WATER LEAK FROM A/C MODULE RESEAL LOWER CASE PROCEDURE

Subject: WATER LEAKS FROM AIR CONDITONING MODULE

Model and Year: 1991 CAPRICE

TO: ALL CHEVROLET DEALERS

Condition: Water leaks from the A/C module lower evaporator case, when making right turns or rapid lane changes.

Cause: Inadequate sealing of the lower evaporator case to the A/C module.

Correction: Remove the lower evaporator case and reseal with RTV sealant, using the following parts and service procedure as specified in the Service Manual. Pages 1B1-27 - 1B1-29

Service Parts:

Quantity Part Number Part Name

1 1052915 Silicone Sealant - RTV 1 **52453695 Filter - Foam

** There is enough material in this part to do several repair jobs.

Parts are currently available from GMSPO.

The following optional RTV Sealer may be purchased locally.

1 59875 Loctite (R) Ultra Black-RTV

IMPORTANT: THE FOLLOWINGS STEPS ARE IN ADDITION TO THE SERVICE MANUAL PROCEDURE ON PAGES 1B1-27-29.

- After cleaning the lower evaporator case, remove the two (2) ridges as indicated in Figure 1, using a soldering iron, rotary file or etc.

- When doing Step 1. of the INSTALL OR CONNECT procedure in the Service Manual, fill the grooves of the lower evaporator case, as indicated in Figure 1 with the RTV sealant. Use enough sealant to leave a bead of 1.5 to 2.0 mm (.060 to .100) above the edges of the grooves. Allow the sealant to skin over before installing the case to the module.

- Cut a piece of the foam filter approximately one (1) inch by two and a half (2.5) inches long. Fold the piece of filter end to end and insert it into the groove, as indicated in Figure 1. Add a bead of RTV from side to side across the groove and the foam filter to hold the filter in place, as shown in the auxiliary view of Figure 1.

Continue on with the installation steps as specified in the Service Manual.

Please update your Service Manuals accordingly.

Labor Operation Number: T1663

Labor Time: 0.9 Hours

FAILURE CODE: 92

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