Water leak through ventilation system

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Author Message   Dudley Harris Posted on Sunday, August 18, 2002 - 01:57 am:    I have a late 94 Disco (facelift model). At the bottom of the windscreen there is a rubber seal, this covers the top of the main cowl, which covers the ventilation intake. It seems that when I get a lot of water on the windscreen (car wash - heavy rain) the water flows under the seal and in behind the cowl, then into the ventilation intake (then onto my carpet). The only way I can think of fixing this is by using silicon to seal between the cowl and the window seal. I am a little hesitant to do this though. I would have though the cowl should be able to stop all water. Has anyone got a similar problem - or better still fixed this problem? Thanks   Don Posted on Sunday, August 18, 2002 - 12:52 pm:    there is a up-date for that condition.it will raise the duct and seal the water out.i dont know if they have it after market or not.but the dealer can get it.if your dealer does not know what you are talking about e-mail me and i will give you the part numbers.   Dudley Harris Posted on Monday, August 19, 2002 - 01:57 am:    Thanks, I'll try the dealer tomorrow. Cheers   Mike g. Posted on Monday, August 19, 2002 - 03:51 pm:    Here's the full info on the warranty claim for this problem. I assume the warranty would have expired, but this still describes the problem, the fix, and the parts required. ------------------------------------ HVAC System Water Leak Repairs AFFECTED VEHICLE RANGE: DISCOVERY (LJ) RA081991 to TA166766 up to TA502644 SITUATION: INTAKE PLENUM WATER INTRUSION Discovery vehicles built prior to VINs TA166766 and TA502644 may experience water leakage through the HVAC air intake located in the plenum area under the wiper valence/plenum moulding. Water enters the plenum between the plenum moulding and lower windshield seal above the air intake and leaks onto the passengers side front floor. Vehicles built after the above VINs have a taller air intake that corrects this condition. Refer to Figure 1 for comparison views of the two plenum styles. This repair is to be performed only on vehicles equipped with the early style plenum. RESOLUTION: PLENUM DIVERTER INSTALLATION Upon evidence of water leakage through the HVAC system, verify the complaint by spraying water on the windshield and plenum moulding in the vicinity of the air intake. Check for water on the passengers front floorboard. If water intrusion is confirmed, perform the repair procedure. PARTS INFORMATION: LRNA020001U Intake Deflector Kit Qty 1 MXC3130PUB Plenum Clips Qty 2 LRNA10570 Sealant (Or equivalent) AWR2947 Seal Strip Qty 1 NOTE: Header junctions are often damaged by water leaks through the air intake. Refer to TIB 86/03/97/NAS for header junction repair instructions:^ LRNAHDGK - Green Header Kit ^ LRNAHDUK - Blue Header Kit ^ LRNAHDSK - Grey Header Kit WARRANTY CLAIMS: 80.15.89127 Time 0.80 hr. Install water deflector kit and seal plenum COMP CODE: 9A5N Normal warranty policy and procedures apply Repair Procedure 1. Refer to the Workshop Manual Sections 80 and 84 and remove the wiper arms and plenum moulding. 2. Remove the two bolts that retain the upper rear of the HVAC air intake. 3. Clean the firewall area along the top edge of the intake and apply a bead of sealant (LRNA10570) to the body where the deflector will be positioned. 4. Install the deflector body from kit LRNA020001U across the top of the intake. (Figure 2) 5. Secure the deflector with the bolts removed in step 2 and torque to 8 Nm (72 lbf. in.). Ensure the deflector is properly sealed to the body. 6. Peel the adhesive strip from the back of the foam seal provided in the kit and install the seal along the top of the diverter. (Figure 2) NOTE: Do not seal the windshield lower seal to the plenum mounding as described in TIB 76/01/95/US. 7. Refer to TIB 76/01/95/US (Water Ingress into the Passenger Footwell) and install deflector AWR2947 on the right side of the plenum moulding if not previously installed. (Figure 3) 8. Remove three foam filter blocks from the right hand side of the plenum housing and seal the three drain holes in the bottom outboard corner of each cavity using sealant. (Figure 4) 9. Install filter blocks and plenum moulding. 10. Assemble removed components. 11. Water test to verify effective repair.   Dudley Harris Posted on Tuesday, August 20, 2002 - 02:03 am:    Thanks - the dealer knew nothing about this. I can now order the parts and do this myself. Cheers