Electrical - MIL ON/Multiple DTC's/Water On Floor
TECHNICALBulletin No.: 09-08-57-001
Date: February 06, 2009
Subject:
Water Intrusion Into Driver and Passenger Foot Wells and/or Check Engine Light Illuminated, DTC P2122, P2123, P2127, P2128, P2138, Reduced Power Mode Operation (Reseal Cowl and Hinge Pillar)
Models:
2008-2009 Chevrolet Captiva Sport
2008-2009 Saturn VUE
Condition
Some customers may comment that water is collecting in the front driver or passenger foot well areas. This water intrusion may also affect the electrical connector located in the base of the driver's side front door hinge pillar. If the connector is compromised by moisture, the vehicle may set codes and/or operate in the reduced power mode.
Cause
There are two possible locations for water intrusion into the foot well area and onto the X 200 harness connector. The first area of concern is the hem flange sealing inboard of the hood hinges, in the upper plenum. These gaps are sealed with an expanding foam topped with a seam sealer. When the vehicle is baked in the paint oven at the factory, the foam may generate bubbles and cause porosity in the sealer, compromising its ability to seal out water. This water intrusion will appear on the inner side of the panel behind the X 200 connector (1).
The other area of concern is the front outer body hinge pillar. The sheet metal in this area may be wavy, causing the front fender side marker lamp wiring harness grommet to not seal. There are also three plastic plugs and a beta patch in this area that may let water past. It will be necessary to remove the front fender liner on the affected side to inspect these components. This water intrusion will appear coming through the hole visible behind the X 200 connector (2).
Correction
Use the following procedure to correct the concern.
1. Remove the front door sill and side carpet retainer on the affected side. Refer to Front Side Door Opening Floor Carpet Retainer Replacement in SI.
Note
Do not attempt to disassemble the joint between the door sill and side carpet retainer. Remove the X 200 body connector.
2. Inspect for water and dry as required. If the carpet is saturated, refer to Floor Carpet Drying in SI.
3. Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement in SI. Loosen wiper linkage as required.
4. Inspect the sealing material in the outer joint area for bubbles (seal area spongy to the touch) and/or porosity (1).
5. Remove all of the foam and sealer using a utility knife and gasket scraper.
6. Reseal the area thoroughly using * Kent High Tech Seam Sealer Part # P10200.
7. Water test the vehicle. It is important to note that when water testing, the leaks may not be easily seen. The lower hinge pillar acts as a well and collects water. Water will not leak into the foot well area until it fills the lower hinge pillar. It is important to inspect this area carefully to ensure it is dry.
8. If the area continues to leak, proceed to the next step. If the leak is corrected, proceed to step # 17.
9. Remove the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement in SI.
10. Remove the foam hinge pillar insulator.
11. Remove the side marker lamp grommet from the front body hinge pillar.
12. Apply * Kent High Tech Seam Sealer Part # P10200 to the perimeter of the grommet. Reinstall the grommet.
13. Remove the three plastic plugs from the front body hinge pillar.
14. Apply * Kent High Tech Seam Sealer Part # P10200 to the perimeter of the plastic plugs. Reinstall the plugs.
15. Seal the edges of the Beta patch with * Kent High Tech Seam Sealer Part # P10200 as shown.
16. Water test the vehicle. Refer to step # 7 for inspection procedure.
17. Inspect harness connector X 200 for moisture. Dry as required and apply Dielectric Lubricant GM Part # 12377900 (in Canada use 10653529).
18. Clear any codes.
19. Reinstall the air inlet grille. Refer to Air Inlet Grille Panel Replacement in SI.
20. Reinstall the foam hinge pillar insulator.
21. Reinstall the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement in SI.
22. Reinstall the front carpet retainer. Refer to Front Side Door Opening Floor Carpet Retainer Replacement in SI.
* We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources.
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