  For front corner seams GO to Pinpoint Test AD.  For drain channel crack GO to Pinpoint Test AE.  
PINPOINT TEST A : HEATER CABLE GROMMET 
TEST CONDITIONSDETAILS/RESULTS/ACTIONS
A1: HEATER CABLE GROMMET
Apply sealant around the outer edge of the grommet  and 
onto the grommet to cable joint 1 
Materials required: sealant (clear/body coloured),  gloves, 
spirit wipe, cloth 2 
Remove excess sealant from the body area 3 
Allow the sealant to cure, and retest suspect area  for 
water entry 4 
Is water still entering the vehicle?  
Yes  Carry out a water leak test and visual inspection o f any 
suspect or wet areas, once the water entry point ha s been 
determined refer to the Water Ingress Paths And 
Recommended Repair Procedure above 
No  Reinstall any trim/panels or component that have be en 
displaced 
PINPOINT TEST B : WINDSCREEN WIPER GROMMET 
TEST CONDITIONSDETAILS/RESULTS/ACTIONS
B1: WINDSCREEN WIPER GROMMET
Remove the grommets, check the grommet and hole 1 
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							apertures for abnormalities/distortion. Apply sealant to the outer edge of the grommet and reinstall 
Remove excess sealant from the body area 2 
Materials required: sealant (clear or black), gloves, spirit 
wipe, cloth 3 
Allow the sealant to cure, and retest suspect area  for 
water entry 4 
Is water still entering the vehicle?  
Yes  Carry out a water leak test and visual inspection o f any 
suspect or wet areas, once the water entry point ha s been 
determined refer to the Water Ingress Paths And 
Recommended Repair Procedure above 
No  Reinstall any trim/panels or component that have be en 
displaced 
PINPOINT TEST C : WINDSCREEN SEAL 
TEST CONDITIONSDETAILS/RESULTS/ACTIONS
C1: WINDSCREEN SEAL
Using a boning tool, lift the edge of windscreen  seal and 
insert the sealant gun nozzle, apply a bead of seal ant 
between the seal and outer frame 1 
Remove excess sealant from the body area 2 
Materials required: sealant (clear/body coloured),  gloves, 
spirit wipe, cloth, Boning tool 3 
Allow the sealant to cure, and retest suspect area  for 
water entry 4 
Is water still entering the vehicle?  
Yes  Carry out a water leak test and visual inspection o f any 
suspect or wet areas, once the water entry point ha s been 
determined refer to the Water Ingress Paths And 
Recommended Repair Procedure above 
No  Reinstall any trim/panels or component that have be en 
displaced 
PINPOINT TEST D : FOOTWELL SEAMS 
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							TEST CONDITIONSDETAILS/RESULTS/ACTIONS
D1: FOOTWELL SEAMS 
 NOTE: A 12 volt hand lamp shone underneath the vehicle and viewed form the interior may assist in tracing leak paths 
Lift or remove floor mats/carpets. With the hood op en carefully direct water from the top, down the scuttle panel and under the vehicle. There are several seams with in the 
footwell, water entry may be from any or all of the se, also 
visually check and seal, the grommets and apertures  in 
the front of the tunnel area as required 
1 
Run sealant along the seams and wipe into joint wit h a 
gloved hand. Grommets can be removed and sealant 
applied around the outer edge before reinstalling 2 
Materials required: sealant (clear/body coloured),  gloves, 
spirit wipe, cloth 3 
Allow the sealant to cure, and retest suspect area  for 
water entry 4 
Is water still entering the vehicle?  
Yes  Carry out a water leak test and visual inspection o f any 
suspect or wet areas, once the water entry point ha s been 
determined refer to the Water Ingress Paths And 
Recommended Repair Procedure above 
No  Reinstall any trim/panels or component that have be en 
displaced 
PINPOINT TEST E : FLOOR SEAMS 
TEST CONDITIONSDETAILS/RESULTS/ACTIONS
E1: FLOOR SEAMS
 NOTE: The floor plate is secured using screws and  a foam construction gasket 
Lift or remove floor mats/carpets. With the hood open carefully direct water from the top, down the scuttle panel and under the vehicle 
1 
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							Pay particular attention to the corners of the floor 
panel  as there is an overlap condition where multiple 
panels meet, apply sealant and wipe it into the ove rlapping panel edges and corners this should prevent further  water 
entry. Sealant can be added to the gasket of the  
removable floor plate as required 
2 
Materials required: sealant (clear/body coloured),  gloves, 
spirit wipe, cloth 3 
Allow the sealant to cure, and retest suspect area  for 
water entry 4 
Is water still entering the vehicle?  
Yes  Carry out a water leak test and visual inspection o f any 
suspect or wet areas, once the water entry point ha s been 
determined refer to the Water Ingress Paths And 
Recommended Repair Procedure above 
No  Reinstall any trim/panels or component that have be en 
displaced 
PINPOINT TEST F : HOOD RELEASE GROMMET 
TEST CONDITIONSDETAILS/RESULTS/ACTIONS
F1: HOOD RELEASE GROMMET
Apply sealant around the outer edge of the grommet  and 
onto the grommet to cable joint 1 
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							Remove excess sealant from the body area 2 
Materials required: sealant (clear/body coloured), gloves, 
spirit wipe, cloth 3 
Allow the sealant to cure, and retest suspect area  for 
water entry 4 
Is water still entering the vehicle?  
