White Plug/Cap In The HVAC Case (Evaporator Drain) - keywords condensation core drain evap floor heater odor passenger water wet

This PI was superseded to update the removal of the drain plug and to update recommendation. Please discard PIC4896.

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

This PI was created to inform service Technicians of a white plug/cap that is installed into the end of the evaporator/HVAC housing drain nipple. This plug/cap is part of the production design and intended to be on the HVAC drain for the life of the car. Its purpose is to prevent airflow directly into the HVAC case and aids in part of the "quiet car" initiative.

The HVAC/evaporator drains now through an opening in the bottom of the drain tube rather than at the end of the tube, as it has been previously.

This change was on any Saturn Aura, Pontiac G6 built since October 2007. The new 2008 Chevrolet Malibu since start of production will also have this plug/cap.

If there is water on the passenger side front floor area, check the operation of the drain. Make sure that small debris is NOT plugging it up. If so please "REMOVE" the white plug and discard it, to prevent any future reoccurrence of the drain plugging up.

Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed.