PLENUM CHAMBER (COWL) AREA WATER LEAKS

---------------------------------------------------------------------- REVISION 12/16/93

THIS BULLETIN IS BEING REVISED TO INCLUDE THE 1994 MODEL YEAR AND THE 1994 DEVILLE AND DEVILLE CONCOURS. PREVIOUS DIVISIONAL PUBLICATION NUMBERS WERE: CADILLAC T-93-72 GM OF CANADA 311604 ----------------------------------------------------------------------

SUBJECT: PLENUM CHAMBER (COWL) AREA WATER LEAKS (SEAL COWL AND DASH PANEL)

MODELS: 1992-94 CADILLAC ELDORADOS AND SEVILLES 1994 CADILLAC DEVILLE AND DEVILLE CONCOURS

CONDITION:

SOME OWNERS MAY EXPERIENCE A WATER LEAK CONDITION AT THE UNDERSIDE OF THE DASH PANEL TO FRONT BODY HINGE PILLAR INNER FORWARD OF THE PARKING BRAKE PEDAL ASSEMBLY.

CORRECTION:

TO REPAIR THIS CONDITION PERFORM THE FOLLOWING PROCEDURES:

1. SEALING THE UNDERSIDE OF THE DASH PANEL TO THE FRONT BODY HINGE PILLAR FROM THE PASSENGER COMPARTMENT:

A. REMOVE FLOOR MAT, PULL BACK THE CARPET TO EXPOSE THE AREA AROUND THE PARK BRAKE PEDAL ASSEMBLY. REFER TO FIGURE 1.

NOTE: IF THE UNDERSIDE OF THE CARPET IS WET, IT MUST BE REMOVED FROM THE VEHICLE. REFER TO SERVICE INFORMATION MANUAL, SECTION 10-3, AND LABOR OPERATION C4208. BOTH THE FLOOR PAN AND THE CARPET MUST BE THOROUGHLY DRY PRIOR TO REINSTALLING THE CARPET.

B. REMOVE PEDAL ASSEMBLY AND ATTACHING NUTS FROM THE LEFT FRONT BODY HINGE PILLAR INNER. REFER TO SERVICE INFORMATION MANUAL, SECTION 5-18.

C. SEAL THE FRONT BODY HINGE PILLAR INNER TO THE DASH PANEL WITH 3M STRIP CAULK, P/N 08578, OR EQUIVALENT. REFER TO FIGURE 1.

D. REINSTALL THE PEDAL ASSEMBLY TIGHTENING THE ATTACHING NUTS TO SPECIFIED (18 N.M OR 13 LBS. FT.) TORQUE.

2. SEALING THE PLENUM CHAMBER (COWL) AREA:

A. REMOVE THE WINDSHIELD WIPER ARMS. REFER TO SERVICE INFORMATION MANUAL, SECTION 8E-19.

B. REMOVE THE PLENUM CHAMBER LEAF SCREEN. REFER TO SERVICE INFORMATION MANUAL, SECTION 10-5.

C. REMOVE THE BOLTS SECURING THE LEFT WINDSHIELD WIPER TRANSMISSION AND ALLOW IT TO REST IN THE BOTTOM OF THE AIR PLENUM. REFER TO SERVICE INFORMATION MANUAL, SECTION 8E-12.

NOTE: BEFORE SEALING AN AREA FOR A WATER LEAK, THAT AREA SHOULD BE CLEANED AND DRIED WITH AN AIR HOSE OR OTHER EFFECTIVE DRYING METHOD. THE BONDING INTEGRITY OF THE SEALER MAY BE COMPROMISED IF IT IS APPLIED TO A WET OR CONTAMINATED SURFACE.

D. FROM INSIDE THE PLENUM CHAMBER SEAL THE VERTICAL SEAM AND THE 3/4" X 3/8" RECTANGULAR HOLE AT THE OUTBOARD EDGE OF THE PLENUM CHAMBER WITH 3M STRIP CAULK, #08758, OR EQUIVALENT. REFER TO FIGURE 2, VIEW A.

E. USING 3M RUBBERIZED UNDER SEAL, #08883, OR EQUIVALENT, SEAL THE FOLLOWING AREAS.

NOTE: RECOMMENDED APPLICATION IS THREE COATS TO EACH AREA WITH APPROXIMATELY ONE MINUTE FLASH TIME BETWEEN COATS.

O STARTING AT THE BOTTOM OF THE VERTICAL SEAM SEALED IN STEP D, APPLY SEALER UPWARD TO THE TOP OF THE PLENUM CHAMBER AND INBOARD TOWARD THE CENTER OF THE VEHICLE. REFER TO FIGURE 2.

