A/C - Water Leaks Onto Vehicle Floor
File in Section: 01 - HVACBulletin No.: 03-01-38-020
Issue Date: November, 2003
Subject:
Air Conditioning (A/C) Condensation Leaking onto the Vehicle Floor During
Times of A/C Usage (Remove Foam Block Obstruction From Evaporator
Drain Hole)
Models Affected:
2003-2004 ION Vehicles with Air Conditioning (RPO C60) built prior to
VIN Breakpoint 4Z131776
Attention: Technician
Condition:
Some customers may comment on moisture leaking onto the floor of the vehicle when the A/C system is running.
Cause:
During assembly of the HVAC module, a foam block used to isolate the evaporator core from the HVAC module case may fall off and float over the top of the drain causing blockage.
Correction:
Remove foam block from drain area and discard.
Service Procedure:
Important:
Prior to performing the following procedures, ensure that the heater core cover front of dash condensate drain is not obstructed.
Important:
The evaporator core is contained in its own compartment with its own unique drain hole (the drain hole is approximately 5 mm (0.20 inches) in diameter). This drain hole allows condensation collected by the evaporator core to flow from the evaporator compartment down to the heater core compartment at which time it exits the vehicle through the heater core cover front of dash condensate drain. The evaporator compartment drain hole is located about 25.4 mm (1 inch) inside and down from where the access hole is being drilled.
Important:
Keep copies of the original template for future use.
1. Locate the area of passenger side of HVAC module on the right side of the console.
2. Cut out template (several included in this bulletin) and place on right side of the HVAC module as shown in the above illustration.
3. Center punch through the template.
Important:
Prior to drilling into HVAC module place an absorbent towel below area to be drilled to collect any condensation that may flow out of the hole
Notice:
To prevent possible damage to the evaporator core, do not drill more than 19 mm (3/4 in) past the HVAC module case wall.
4. Using a 15/16 in (24 mm) hole saw, drill hole at the specified location.
5. Using a deburring type tool, remove all drill shavings from around access hole to ensure a proper fit for the cap plug. Do not allow these shavings to fall into the access hole.
6. Once the access hole is drilled, using a work light, illuminate through the hole to identify location of 5 mm (0.20 in) drain opening located 25.4 mm (1 inch) inside and down from access hole opening.
Important:
The evaporator core is wrapped with a foam insulator. This insulator is visible through the access hole. Do not mistake the evaporator insulator for the loose foam block that you are trying to retrieve.
7. Locate the 6.35 mm x 25.4 mm x 50.8 mm (1/4 in x 1 in x 2 in) foam block and remove with a pair of needle nose pliers or similar tool and discard.
8. To verify 5 mm (0.20 in) drain is open, with the vehicle on level ground, add approximately 4 ounces of water through access hole opening. The water should immediately drain through the front of dash condensate drain. If the water does not drain through the front of dash condensate drain, re-inspect the 5 mm (0.20 in) drain opening for other debris.
9. Once the foam block and/or debris has been removed and the drain is functional, apply a bead of Kent(R) Leak Chek Sealer (P/N 10070), or equivalent, around the perimeter of cap plug (P/N 25652432).
10. Install cap plug into access hole opening to re-seal HVAC module.
11. Wipe off excess sealant.
Parts Information:
Claim Information:
To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for D9993 (HVAC Module, Foam Block - Removal).
Retail Reimbursement Information
One tube of Kent(R) Leak Chek Sealer will seal approximately 20 vehicles.
Important:
The actual dimensions of template should be 55 mm wide x 50 mm high.
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