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HOMESERVICE MANUALSSATURN1997SC1 AUTOMATICREPAIR AND DIAGNOSIS (SINGLE PAGE)QUICK LOOKUPSTECHNICAL BULLETINSTECHNICAL SERVICE BULLETINSINTERIOR/EXTERIOR TRIMWATER LEAKS INTO FRONT FOOTWELL FROM FRONT OF DASH (94-T-32A)
1997 Saturn SC1 Automatic

Water Leaks Into Front FOOTWELL From Front Of Dash (94-T-32A)

1997 Saturn SC1 AutomaticSECTION Water Leaks Into Front FOOTWELL From Front Of Dash (94-T-32A)
Publication date: 1998-04-01
Reference number: 94-T-32A
Supersedes refnos: 94-T-32

WATER LEAKS INTO FRONT FOOTWELL FROM FRONT OF DASH

WATER LEAKS INTO FRONT FOOTWELL FROM FRONT OF DASH

TECHNICAL SERVICE BULLETIN

Reference Number(s): 94-T-32, 94-T-32A, Date of Issue:  April, 1998
Superceded Bulletin(s): 94-T-32

WATER LEAKS INTO FRONT FOOTWELL FROM FRONT OF DASH (REPAIR SEALER SKIPS OR HVAC CASE SEALS)

APPLICATION

Model(s): 1991-92 Saturn SC2, SL, SL1, SL2

1993-98 Saturn SC1, SC2, SL, SL1, SL2, SW1, SW2

Group/Seq. No.: Body - 10

Corporation No.: 481503R

Bulletin No.: 94-T-32A

Date: April, 1998

NOTE: Due to the addition of model years, this bulletin supersedes 94-T-32.

CONDITION

Some customers may comment that their front footwell carpet is wet and/or has a musty, mildew odor.

CAUSE

Water leaks into front footwell:

  • From a possible sealer sip at the "smile" joint in the engine compartment.
  • From a possible sealer skip behind the front strut tower, at the upper outer corner where the strut tower cap meets the cowl panel.
  • Past the HVAC distribution case seals.

CORRECTION

Identify water leak path as outlined in the "Procedures" section of this bulletin.

PROCEDURES

  1. Verify that the front footwell carpet is wet or exhibits a musty mildew odor or moisture exists under the carpet.
  2. Remove the carpet according to "Carpet and Acoustic Material" procedures in the "Vehicle Interior Systems" section of the appropriate year "Body/Collision Repair Service Manual" or Body/Repair Service Manual".
  3. With the aid of a helper inside the vehicle (to help detect actual water leak point), apply an unrestricted flow of water locally to the "smile" joint. See Fig 1
    NOTE: To detect water leak, always start at the lowest point and work up.
  4. If a water leak is detected at the "smile" joint, proceed to "Smile Joint Water Leak Repair" in this bulletin. If a water leak is not detected at the "smile" joint, proceed to the next step.
  5. Apply an unrestricted flow of water to the front strut tower, at the upper outer corner, where the strut tower cap meets the cowl panel. See Fig 2 .
  6. If a water leak is detected at the strut tower area, proceed to "Strut Tower Area Water Leak Repair" in this bulletin. If a water leak is not detected at the strut tower area, proceed to the next step.
  7. Position hose so that the water flows into the plenum and out plenum drains, over HVAC distribution case seals (TV valve seal, heater core pip seal and case drain seal). See Fig 4
    NOTE: The hose can be positioned so that water flows through the shroud top vent grille assembly into the plenum area. Water leak may take up to 15 minutes to appear inside vehicle. Make sure to periodically check the front footwell areas for signs of water leakage.
  8. If water leak is detected, proceed to HVAC DISTRIBUTION SEALS  WATER LEAK REPAIR. If not water leak is detected, refer to "Water Leaks" section of the appropriate year "Body/Collision Repair Service Manual or Body/Repair Service Manual".

SMILE JOINT WATER LEAK REPAIR

  1. If water leak is detected in the "smile" joint area, clean and dry area to be repaired using compressed air and nozzle.
  2. Using Kent Industries High Tech Leak Chek Seam Sealer (P/N 10105) or equivalent, apply sealant inside retention channel from inside or outside the vehicle at water leak point. See Fig 5
  3. Verify repair by water testing after sealant has been allowed to dry according to manufacturer's recommended instructions.
  4. After verifying repair, go back and perform steps 5 and 6 under "Procedures" to make sure there are no water leaks in the shock tower area or HVAC distribution seal areas.

STRUT TOWER AREA WATER LEAK REPAIR

  1. If water leak is detected in the strut tower area, clean and dry area to be repaired using compressed air and nozzle.
  2. Using Kent Industries High Tech Leak Chek Seam Sealer (P/N 10105) or equivalent, pump sealant into corner, filling corner with sealant. See Fig 6
    NOTE: Make sure to pump sealant under the lip of the cowl panel, where it overlaps the strut tower.
  3. Verify repair by water testing after sealant has been allowed to dry according to manufacturer's recommended instructions.
  4. After verifying repair, go back and perform step 6 under "Procedures" to make sure there is no water leak in the HVAC distribution seal area.

HVAC DISTRIBUTION SEALS WATER LEAK REPAIR

  1. If water leak is detected in the HVAC distribution seals, clean and dry seal area to be repaired using compressor air and nozzle.
  2. Using Kent Industries Leak Chek Spray Water Leak Sealer (P/N 50265) or equivalent, spray seals with two coats. See Fig 7 er to manufacturer's recommended application instructions.)
  3. Verify repair by water testing after sealant has been allowed to dry according to manufacturer's recommended instructions.
Fig 1: Smile Joint - Apply Water To Detect Actual Water Leak Point
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