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TSB 20/04 - Focus Water ingress

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#1 ·
Subject/Concern: FOCUS: WATER INGRESS INTO THE PASSENGER FOOTWELL THROUGH THE COWL PANEL GRILLE AND POLLEN FILTER

Cause: Inadequate seal between the passenger side cowl panel grille and the windshield in the area around the pollen filter.

Action: Passenger side cowl panel grille should be removed and an additional cowl panel grille-sealing strip should be installed.

Service Procedure
Concern Description:
If a customer expresses a concern about water ingress into the passenger foot well, the probable cause is an inadequate seal between the cowl panel grille and the windshield in the area of the pollen filter.

The cowl panel grille on the passenger side should be removed and an additional cowl panel grille-sealing strip should be installed.


Service Action:
1. Position the wiper arm in the vertical position by switching ignition off when wiper is in the middle of its cycle/travel.
2. Using a suitable tool (eg. Painter's pallet knife), separate the butyl-sealing strip that is located between the windshield and the passenger side cowl panel grille. Note: only separate the butyl on passenger side cowl panel grille.
3. Open the bonnet.
4. Remove the cowl panel grille (Figure 1) on the passenger side (driver and passenger sides shown).

Instructions for Figure 1:
1. Remove the screw cover. Please NOTE: 1 screw cover ONLY (circled in Figure 1)
2. Remove the screw.
3. Release the 3 front clips, lever up the cowl panel and release the 2 rear clips.
5. Remove the 2 white sliding clips (shown by arrows on Figure 2) from the corresponding mountings on the body panel.
6. Once white sliding clips are removed, re-attach the sliding clips onto the corresponding mountings on the back of the cowl panel grille.
7. Thoroughly clean the area of the windshield where the cowl panel grille will make contact. Make sure that any dirt and residues of adhesive and butyl-sealing strip are completely removed.
8. Remove the pollen filter-retaining flap (Refer to Fig 3). Arrows in figure 3 define fixing points of strap.
9. Note the orientation/direction of flow of the pollen filter, then remove the pollen filter and check if the filter is wet/damp. If the filter element is wet, install a new one (see Parts required).
10. Clean the protective grille (defined by arrow in Figure 4) underneath the rubber protective edge in the area between the windshield wiper motor and the filter housing.
11. Detach the one side of protective backing from the double-sided adhesive cowl panel grille sealing strip (see parts required).
12. Start to affix/attach the cowl panel grille sealing strip to the edge of the cowl panel grille. Make sure you leave a 6mm gap between edge of sealing strip and edge of cowl panel grille. The small inset diagram E46718 in Figure 5 shows a cross section of the edge of the cowl panel grill when installed against the windscreen with the sealing strip in the correct position.
Note: Start the attachment at the side of the cowl panel grille that sits closest to the middle of the vehicle (refer to circled 1 in Figure 5 ).
13. Continue to attach the cowl panel-grille sealing strip along the edge of the cowl panel grille. When the end of the cowl panel is reached, bend back about 40mm of the protective backing. (refer to circled 2 in Figure 5). Note: you will need to use this 40mm tab to help remove the other side of sealing strip once the cowl panel is installed.
14. Place the passenger side cowl panel grille in its installation position.
15. Adjust positioning of cowl grille so that all cowl panel grille clips line up with the appropriate holes, then gently press the cowl panel grille fully until all clips are fully engaged. NOTE: Make sure that all clips are fully engaged.
16. Beginning from 40mm tab at edge of cowl grille, slowly remove the protective backing from the cowl panel grille-sealing strip. When protective backing is fully removed, attach as much of 40mm tab to the edge of cowl grille panel as possible. Neatly cut of any excess length from 40mm tab.
17. Press the cowl panel grille fully into place against the windshield using a suitable roller.
18. Re-install the cowl panel screw and screw cover.
 
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