Campaign - A/C Evaporator Drain Tube Inspection

No: H122
Ref:
Issue: 1
Date: 07/25/03

SERVICE ACTION

HVAC Drain Tube Inspection

Correction





AFFECTED VEHICLE RANGE:

SITUATION:

WATER CONTAMINATION OF INTERIOR COMPONENTS

Under certain conditions the drain tube from the HVAC interior plenum can be restricted or blocked.

Water collects in the plenum and eventually run into the passenger compartment.

The following causes have been identified:

^ Drain tube not fitted correctly to the evaporator unit

^ Drain tube restricted by the carpet

^ Drain tube kinked when located into clip

^ Drain tube not secured in the correct position.

RESOLUTION:

INSPECT AND CORRECT UNSOLD VEHICLES

As part of the customer vehicle preparation process prior to retail delivery, unsold vehicles in the affected VIN range should be inspected and if warranted corrective action taken to ensure free flow of condensate though the drains in the HVAC system.

PARTS INFORMATION:

No parts required





WARRANTY CLAIMS:

Normal warranty policy and procedures apply. Material allowance is included in labor operation.

REPAIR PROCEDURE

TEST PROCEDURE FOR DRAIN FUNCTION:

1. Release and remove convoluted duct from between the evaporator and heater.

2. Protect the inside of the vehicle to prevent spillage of water into the interior of the vehicle.

3. Carefully pour water into the evaporator until a steady flow is observed from the drain tube.

^ If the water flow from the drain tube is restricted, go to the repair procedure below.

^ If the water flow is not restricted, install the ducting to the evaporator and the heater. Install the campaign label.

REPAIR PROCEDURE:





1. Remove the bolt securing the evaporator (Figure 1).

2. Release the evaporator by pulling it gently rearward.





NOTE:
It may be necessary to cut part of the carpet (Figure 2) or re-position the evaporator in the following steps.

3. Ensure the drain tube is correctly fitted and adjust the tube if necessary.

4. Verify that the carpet does not restrict the drain tube.

5. Remove two bolts and remove the underbody heat shield.

CAUTION:
Care in re-locating the tube is required. It is easy to twist it again! Do not remove the "duckbill" end piece of the pipe! Removal of the duckbill end will result in an aggravation of the problem.





6. Refer to Figure 3 and adjust the drain tube until it is correctly orientated.

7. Tighten the evaporator bolt to 7Nm (5 lbf.ft).

8. Install protective coverings inside the vehicle.

9. Carefully pour water into the evaporator until a steady flow is observed from the drain tube and the carpet remains dry.

10. Install the underbody heat shield.

11. Install and secure the ducting to the evaporator and heater, ensuring that the ducting is seated correctly all round.

INSTALL CAMPAIGN LABEL





NOTE:
Campaign labels may have multiple Campaign numbers written on them if multiple campaigns are performed at the same time.

1. When all specified repairs have been accomplished, prepare the campaign label (LRN0002LABEL) as follows:

a) Place the label on a hard surface.

b) Use a ballpoint pen to neatly write/scribe in the bare aluminum areas of the label the following information:

^ Service Campaign code "H122"

^ Your retailer code

^ The date of repair

2. Clean all grease and dirt from the radiator support member.

3. Peel the completed campaign label from the backing paper and position it on the cleaned area.

4. Roll the label with the special roller tool to ensure proper adhesion.