Trunk - Water Drains Into Luggage Compartment
NO.: 92-T-38ADATE: November, 1993
GROUP: Body
CORP. NO.: 281504R
SUBJECT:
Water Drains From Rear Compartment Lid Into Luggage Compartment When Lid Is Opened (Seal Lower Corners of Lid and Existing Drain Holes, and Add New Drain Holes)
Due to revisions in the affected model years, this bulletin supercedes bulletin 92-T-38, which should be discarded.
MODELS AFFECTED:
All 1991 - 1994 Saturn Coupes
CONDITION:
Water retained in lower portion of rear compartment lid assembly after a car wash or rain may drain into luggage compartment when compartment lid is opened.
CAUSE:
When lid is opened after a car wash or a rain, water retained between rear compartment lid lower panel and rear compartment lid assembly flows to the outboard lower corners. This water draining from the outboard lower corners drains into the rear compartment as the lid assembly is directly over the inside of the rear compartment causing water to drip into the rear compartment.
If the car is driven or sits after a car wash or rain, the water will flow out of the drain holes located at the bottom of the rear compartment lid lower panel to the outside of the vehicle.
CORRECTIVE ACTION:
Apply sealer, at the outboard lower corners between the rear compartment lid lower panel and rear compartment lid, and to the existing drain holes. Seal outboard rear compartment lid lower panel to rear compartment lid assembly fasteners and add new drain holes.
PROCEDURES:
1. Clean areas to be sealed (outboard lower corners and lower edge) with a mild detergent and water solution, then blow dry.
2. Remove two outboard fasteners, retaining rear compartment lid lower panel to rear compartment lid assembly. (Refer to Figure 1.)
3. Wrap shoulder of bolt with 3M Strip-Calk P/N 08578 or equivalent.
4. Install bolts. If proper amount of 3M Strip-Calk is used, a small amount will be squeezed out around shoulder of bolt when tightening bolt
Torque: 6 N-m (53 lbs.in.)
5. Clean excess 3M Strip-Calk from around bolts.
6. Clean the outboard lower corners with isopropyl alcohol and allow to dry.
7. Seal outboard lower corners as shown in illustration using Kent Industries Hi-Tech Black Seam Sealer P/N 10070 or equivalent. Push, rather than pull, the sealer with the nozzle to force a greater amount of sealer between rear compartment lid lower panel and rear compartment lid assembly.
8. Clean excess sealer from panels using Kent Industries Acrysol P/N 20005 or equivalent.
9. Allow sealer to cure according to manufacturer's recommendations.
10. Clean entire surface around all rear compartment lid lower panel drain holes using isopropyl alcohol.
11. Seal five original slotted drain holes using Kent Industries Hi-Tech Leak Check Clear P/N 10200 or equivalent.
12. If present, seal two rectangular drain holes at outboard corners of lower panel using Kent Industries Hi-Tech Leak Check Clear P/N 10200 or equivalent. (Refer to Figure 2.)
13. Allow sealer to cure according to manufacturer's instructions.
14. Drill four, 1/4 in. holes in rear compartment lid lower panel as shown in Figure 2.
15. Prime exposed plastic at all four new drain holes using appropriate primer materials. (Refer to "General Information" section of the "1991-1992 Body/Collision Repair Service Manual.")
16. Paint the sealer that was applied to drain hole locations and paint the primer applied to new drain holes using appropriate Saturn touch-up paint or equivalent.
17. After all repairs have been completed, close rear compartment lid and water test area by running an unrestricted flow of water over deck lid assembly for three minutes.
18. Open rear compartment lid assembly and check sealed areas for leaks.
19. If leak is present, apply additional sealer to area (or areas) leaking. Repeat Steps 17 and 18 to verify repair.
CLAIM INFORMATION:
To receive credit for this repair, submit a claim through the Saturn Dealer System as shown.