Body - Water Entry Into Front Footwell
501-24DATE
6/98
Amended 9/98
XK8
MODEL
1998 MY
XK8 Range
VIN
024687-026557
see list for exceptions
Water Entry Into Front Footwell - Repair Procedure - Service Action S824
Remove and destroy Bulletin 501-24, dated 6/98.
Replace with this Bulletin.
Revisions are marked with a bar and in bold text.
Issue:
Some 1998 MY XK8 vehicles within the above VIN range (except those listed at the end of this bulletin) which were checked at the factory) may experience water entering the front footwell.
The outer corner area of the upper bulkhead on vehicles with this condition may have to be resealed.
Action:
Vehicles within this VIN range (except those listed at the end of this bulletin, checked at the factory) must be tested, and if necessary, repaired as described below:
WORKSHOP PROCEDURE
The following instructions apply to both left and right sides of the vehicle.
Seam areas which have been shown to leak are shown in Illustration 1, as follows:
A. In the top corner, inside the false bulkhead area under the plenum finisher.
B. Between the rear upper corner of the fender and the cowl.
Note:
Before applying water to these areas, pull down the top outer corner of the toe board insulation and insert some paper towels or clean rags to show and absorb any possible leakage.
TESTING FOR POSSIBLE LEAKS
Location A.
1. Aim a jet of water in the direction of arrow A, Illustration 1, (under the finisher, to the rear), into that area for at least 2 minutes.
Note:
If a suitable 90° nozzle can be attached to the water hose it will increase the effectiveness of the jet, in that area.
2. Wait for at least 2 minutes.
3. Check the area for the presence of water by removing the paper or rag and then looking for absorbed water.
4. Check for evidence of water in the area, visually with the aid of a lamp and also by feel.
Location B.
1. Remove both windshield wipers and the plenum finisher.
2. Remove the two mounting screws furthest to the rear of the front fender. Support the rear of the fender with a wedge, to provide access to the seam (Illustration 1.)
3. Aim a jet of water in the direction of arrow B, (under the fender, to the side), into that area for at least 2 minutes.
4. Wait for at least 2 minutes.
5. Check the area for the presence of water by removing the paper or rag and then looking for absorbed water.
6. Check for evidence of water in the area, visually with the aid of a lamp and also by feel.
7. If the area is dry, at both sides, then the vehicle is OK. Refasten the fender and then reinstall the plenum finisher and windshield wipers.
8. If water is detected, proceed with the following repair procedure:
SEALING LEAKS
1. Remove both windshield wipers and the plenum finisher.
2. Use a lamp and mirror to examine the areas to be sealed. Since it is not possible to see the gap that is the cause of the leak, the whole available area of the seam must be resealed.
3. Seal the seams in the A-pillar, plenum and fender areas, (A, Illustration 2), with suitable clear sealant.
4. Seal the seams in the area below the plenum panel and up into the outer corners, (B, Illustration 2), with a suitable caulking compound and a suitable clear sealant.
5. Fill the area, (C, Illustration 2), below the fender edge, with a suitable caulking compound.
Note:
Suitable sealants are listed under Parts Information.
6. Seal the seam, in the area exposed by the lifting of the rear of the fender, with a suitable clear sealant.
7. Check the effectiveness of the sealing operation by repeating the water tests described above. If a leak is still evident, repeat the sealing procedure and retest.
8. Refasten the fender and then replace the plenum finisher and windshield wipers.
Note:
The materials listed in the table below meet the required specification, other locally available materials which are of an equivalent specification may be used.
Parts Information:
Warranty Information:
NOTE:
Always perform a DCS claim search first to determine whether this service action has been performed on this vehicle. The warranty selection under the vehicle inquiry will give a listing of all claims against the vehicle.If S824 appears in the fault code field, do not perform this service action.
CLAIM SUBMISSION PROCEDURE:
Warranty summary codes have been assigned to this service action in order to simplify claim submission. The dealership will be reimbursed the parts and labor time allowance as indicated.
DCS DEALERS
Submit claims using the appropriate summary code for the vehicle model and work performed. Follow standard campaign submission procedures.
NON-DCS DEALERS
Submit claims on the Recall Campaign Summary form W-25. Enter the appropriate summary code for the vehicle model and work performed in the Repair Code column. Do not use the WI warranty claim form.
VEHICLES REWORKED IN PLANT PRIOR TO SHIPPING
(Service Action rectification not required for these vehicles)