Issue #1 - Liftgate Opening
Root Causes
Seal is severely rolled inboard or outboard
Liftgate is mis-adjusted and creates a large seal gap
Enlargement
Issue #2 - Hood Opening, Potential leak at A-post to plenum joint
Root Causes
Foil backed mastic patch missing
Foil backed mastic patch not installed correctly
Enlargement
Issue #3 -Tail Lamp Area, Potential leak through tail lamp PLP plugs
Root Causes
Grommet not sealing to BSA (need clear sealer rework)
Enlargement
Issue #4 - Under Fender Forward of Door, Potential leak through seam at cowl side to load beam
Root Causes
Seam is not sealed
Enlargement
Issue #5 - Under Fender Forward of Mirror, Potential leak through fender baffle attach holes
Root Causes
Missing sealer between fender baffle clips and body
Enlargement
Issue #6 - Rear Door, Potential water leak through division bar Leak shows up at rear bolster
Root Causes
Notch and foam missing on outer belt at division post
Bolster not lined with closed cell foam for seal
Enlargement
Enlargement
Issue #7 - Liftgate, Potential water leak through hem flange and does not drain properly
Root Causes
Hem sealer skip
Loose hem
Enlargement
Issue #8 - Liftgate Opening, Potential water leak through roof to bodysideseam
Root Causes
Skip or void in vinyl sealer
Enlargement
Issue #9 - Liftgate Opening, Potential water leak through hinge bolts
Root Causes
Distorted clearance hole
Damaged hinge gasket
Bolt head gaps to hinge
Must seal with clear sealer
Torque on fasteners not to spec
Enlargement
*** Continued in next post ***
Root Causes
Seal is severely rolled inboard or outboard
Liftgate is mis-adjusted and creates a large seal gap

Enlargement
Issue #2 - Hood Opening, Potential leak at A-post to plenum joint
Root Causes
Foil backed mastic patch missing
Foil backed mastic patch not installed correctly

Enlargement
Issue #3 -Tail Lamp Area, Potential leak through tail lamp PLP plugs
Root Causes
Grommet not sealing to BSA (need clear sealer rework)

Enlargement
Issue #4 - Under Fender Forward of Door, Potential leak through seam at cowl side to load beam
Root Causes
Seam is not sealed

Enlargement
Issue #5 - Under Fender Forward of Mirror, Potential leak through fender baffle attach holes
Root Causes
Missing sealer between fender baffle clips and body

Enlargement
Issue #6 - Rear Door, Potential water leak through division bar Leak shows up at rear bolster
Root Causes
Notch and foam missing on outer belt at division post
Bolster not lined with closed cell foam for seal

Enlargement

Enlargement
Issue #7 - Liftgate, Potential water leak through hem flange and does not drain properly
Root Causes
Hem sealer skip
Loose hem

Enlargement
Issue #8 - Liftgate Opening, Potential water leak through roof to bodysideseam
Root Causes
Skip or void in vinyl sealer

Enlargement
Issue #9 - Liftgate Opening, Potential water leak through hinge bolts
Root Causes
Distorted clearance hole
Damaged hinge gasket
Bolt head gaps to hinge
Must seal with clear sealer
Torque on fasteners not to spec

Enlargement
*** Continued in next post ***