Carpet - Wet/Musty Odors
BULLETIN NO.: 94-T-32ISSUE DATE: August, 1994
GROUP/SEQ. NO.: Body-10
CORPORATION NO.: 481503
TECHNICAL INFORMATION BULLETIN
SUBJECT:
Water Leaks Into Front Footwell from Front of Dash (Repair Sealer Skips or HVAC Case Seals)
MODELS AFFECTED:
1991-1994 Saturns
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 skip 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 waterleak 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 "Body/Collision Repair Service Manual."
3. With the aid of a helper inside the vehicle (to help detect actual waterleak point), apply an unrestricted flow of water locally to the "smile" joint.
IMPORTANT:
To detect waterleak, always start at the lowest point and work up.
4. If a waterleak is detected at the "smile" joint, proceed to "Smile Joint Waterleak Repair" in this bulletin. If a waterleak 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.
6. If a waterleak is detected at the strut tower area, proceed to "Strut Tower Area Waterleak Repair" in this bulletin. If a waterleak 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 (TXV valve seal, heater core pip seal and case drain seal).
IMPORTANT:
The hose can be positioned so that water flows through the shroud top vent grille assembly into the plenum area. Waterleak 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 waterleak is detected, proceed to "HVAC Distribution Seals Waterleak Repair" in this bulletin. If no waterleak is detected, refer to "Waterleaks" section of the "Body/Collision Repair Service Manual" for further waterleak diagnosis.
Smile Joint Waterleak Repair
1. If waterleak 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 waterleak point.
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 waterleaks in the shock tower or HVAC distribution seal areas.
Strut Tower Area Waterleak Repair
1. If waterleak 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.
IMPORTANT:
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 waterleak in the HVAC distribution seal area.
HVAC Distribution Seals Waterleak Repair
1. If waterleak is detected in the HVAC distribution seals, clean and dry seal area to be repaired using compressed air and nozzle.
2. Using Kent Industries Leak Chek Spray Water Leak Sealer (P/N 50265) or equivalent, spraying seals with two coats. (Refer 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.
CLAIM INFORMATION:
To receive credit for this repair, submit a claim through the Saturn Dealer System. See illustration.