Yes  Carry out a water leak test and visual inspection o f any 
suspect or wet areas, once the water entry point ha s been 
determined refer to the Water Ingress Paths And 
Recommended Repair Procedure above 
No  Reinstall any trim/panels or component that have be en 
displaced 
PINPOINT TEST G : PEDAL BOX GROMMET 
TEST CONDITIONSDETAILS/RESULTS/ACTIONS
G1: PEDAL BOX GROMMET
Remove the grommet and check both the grommet and hole aperture for abnormalities/distortion, apply s ealant to the outer edge of the grommet and reinstall 
1 
Remove excess sealant from the body area 2 
Materials required: sealant (clear/body coloured),  gloves, 
spirit wipe, cloth 3 
Allow the sealant to cure, and retest suspect area  for 
water entry 4 
Is water still entering the vehicle?  
Yes  Carry out a water leak test and visual inspection o f any 
suspect or wet areas, once the water entry point ha s been 
determined refer to the Water Ingress Paths And 
Recommended Repair Procedure above 
No  Reinstall any trim/panels or component that have be en 
displaced 
PINPOINT TEST H : AIR INTAKE DUCT TO BLOWER 
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							TEST CONDITIONSDETAILS/RESULTS/ACTIONS
H1: AIR INTAKE DUCT TO BLOWER
 NOTE: The wing install process is to lower the wing into place along the face of the scuttle panel, this can displace the 
foam seal attached to the blower box 
Check the condition and location of the foam gasket  joint 
between the air intake duct, and the blower box ins talled 
to the scuttle panel 1 
If possible apply sealant to the aperture with the  wing 
installed 2 
If it is not possible to seal the aperture with the  wing 
installed, remove the wing to complete the repair 3 
Materials required: sealant (clear/body coloured),  gloves, 
spirit wipe, cloth 4 
Allow the sealant to cure, and retest suspect area  for 
water entry 5 
Is water still entering the vehicle?  
Yes  Carry out a water leak test and visual inspection o f any 
suspect or wet areas, once the water entry point ha s been 
determined refer to the Water Ingress Paths And 
Recommended Repair Procedure above 
No  Reinstall any trim/panels or component that have be en 
displaced 
PINPOINT TEST I : BLOWER BOX 
TEST CONDITIONSDETAILS/RESULTS/ACTIONS
I1: BLOWER BOX
Direct water around the blower box, if a leak is fo und and it is possible to identify the particular area of the leak then sealant can be applied to the seam where the blower  box 
sits on the bulkhead and wiped in if possible 
1 
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							If it is not possible to highlight the actual area of the ingress the remove the blower box and check the int egrity of the foam gasket, replace gasket as required, adding a 
fine bead of sealant to the gasket before carefully  
reinstalling to ensure a good seal 
2 
On some 07 model year vehicles there may be water  
actually dripping through the blower box grille in  the 
passenger footwell, this is caused by a problem wit h the 
sealing of the two halves of the blower box itself,  and 
replacement of the blower box is recommended 3 
Materials required: sealant (clear/body coloured),  gloves, 
spirit wipe, cloth, replacement gasket, blower box 4 
Allow the sealant to cure, and retest suspect area  for 
water entry 5 
Is water still entering the vehicle?  
Yes  Carry out a water leak test and visual inspection o f any 
suspect or wet areas, once the water entry point ha s been 
determined refer to the Water Ingress Paths And 
Recommended Repair Procedure above 
No  Reinstall any trim/panels or component that have be en 
displaced 
PINPOINT TEST J : AIR INTAKE 
TEST CONDITIONSDETAILS/RESULTS/ACTIONS
J1: AIR INTAKE
Ensure that the interfaces shown in Fig 1 and Fig 2  are 
correctly made, no ripples or damage. Fig 3 indicat es the 
2 faces when installed 1 
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							For repairs to a minor water ingress issue, it may be 
possible to apply a bead of sealant to affected are a and 
smooth in 2 
For removal and installation of the wing air duct ( fig 1). 
Care must be taken to ensure a good mating interfac e 
between the duct and foam gasket on the blower 3 
Materials required: sealant (clear/body coloured),  gloves, 
spirit wipe, cloth 4 
Allow the sealant to cure, and retest suspect area  for 
water entry 5 
Is water still entering the vehicle?  
Yes  Carry out a water leak test and visual inspection o f any 
suspect or wet areas, once the water entry point ha s been 
determined refer to the Water Ingress Paths And 
Recommended Repair Procedure above 
No  Reinstall any trim/panels or component that have be en 
displaced 
PINPOINT TEST K : CLUTCH/BRAKE PEDAL BOX 
TEST CONDITIONSDETAILS/RESULTS/ACTIONS
K1: CLUTCH/BRAKE PEDAL BOX
Apply sealant around the pedal box seams, wipe seal ant 
into seams 1 
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