GM Service Manual Online
For 1990-2009 cars

Water Leaks into Passenger and/or Luggage Compartment

Subject:Water Leaks into Passenger and/or Luggage Compartments (Identify Areas and Repair)

Models:All 1991 Saturn SL, SL1, and SL2's



Condition

Water leaks in the passenger compartment and/or luggage compartment. Water leak into front compartment may also result in a condition of inoperative power door locks.

Correction

Identify potential water intrusion locations, provide corrective procedures for the repair of confirmed leak locations and to relocate power door lock relay as required.

Some vehicles may experience a water leak condition in the passenger compartment and/or luggage compartment. The symptoms for this condition can be:

    • Water in the passenger compartment (under carpet) beneath rear seat cushion and/or luggage compartment
    • Musty/mildew odor
    • Power door locks inoperative

Procedures: PASSENGER COMPARTMENT COWL WATER LEAK CORRECTION

If the vehicle exhibits a musty/mildew odor and/or power door lock failure, this may be caused by moisture under the carpet. Remove the left front carpet retainer and inspect the carpet insulation for moisture. If moisture is present, us the following steps to identify and correct the water leak condition:

Note: Unless otherwise specified, the procedures mentioned in the following steps are located in the"Vehicle Interior Systems section of the Body Service Manual.


    Object Number: 879610  Size: MH
  1. Remove the carpet assembly from the vehicle following the Carpet removal procedures.
  2. Remove the center pillar molding from the vehicle following the Center Pillar Garnish Molding removal procedures.
  3. Remove the rear seat cushion from the vehicle following the Rear Seat removal procedures.
  4. Remove the shroud top vent grille from the vehicle following the Shroud Top Vent Grille removal procedures in the Front End section of the Body Service Manual.
  5. With a helper inside the vehicle to detect the actual leak point, apply an unrestricted (no nozzle) water flow to the area. Begin at the base of the suspected area and move upward slowly.
  6. Inspect for water leaking into the vehicle interior at the upper left hand corner of the front dash behind the instrument panel.

    Object Number: 879609  Size: SH
  1. Using 3M™ Automotive Joint and Seam Sealer P/N 08648 or equivalent, apply a bead of sealer to the seam shown in figures 1 and 2.
  2. Using a brush, apply a bead of sealer to the upper section of the cowl seam accessed through the plenum opening.

  3. Object Number: 1206194  Size: SH
  4. Apply an unrestricted (no nozzle) water flow to the dash and wheelhouse seal shown in Figure 3 on both left and right sides of the vehicle.
  5. If a water leak is detected, apply a bead of 3M™ Seam Sealer P/N 08648 or equivalent, and brush uniformly along the seam.
  6. Allow the sealer to set-up.
  7. Water test the area to make sure that no other water leaks are present.
  8. Install the cowl panel and interior trim items.

POWER DOOR LOCK RELAY RELOCATION

General Information

On vehicles equipped with power door locks, the power door lock relay package is located under the rear of the drivers seat carpeting. This location could become wet if a water leak developed. To prevent water damage to the door lock relay, it should be moved forward to a higher location on the cross rail between the rear HVAC duct and the center console under the carpet.

    Important: If the power door lock relay i wet or shows signs of having been wet, you must also replace the power door lock relay.


    Object Number: 879497  Size: SH
  1. Remove the drivers seat.
  2. Locate the power door lock relay through the opening in the carpet under the drivers seat (Figure 4), and remove the tape that attaches the relay to the left body ground splice pack.
  3. Move the power door lock relay forward to a position under the carpet between the HVAC duct and the center console on the body cross rail (Figure 5). Place the relay so that it does not interfere with the seat attachment points.

POWER DOOR LOCK RELAY REPLACEMENT


Object Number: 879341  Size: SH

If the power door lock relay is wet or there is reason to believe that the relay has been wet, replace the relay and relocate as previously described. If the terminals are corroded, replace the terminals using the Cut Lead Installation procedures in the Trouble Shooting Service Manual. In extreme cases, the power door lock connector may also need to be replaced

1208859 -- Power door lock relay

1209561 -- Power door lock relay connector.

12112425 -- Power door lock terminal cut lead

Center Pillar Applique Water Leak Detector


Object Number: 882858  Size: SH

With a helper inside the vehicle to detect the actual water leak point, apply an unrestricted (no nozzle) water flow to the center pillar applique. Apply water over the top and sides of the applique. Watch for water intrusion at the base of the center pillar in the interior of the vehicle. If the water leak is located at the center pillar location, use the following steps to repair.

  1. Remove the center pillar applique lower retaining push pins and pull the applique outward to disconnect the upper retainer (Figure 6)
  2. Apply a bead of 3M™ strip-calk P/N 08578 or equivalent around the perimeter of the upper and lower retainer (Figure 6)
  3. Install the center pillar applique by engaging the clip at the upper location.
  4. Apply a bead of strip-calk sealer around the lower retainers and install the retainers. Do not install the center retaining push pins at this time.
  5. Apply strip-calk sealer at the lower retainer push pin location and install the center retaining push pin.
  6. Clean off excessive sealer and water test to ensure that no other leaks are present.
  7. Repeat the above steps on the opposite side.

WATER LEAK AT THE REAR SEAT LOCATION


Object Number: 1206197  Size: MH

Apply an unrestricted (no nozzle) water flow to the wheel house outer panel to inner panel retainer clips shown in Figure 7 from the outside of the vehicle. If the water leak is identified in this area with water accumulating under the rear seat cushion, use the following steps to repair:

  1. Apply a bead of 3M™ Automotive Joint and Seam Sealer P/N08648 to the forward 2 retainers to the body in the wheelhouse area, and brush a bead uniformly around the retainer.
  2. Water test the area to ensure that no other leaks are present.

LUGGAGE COMPARTMENT WATER LEAK CORRECTION

Apply an unrestricted (no nozzle) water flow to the left or right quarter panel retaining bolt FIGURE 8. If the water leak is noted in this area, use the following steps to repair:

  1. Inspect the bolt for a copper colored washer. If the washer is present, remove the retaining bolt and discard the washer.
  2. Install the retaining bolt.
  3. If the water leak is located at the left or right rear body seam (Figure 9), apply a bead off 3M™ Automotive Joint and Seam Sealer P/N08648 or equivalent and brush uniformly across the seam.
  4. Water test the luggage compartment to ensure that no other leaks are present.

Claim Information

To receive credit for the repair, submit a claim through the Saturn Dealer System using the labor operation(s) listed below.

--

Case type

Description

Labor Operation Code

Time

--

VW

Cowl Waterleak Correction

T9501

3.5 hrs

VW

Power Door Lock Relay Relocation

T9502

0.2 hrs

VW

Power Door Lock Relay Replacement

N2840

0.2 hrs

VW

Power Door Lock Relay terminal Repair and/or Connector Replacement

T9503

0.7 hrs

VW

Center Pillar Applique Waterleak Correction

T9504

0.5 hrs (per side)

VW

Rear Seat (Wheelhouse) Waterleak Correction

T9505

0.8 hrs (per side)

VW

Luggage Compartment Waterleak Correction

T9506

0.8 hrs