Location I
LOCATION I: RIGHT FRONT SIDE OF PASSENGER COMPARTMENTLocation of Water Leak Source
1. Remove the dash undercover, scuff plate and kick panel. Pull back the carpet and pad. Remove the front seat, carpet, and pad if necessary.
2. At least 12 minutes should be spent during initial hose testing, because the water may have to move through several body seams before being detected.
3. Turn the water pressure to the hose so that a 12" to 18" stream of water is present while the hose is in a vertical position.
4. Get inside the vehicle and use a flashlight to help locate the water entry point.
5. With the door closed, watch for water leaks during hose test. Have an assistant slowly direct the water stream up from the bottom portion of the door-to-fender seam, then up the "A" pillar to the top of the door and around the windshield. Next, have the assistant slowly direct water along the window beltline molding (if the vehicle is a four door, perform this test on both the front and rear doors.) Figures 1 and 2.
NOTE:
DO NOT direct water into blower motor opening (under cowl panel).
6. Note which area the water enters the vehicle. Refer to the appropriate location's repair procedure. Figure 3.
AREA A: KICK PANEL
AREA B: UNDER DASH
AREA C: CORNER OF FIREWALL AND INNER FENDER
AREA D: OVER SILL PLATE
Repair Procedure
AREA A: KICK PANEL
1. Remove kick panel and inspect.
2. Make sure that the door electrical harness boot and the sunroof drain hose grommet are seated. Check that the sunroof drain hose is not kinked and extends through the lower kick panel. Figure 4.
3. Remove the drip-rail molding and inspect rain-rail seams for missing sealer or pinholes. Seal any suspected sealer defects. Figure 5.
4. Open the sunroof. Using a squeeze bottle filled with water, pour water down the front drain holes. Check for signs of leakage at the sunroof drain tube-to-drain hose.
5. If the leak is still present, remove cap and screw from the front windshield header. Remove the "A" pillar side molding. Check the drain hose for kinks. Figure 6.
6. If necessary, reposition the hose so that there are no loops, kinks or pinched areas. Repeat the water test. Make sure that the sunroof drains properly with no leaks. Figure 7.
7. If necessary, remove the damaged section of hose. Install a replacement piece of hose with a 9.5 mm (3/8 inch) outside diameter which provides a tight fit to the existing hose.
AREA B: UNDER DASH
1. Confirm that the upper cowl drain plug (black tube) has been modified (the dimension of the drain hole has been enlarged to 10 mm). Also confirm that there are no obstructions and that the plug drains properly.
2. Using a mechanic's mirror, look for signs of water leakage under the dash (e.g. water/washer solvent stains).
3. Set the heater control air intake control lever to the first position. Remove the blower fan (3 screws) and look for water entering the blower motor opening.
4. Check all grommets shown in Figure 8 for leaks by spraying water on each one. Replace any grommets that leak.
Note:
Apply silicone sealer to the bottom of the grommet during installation.
5. If the grommets do not leak, seal the baffle seam by reaching up through the blower motor opening and seal the areas indicated in Figure 8.
6. If water is leaking from the the firewall, check for studs and grommets that might be loose or improperly seated on the engine side of the firewall. If necessary, remove, redress, and reinstall the studs. Retap the holes and, if necessary, replace the bolts. Apply sealer to the threads before installing the bolts. Apply silicone sealer to the bottom of the grommets prior to installation.
7. If a leak is found, remove the black plastic cowl vent, then remove the foam strip from the underside.
Note:
Before installing the new foam pads, make sure to apply sealer to both sides of the pad.
8. Reinstall the black plastic cowl vent. Perform a water leak test by directing water around the outer edges of the cowl vent. Inspect for water leakage or moisture.
AREA C: CORNER OF FIREWALL AND INNER FENDER
1. Lift carpet and pad, and feel for water. If water is present, remove windshield wipers and cowl plate. Check for missing sealer or holes among the lower "A" pillar- to-cowl seam. Apply sealer to any suspected areas. Figure 9.
Note:
This procedure should only be done by experienced body shop personnel.
2. Remove the door jamb nut and bolt, also remove the four (4) upper fender bolts. Using a mechanics mirror, inspect sealer hidden by the upper fender for skips and pinholes. Figure 9.
Note:
The illustration shows the fender removed. Complete fender removal is not required.
Caution:
Use care when moving fender for inspection and resealing body seams. Do not allow the fender to buckle.
AREA D: OVER SILL PLATE
1. While an assistant directs water along the beltline molding, inspect for water entering from over the plastic sill plate. Figure 10.
2. If water is entering over the sill plate, remove the door panel and check that the plastic sheeting Butyl sealer is pressed firmly against the door frame. Also, check that no gaps are present between the sheet metal and the plastic.
3. Confirm that the door drain holes are draining properly and are not obstructed.
Note:
If Butyl sealer is hard or non-pliable, new sealer will need to be applied to the plastic sheeting to properly seal water leaking from these areas.