Discovery 2. Manual — part 281

CORROSION PREVENTION AND SEALING

SEALING 77-4-19

Interweld sealer

Interweld sealing areas - rear end. Seams symmetrically opposite to those shown must also be treated.

M77 1681A

CORROSION PREVENTION AND SEALING

77-4-20 SEALING

Interweld sealing areas. Seams symmetrically opposite to those shown must also be treated.

1 10 mm (0.393 in) x 2 mm (0.078 in) 'Butyl strip'
2 10 mm (0.393 in) x 1 mm (0.039 in)'Butyl strip'

3 Interweld sealant

Butyl tape is also applied to the bodyside rear glass aperture flanges. On the forward edge of the aperture a 15 mm
(0.590 in) x 2 mm (0.078 in) strip is applied, and on the lower and rearward edges a 10 mm (0.393 in) x 2 mm (0.078
in) strip is applied.

During production, interweld sealer is applied to critical joint areas. The material used is a heat cured, rubber based
sealant which serves to seal two metal surfaces and prevent the ingress of moisture, dust and fumes. Before refitting
a replacement panel, apply interweld sealer to areas indicated or to the mating panel face.

Those joints which require the application of interweld sealers are detailed in the previous illustrations. Only joints
applicable to service panels are included.

M77 1682A

1

2

3

CORROSION PREVENTION AND SEALING

SEALING 77-4-21

Gap fill sealer

Gap fill sealer - front header and roof bows

Gap fill sealer - front and rear doors

The previous illustrations show the areas where gap-fill (anti-flutter) sealer is applied. The material bonds two surfaces
together but allows for a certain amount of movement between the two bonded surfaces.

M77 1722B

M77 1724B

CORROSION PREVENTION AND SEALING

77-4-22 SEALING

Water leaks

Where water leakage is involved, always adopt a logical approach to the problem using a combination of skill,
experience and intuition. Do not reach a conclusion based only on visual evidence, such as assuming that a wet
footwell is caused by a leak emanating from the windscreen. It will often be found that the source of the leak is
elsewhere. Use of the correct procedure will increase the chance of locating a leak, however obscure it may seem.

Tools and equipment
The following tools and equipment are recommended for the purpose of detection and rectification of water leaks:

1 Garden sprayer (hand-operated)
2 Wet/dry vacuum cleaner
3 Dry, absorbent cloths
4 Battery torch
5 Small mirror
6 Weatherstrip locating tool
7 Trim panel remover
8 Small wooden or plastic wedges
9 Dry compressed air supply

10 Hot air blower
11 Sealer applicators
12 Ultrasonic leak detector

During leak detection, the vehicle should be considered in three basic sections:

l

The front interior space;

l

The rear passenger space;

l

The loadspace or boot.

Testing
From the information supplied by the customer it should be possible for the bodyshop operator to locate the starting
point from which the leak may be detected. After the area of the leak has been identified, find the actual point of entry
into the vehicle.

A simple and effective means in the first instance is an ordinary garden spray with provision for pressure and jet
adjustment, which will allow water to be directed in a jet or turned into a fine spray. Use a mirror and a battery-powered
torch (NOT a mains voltage inspection lamp) to see into dark corners.

The sequence of testing is particularly important. Start at the lowest point and work slowly upwards, to avoid testing
in one area while masking the leak in another. For example, if testing started at the level of the windscreen, any water
cascading into the plenum chamber could leak through a bulkhead grommet and into the footwells. Even at this point
it could still be wrongly assumed that the windscreen seal was at fault.

Another important part of identifying a water leak is by visual examination of door aperture seals, grommets and
weatherstrips for damage, deterioration or misalignment, together with the fit of the door itself against the seals.

Sealing
When the point of the leak has been detected, it will then be necessary to rectify it using the following procedure:

1 Renew all door aperture seals and weatherstrips which have suffered damage, misalignment or deterioration
2 Check all body seals to ensure that they are correctly located on their mounting flanges/faces using a lipping

tool if necessary

3 Dry out body seams to be treated using compressed air and/or a hot air blower as necessary
4 Apply sealant on the outside of the joint wherever possible to ensure the exclusion of water
5 When rectifying leaks between a screen glass and it's weatherstrip (or in the case of direct glazing, between the

glass and bodywork), avoid removing the glass if possible. Apply the approved material at the appropriate
location (i.e. glass to weatherstrip or glass to body)