Renault trafic 01- leaking scuttle fix guide save your injectors - Renault Forums :: Independent Renault forum

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post #1 of 10 (permalink) Old 13th July 2014 Thread Starter
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Renault trafic 01- leaking scuttle fix guide save your injectors

this is a guide i found that i thought id share a leaking scuttle is a common problem on renault trafics water in the engine bay causes all sorts of problems i myself have had a 1000 pound bill for stuck injectors caused by this its well worth the small cost of putting right

"LEAKING SCUTTLE FIX " -

PART 1
shows what else this leak buggers up. If you have not done this fix I would strongly suggest you do.

This is a very thorough HOW TO so please follow carefully. it wont let me post up in one, so i'll label it as Part 1 & Part 2 etc..

The seals are from screwfix.. so i will list these first as you will need these before you start.

1) Dry Glaze seal item No. 43490 10.79
2) Extra thick rubber foam seal item No. 40425 6.38
3) A tube of black exterior quality sealant ( unibond easy finish is ideal )
4) Main dealer trim rivet clips there are two types 91169620 0.85 ea + vat & 91169621 1.76 ea + vat ( I just ordered 1/2 doz of ea as it was not clear at the time exactly which was which. I will know this weekend when they arrive so can advise if needed after that.

You will also need a 24hr DRY period. This means NO washing windscreen etc as well.

I'll post up all the pic's as thumbnails for those that need a bit more guidance but for those mechanically minded just pay attention to the Heater Blower Horror area , the seals and the additional sealant / bonding in of everything.

Step 1 - " Strip it all out "
Remove both side wind deflectors at bottom corner of windscreen, Wiper Arms, rubber wiper drive seal, rubber bonnet seal and top plastic scuttle cover, followed by the long narrow trim ( this simply slides to the right and lifts off ). Next remove all the torx bolts visible on the metal scuttle, the 2 drain pipes ( 1 each end ) and the 10mm nut holding the wiper motor underneath ( L/H end of blower ) followed by the 2 large wiper drive nuts above, separate the 2 washers carefully from the rubber seals and and ease the wiper gear down. Now undo the 1 bolt hold panel down which is again on the left hand end of the blower and goes through a white plastic craddle.

Lift out the metal Scuttle Panel ( the seal to be replaced is on the edge and is poop !) Peel this off, remove all the residue ( Carb cleaner is perfect for this as it destroys rubber!) and clean up so all is spotless!

Step 2 - " The Horrors unfold " - Note I only discovered this as it had been raining had the whole day before. If it had been dry this would of gone un-noticed.

Look on the top of the heater blower insulation for water marks.. this leak does not just drip through onto the air filter and then injectors / fuse box.... it also fills the inside of this insulation!!! Remove the lower section 12 x 8mm ( bit fiddly for the ones at the back but you will get em) as in the bottom is a pocket that sit around the recirculation flap control motor unit. This fills with water and looks ok from the outside but look at what is inside!!


LEAKING SCUTTLE FIX

PART 2

View attachment 6568
The mess at the bottom is your recirc' flap motor and this is the cause of my fault codethat related to air con ( Which I dont even have ) but kept being thrown up and stored in ECU and was causing all kinds of silly glitches. Nice aye! The part No. for this is 91158688 75 ! looking for one on flea bay

Also remove and check the thermal resistor pack as this is also corroded inside but not too bad so can clean up and refit.
Tis in the side of the blower 1x 6mm bolt and then lift upwards.

Step 3 - The resealling!

Thoroughly clean all the parts removed, the bottom of windscreen and exposed painted section below. ( this must all be spotless )

Apply the new rubber seal to the edge of metal scuttle where old one was. Keep it back 1-2mm from outer edge .

Replace the foam strips on either end and then add another piece of the rubber edge strip over the top (it wont seal down properly without it )


Step 4 - Refiit + additional sealant required to overcome design flaw.

Apply a thin bead of black sealant to the new rubber seals at the inner edge of the long section and the outer edge of the end sections.

Ease into place without disturbing the sealant and line up the bolt holes. Place all the bolts in the holes and apply sealant under the heads before tightening ( if you dont do this it will leak in the winter through these )

The main issue with this problem is the windsreen does not continue over the scuttle which leaves a gap of about half and inch and in that space they decided to fit 5 retainer clips (this is what the top scuttle cover clips onto. poop design it really is.
Pay particular attention to this part.
This space collects all the water off the screen and due to the shape (hollow in the centre) pools up until it runs over the lip created by the scuttle (except most goes behind it) The retainer clips are also stuck on with foam and there is a hollow section in the middle which also saturates . These retainers push through the body like a tube so perfect for dropping water right onto the electrics EGR , Blower, Injectors. You can feel them underneath from engine side.
You will need to apply a thick bead of sealant from the top of the scuttle lip onto the body all the way along and smooth it off to form a ramp. It does not have to be neat as it wont be seen b ut you need to make sure you get it in and around the retainer clips including the hole in the centre of them as well.
I also placed some foil tape up under the screen and over this sealant lapping it onto the scuttle. This forms a 100% seal forever. Up to you if you go this bit further, I had the tape anyway and think it makes for a better job. ( 50mm wide adhesive foil tape ) See Part 3 pics at the end for this part (wont let me upload anymore)

There are two spare holes with rubber bungs in, remove these, apply sealant to the grooves, refit (ensuring the groove locates properly ) and apply sealant at the very outer corners of the scuttle where it sits over the wing (small gap)

Remove the grommets around the wiper drives and do the same here as this will also leak .
Refit the long narrow strip, sliding to the left.

Now to refit the drain tubes...! make sure the grooves are clean and dry. Poke the ends through the hole in wing and push the top through the hole from underneath so it is sticking up and apply sealant all around the opening on the metal. push the drain down again making sure the groove engages and wipe off the excess sealant from top and underneath to make a good seal. These are also poop allow all the water collect in the scuttle to run out of the space between the rubber and scuttle, so make sure you get this sealed well.

Thats the sealing done so you can now refit the bottom rubbers over the wiper drives, top scuttle, top rubbers over wiper drives and make sure they lock over the bottom ones, then the retainers.

The seal on the small wind deflectors can also be renewed using the foam type seal again keeping it back slightly from the edge as it will be seen.
replace clips, rubber bonnet trim and wiper arms and then allow sealant to set for 24hr before getting any water near it.

Job done! and a must to save your injectors / electrics !
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post #2 of 10 (permalink) Old 13th July 2014
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Re: Renault trafic 01- leaking scuttle fix guide save your injectors

Can also refer to this one also:

Trafic Scuttle Panel Removal with pics
http://www.renaultforums.co.uk/showthread.php?p=1425074#post1425074
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Re: Renault trafic 01- leaking scuttle fix guide save your injectors

The amount of rivets and panel clips I've bought over the period I've had my van will surely keep renault in cigars at their annual Christmas party
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post #4 of 10 (permalink) Old 13th July 2014
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Re: Renault trafic 01- leaking scuttle fix guide save your injectors

Quote:
Originally Posted by cunstine View Post
The amount of rivets and panel clips I've bought over the period I've had my van will surely keep renault in cigars at their annual Christmas party
I would buy rivets at Halfords, they are good quality & cheaper. Bet we don't get an invite to their party.
Currently in chuffer690's garage:
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Last edited by chuffer690; 28th August 2016 at 08:15 PM.
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post #5 of 10 (permalink) Old 16th July 2014 Thread Starter
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Re: Renault trafic 01- leaking scuttle fix guide save your injectors

Yeah they are too busy brainstorming terrible design faults that cost the consumer thousands to send our invites out '
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