O THROUGH THE ACCESS HOLE IN THE UPPER MOTOR COMPARTMENT RAIL, SEAL THE BOTTOM EDGE OF THE PLENUM CHAMBER DRAIN. REFER TO FIGURE 2, VIEW A.

3. SEALING THE COWL FROM INSIDE THE WHEELHOUSE AREA:

A. RAISE THE VEHICLE ON A HOIST AND REMOVE THE LEFT FRONT WHEEL.

B. REMOVE THE LEFT FRONT BLACK PLASTIC WHEELHOUSE PANEL. REFER TO SERVICE INFORMATION MANUAL, SECTION 10-5.

C. REMOVE THE FENDER SOUND INSULATOR. REFER TO SERVICE INFORMATION MANUAL, SECTION 10-5.

D. THE FOLLOWING SEAMS ARE TO BE SEALED FROM THE WHEELHOUSE AREA WITH 3M RUBBERIZED SEAL, #08883, OR EQUIVALENT.

O REFER TO FIGURE 3. DIRECT THE NOZZLE THROUGH THE OBLONG 1-1/4" X 3" ACCESS HOLE ON THE OUTBOARD SIDE OF THE REAR VERTICAL WALL OF THE UPPER MOTOR COMPARTMENT RAIL. SEAL THE 3" VERTICAL AND THE 3" HORIZONTAL SEAMS DEPICTED IN FIGURE 3, VIEW A. THE PATH OF THE SEALER SHOULD COVER THE SPOT WELD INDENTATIONS TO SEAL OFF ANY POSSIBLE WELD BURN THROUGHS.

O REFER TO FIGURE 3, VIEW B. FROM THE INBOARD SIDE AT THE REAR VERTICAL WALL OF THE UPPER MOTOR COMPARTMENT RAIL, REMOVE THE EXCESS SEALING TAPE AND SEAL THE ENTIRE SEAM.

E. IF THE VEHICLE IS EQUIPPED WITH A SUNROOF, CHECK THE ROUTING OF THE DRAIN HOSE AND RESEAL AROUND THE HOSE WITH 3M STRIP CAULK, #08578, OR EQUIVALENT. MAKE SURE THE HOSE DOES NOT BECOME OBSTRUCTED OR KINKED.

4. LOWER THE HOIST AND PERFORM WATER TESTS ON ALL AREAS SEALED TO ENSURE WATER LEAKS HAVE BEEN STOPPED.

5. REINSTALL THE LEFT WINDSHIELD WIPER TRANSMISSION PER SERVICE INFORMATION MANUAL, SECTION 8E-12.

6. REINSTALL THE PLENUM LEAF SCREEN PER SERVICE INFORMATION MANUAL, SECTION 10-5.

7. REINSTALL THE WIPER ARMS PER SERVICE INFORMATION MANUAL, SECTION 8E-19.

8. RAISE THE HOIST.

9. REINSTALL THE FENDER INSULATOR MAKING SURE THE INSULATOR IS POSITIONED PROPERLY TO AVOID ROAD NOISE. REFER TO SERVICE INFORMATION MANUAL, SECTION 10-5.

10. REINSTALL THE BLACK PLASTIC WHEELHOUSE PANEL PER SERVICE INFORMATION MANUAL, SECTION 10-5.

11. REINSTALL THE WHEEL AND LOWER THE VEHICLE.

WARRANTY INFORMATION:

FOR VEHICLES REPAIRED UNDER WARRANTY, USE: LABOR OPERATION: T6644 2.5 HOURS

FIGURES: 3

GENERAL MOTORS BULLETINS ARE INTENDED FOR USE BY PROFESSIONAL TECHNICIANS, NOT A "DO-IT-YOURSELFER". THEY ARE WRITTEN TO INFORM THOSE TECHNICIANS OF CONDITIONS THAT MAY OCCUR ON SOME VEHICLES, OR TO PROVIDE INFORMATION THAT COULD ASSIST IN THE PROPER SERVICE OF A VEHICLE. PROPERLY TRAINED TECHNICIANS HAVE THE EQUIPMENT, TOOLS, SAFETY INSTRUCTIONS AND KNOW-HOW TO DO A JOB PROPERLY AND SAFELY. IF A CONDITION IS DESCRIBED, DO NOT ASSUME THAT THE BULLETIN APPLIES TO YOUR VEHICLE, OR THAT YOUR VEHICLE WILL HAVE THAT CONDITION. SEE A GENERAL MOTORS DEALER SERVICING YOUR BRAND OF GENERAL MOTORS VEHICLE FOR INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THE INFORMATION.

COPYRIGHT 1993 CADILLAC MOTOR CAR DIVISION, GENERAL MOTORS CORPORATION. ALL RIGHTS RESERVED.