By Frank on Thursday, May 17, 2001 - 10:57 am: Edit

I pulled up the carpet under the passenger footspace and could not beleive the amount of water. Where is the A/C condensation supposed to drain? I looked under the vehicle on the passenger side and the only thing resembling a plastic nipple was a little plug to let water out of the passenger side footwell. That helped get the water out, but I need to stop it from coming in, if you know what I mean.

If someone could bear with me and explain in great detail where the clogged A/C drain is, I would be most appreciative.

By Axel Haakonsen (Axel) on Thursday, May 17, 2001 - 11:00 am: Edit

They are on each side of the transmission, way up in there. Use a straightened clothes hanger to reach them and clean them out.

By Rob on Thursday, May 17, 2001 - 03:51 pm: Edit

Frank,

Ahh I see that I may have been right. Get under that truck with a flashlight! Axel is right. Next to the transission (on the inside) you will see what looks like a back pen cap. Wait until the truck cools down and look and feel and you will find it. I think when someone told me about it they were more specific. I'll see if I can find something. In the mean time get under there.

By Rob on Thursday, May 17, 2001 - 04:12 pm: Edit

If it just happens when it rains it might be this.
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.

By Rob on Thursday, May 17, 2001 - 04:24 pm: Edit

Frank,

Send me your email and I will send you a picture of the nipple location

By Frank on Thursday, May 17, 2001 - 04:49 pm: Edit

Rob -

you are the man. I just shot you an email. Thanks.