Water Leaks Into Front Driver and/or Passenger Foot Wells Near Front Speaker Grill Area After Sustained Heavy Rain (Seal Speaker Drip Cover to Speaker Frame)

This bulletin is being updated with additional model years. Please discard Corporate Bulletin Number 03-08-44-012 (Section 08 - Body & Accessories).

Some customers may comment that the front foot well carpet is wet after the vehicle is exposed to sustained heavy rain.

After sustained heavy rain, water may accumulate between the speaker frame and the speaker plastic drip cover. The accumulated water may wick through the lower speaker attachment bolt hole and run down the inner door panel and leak into the interior compartment under the doorsill trim plate.

Remove the drip cover from the speaker frame and apply KENT® HIGH TECH SEAM SEALER - CLEAR TRANSPARENT, or equivalent, to the back of the speaker frame where the drip cover contacts the speaker frame following the procedure below:

1. Remove the side front door trim panel. Refer to Trim Panel Replacement - Side Front Door in SI or the appropriate Saturn ION Service Manual.
2. Remove the speaker.



3. Remove the drip cover from the speaker frame by unsnapping the four locking tabs on the cover near the fastener holes.

A small flat head screwdriver may be needed to pry back the cover.




4. Apply a 1/4 in (6 mm) bead of KENT® HIGH TECH SEAM SEALER - CLEAR TRANSPARENT, or equivalent, around the speaker frame where the drip cover contacts the back of the speaker frame.
5. Install the drip cover to the speaker frame.
6. Install the speaker.
7. Install the side front door trim panel. Refer to Trim Panel Replacement - Side Front Door in SI or the appropriate Saturn ION Service Manual.
8. Repeat the process for the other front door.
9. If the carpet near the door speaker on either side is wet or has a musty mildew odor, or moisture is present under the carpet, pull back the carpet to allow fresh air to dry the carpet and padding. A small fan may be used to aid in the drying process.
10. Verify that the musty mildew odor is gone and the carpet is dry. If the carpet still has a musty mildew odor, refer to Eliminating Unwanted Odors in Vehicles in SI or the appropriate Saturn ION Service Manual.

To order KENT® HIGH TECH SEAM SEALER - CLEAR TRANSPARENT, go to www.kent-automotive.com

One tube (5 oz) of KENT® HIGH TECH SEAM SEALER - CLEAR TRANSPARENT can perform approximately 10 vehicle repairs outlined in this bulletin. (Total material allowance = $1.57 per vehicle in the U.S., $2.23 per vehicle in Canada.)

For vehicles repaired under warranty, use:

U.S. Saturn Retailers

It will be necessary to sell the seam sealer to the CSO as "material" using net item code "M". Claims received in the amount of $1.57 will be accepted. Claims exceeding the amount of $1.57 will be returned with return reason 143 - material amount greater than maximum allowed.

Canadian Saturn Retailers

Applicable miscellaneous items, such as sealers and sealants, should be added to the part allowance amount and claimed in the Parts Cost column and not included in the Net Amount (DMN) column of the warranty claim.