WATER LEAKS PASS/LUGGAGE COMP. POWER DOOR LOCKS INOP. Saturn Saturn 1992

For 1990-2009 cars

# WATER LEAKS PASS/LUGGAGE COMP. POWER DOOR LOCKS INOP

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

Due to the addition of "MODELS AFFECTED," this bulletin supersedes bulletin 91 - T - 11, which should be discarded.

#### MODELS AFFECTED: 1991 1992 Saturns

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:

o Water in the passenger compartment (under carpet) beneath rear seat cushion and/or luggage compartment

o Musty/mildew odor

o 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, use 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/Collision Repair Service Manual."

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 front of dash behind the instrument panel.

7. 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.

8. Using a brush, apply a bead of sealer to the upper section of the cowl seam accessed through the plenum opening.

9. 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 and inspect for water intrusion into the vehicle.

10. If a water leak is indicated, apply a bead of 3M Seam Sealer P/N 08648 (or equivalent), and brush uniformly along the seam.

11. Allow sealer to set-up.

12. Water test area to make sure that no other water leaks are present.

13. Install 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 driver's 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 is wet or shows signs of having been wet, you must also replace the power door lock relay.

1. Remove driver's seat.

2. Locate the power door lock relay through the opening in the carpet under the driver's 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

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 "Troubleshooting" section of the "Electrical Trouble Shooting Service Manual." In extreme cases, the power door lock connector may also need to be replaced.

12088519 - Power door lock relay 12059561 - Power door lock relay connector 12112425 - Power door lock terminal cut leads

#### CENTER PILLAR APPLIQUE WATER LEAK CORRECTION

With a helper inside the vehicle to detect the actual 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 openings.

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 make sure that no other leaks are present.

7. Repeat the above steps on the opposite side.

#### WATER LEAK AT THE REAR SEAT LOCATION

Apply an unrestricted (no nozzle) water flow to the wheelhouse outer panel to inner panel retainer clips shown in Figure 7 from 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/N 08648 to the forward two (2) retainers to the body in the wheelhouse area, and brush a bead uniformly around the retainer (Figure 7).

2. In the interior of the vehicle, apply a bead of joint and seam sealer to the forward two (2) retainers exposed at the interior side of the wheelhouse and brush a bead uniformly around the retainer.

3. Water test the area to make sure 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 of 3M Automotive Joint and Seam Sealer P/N 08648 (or equivalent) and brush a bead uniformly across the seam.

4. Water test the luggage compartment area to make sure 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.

Labor Case Operation Type Description 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 T9504 0.5 hrs Correction (per side) VW Rear Seat (Wheelhouse) Waterleak T9505 0.8 hrs Correction (per side) VW Luggage Compartment Waterleak T9506 0.8 hrs Correction

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.