Interior - Left Front Footwell Area Water Leak
9233saturn01
NO.: 92-T-20
DATE: May, 1992
GROUP: Body
CORP. NO.: 281502
SUBJECT:
Water leak at Left Front Footwell Area (Apply Sealant Between Grommet and Tube and Wrap Harness with Waterproof Tape)
MODELS AFFECTED:
All 1991 Saturns built before vehicle identification number (VIN) MZ134076
CONDITION:
Water may enter the left front footwell area between the engine wire harness grommet and the tube and/or by following individual wires through the grommet (refer to Figure 2).
CAUSE:
Engine wire harness causes grommet to distort and loose its seal. In addition, an early design of the wire harness allows water to follow the individual wires in the harness past the grommet.
CORRECTIVE ACTION:
Apply sealer to top half of the engine wire harness grommet and/or wrap engine wire harness with a waterproof tape along upper motor rail.
PROCEDURE
Verify that this is the source of water intrusion by running an unrestricted flow of water (no nozzle) between the left fender and windshield, as shown in Figure 1. From inside of vehicle, inspect for water leak where the wire harness passes through the hinge pillar. If water is present, perform the following procedures.
NOTE:
Unless otherwise specified, the procedures mentioned in the following steps are located in the "Front End" section of the "Body/Collision Repair Service Manual."
1. Raise the hood.
2. Remove left front wheelhouse liner.
3. Remove left fender extension.
4. Remove all fasteners from engine rear half of fender to allow access to the grommet area.
5. Disconnect four wire harness clips that retain the wiring harness to the upper motor rail.
6. Remove clips from the wiring harness.
7. Remove conduit from the wiring harness.
8. Starting at the grommet, wrap the wire harness with a waterproof electrical tape such as 3M(R) Vinyl Plastic Electrical Tape (P/N 54007-06143 or equivalent) to just past the most forward clip position on the motor rail, as shown in Figure 2.
9. Attach wire harness to upper motor rail using replacement connector P/N 8905262 or equivalent.
10. Apply a bead of Kent Industries Sealer (P/N 10510 or equivalent) along the top half of the engine wiring grommet as shown in Figure 2.
11. Allow sealer to cure (according to manufacturer's recommendations).
12. Water test the area to make sure that no other water leaks are present.
13. Install rear half of upper fender.
14. Install fender extension.
15. Install front wheelhouse liner.
PARTS REQUIREMENTS:
8905262 Connector Replacement Pack
CLAIM INFORMATION:
To receive credit for this repair, submit a claim through the Saturn Dealer System as follows:
Labor
Case Operation
Type Description Code Time
VW Apply Sealer to Engine Wire T9572 1.1 hrs
Harness Grommet and Wrap
Wire Harness with Waterproof Tape