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Waterleak at Right and/or Left Footwell Area Inside Passenger Compartment

Subject:Waterleak at Right and/or Left Footwell Area Inside Passenger Compartment (Clear Bottom Rear Drain Hole of Body Seam Sealer at Upper Frame Rail)

Models:All 1999 Saturn vehicles



Condition

After water normally enters upper frame rail, it cannot drain at rear of frame rail because the drain hole has been sealed over by a bead of body seam sealer. Once the water level is high enough, it may pass over the baffle in the rear of frame rail, and leak into the passenger compartment.

Cause

Incorrect application of body seam sealer.

Correction

Clear drain hole and clean with a file.

Procedures

To determine if the bottom rear drain hole in the front upper frame rail has been blocked by body seam sealer, use the following procedure:

  1. Remove front wheelhouse panel. Refer to "Front Wheelhouse Panel" removal procedure in the 98-99 Body Repair Service manual.

  2. Object Number: 877996  Size: MF
  3. Refer to the illustration and locate the bottom rear drain hole in the upper frame rail.
  4. Pour water into the frame rail from the top, to verify that the drain hole is blocked.
  5. • If the water passes through the drain hole, refer to technical bulletin 94-T-32B for further waterleak diagnostic procedures.
    • If water does not pass through the drain hole, clear body seam sealer from drain hole using a flat file as shown in illustration. Watertest to confirm that drain hole is clear. If original waterleak still exists, refer to technical bulletin 94-T-32B for additional waterleak diagnostic procedures.
  6. Repair any spaceframe paint damage as necessary.
  7. Install Front Wheelhouse panel. Refer to "Front Wheelhouse Panel" installation procedure in the 98-99 Body Repair service manual.

Claim Information

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System as follows:

Case Type

Description

Labor Operation Code

Time

VW

Diagnose and Repair Waterleak

Z4016

0.5 hrs

VW

Diagnose and Repair Waterleak in Left Front Footwell Area

Z4017

0.5 hrs