WATERLEAK INTO SPARE TIRE WELL (INSTALL DRAIN HOLE PLUG ETC.). Saturn Saturn 1993

For 1990-2009 cars

# WATERLEAK INTO SPARE TIRE WELL (INSTALL DRAIN HOLE PLUG ETC.)

#### SUBJECT: Waterleak into Spare Tire Well (Install Liftgate Inner Panel Drain Hole Plug, and Trim Portion of Outer Lip from Weatherstrip and/or Apply Sealer to Spaceframe Lap Joint)

#### MODELS AFFECTED: 1993 Saturn Station Wagons built before, and including VIN PZ232933.

CONDITION: Some 1993 station wagons may leak water around the rear liftgate area causing water to accumulate in the spare tire well.

CAUSE: Water leaks may be caused by one or all of the following causes:

o Water directed at bottom center of rear liftgate (latch) area forces water into center drain hole, up and over water barrier, down latch and into spare tire well.

o Outer lip of rear liftgate weatherstrip funnels water into the seam of the weatherstrip flange at the bottom of the rear liftgate opening.

o Sealer skips at rear liftgate opening spaceframe lap joints.

CORRECTIONS: Install liftgate inner panel drain hole plug into center location and remove liftgate inner panel drain hole plug from left side of rear liftgate, then watertest vehicle. If water leak is still present, follow the procedures in this bulletin to:

o Trim portion of outer lip from weatherstrip and apply weatherstrip adhesive to weatherstrip, and/or;

o Apply seam sealer to spaceframe lap joints.

#### PROCEDURES

1. Open rear liftgate.

2. Install a liftgate inner panel drain hole plug (P/N 21121827) into center drain hole at bottom of rear liftgate as shown in illustration.

3. Pierce center of the left liftgate inner panel drain hole plug, located 305 mm (12 inches) to the left of center by using a cotter pin removal tool or an awl. Carefully pry liftgate inner panel drain hole plug from hole and discard.

#### IMPORTANT: Using a pointed tool such as an awl to pierce the center of the liftgate inner panel drain hole plug for removal reduces the possibility of paint damage.

4. Remove spare tire.

5. If necessary, dry spare tire well.

6. Close rear liftgate and run an unrestricted flow of water at the top center of rear liftgate and inspect rear of spare tire well for water.

a. If water is present, go to Step 7.

b. If no water is present from this waterflow location, refer to "Waterleaks" in the "General Information" section of the "Body/Collision Repair Service Manual."

7. Using a "china" marker and a tape measure, measure 686 mm (27 inches) to each side of the butt joint at bottom of rear liftgate opening and make a mark on the weatherstrip. (Refer to illustration.)

8. Remove bottom third of rear liftgate weatherstrip from metal flange.

9. Starting at marks on weatherstrip, trim outer lip from bottom third of weatherstrip on each side of vehicle.

10. Remove rear liftgate opening sill plate trim molding.

11. Turn weatherstrip over 180 degrees. Using 3M Weatherstrip Adhesive (P/N 08008) or equivalent, apply a 3.18 mm (1/8 inch) bead inside bottom third of weatherstrip retention channel as shown in illustration and reinstall weatherstrip, press down firmly to make sure seal is fully seated.

#### IMPORTANT: It is essential that weatherstrip is fully seated along the entire upstanding metal flange.

12. Install rear liftgate opening sill plate trim molding over the top of inner lip of weatherstrip.

13. Close rear liftgate and run an unrestricted flow of water at top corner of rear liftgate and inspect rear spare tire well for water.

a. If leak is present, go to Step 14.

b. If leak is not present, install spare tire, repair is complete.

14. Dry spare tire well, open rear liftgate and run an unrestricted flow of water over lap joint 1, one side of the vehicle at a time, and inspect for water leaking into spare tire well. (Refer to illustration on facing page.)

a. If leak is present, go to Steps 17 and 18.

b. If leak is not present, go to Step 15.

15. Direct an unrestricted flow of water over lap joint 2, one side of the vehicle at a time, and inspect for water leaking into spare tire well. (Refer to illustration on facing page.)

a. If leak is present, go to Steps 17 and 18.

b. If leak is not present, go to Step 16.

16. Direct an unrestricted flow of water over lap joint 3, one side of the vehicle at a time, and inspect for water leaking into spare tire well. (Refer to illustration on facing page.)

a. If leak is present, go go Steps 17 and 18.

b. If leak is not present at any of the lap joints, install spare tire and refer to "Waterleaks" in the "General Information" section of the "Body/Collision Repair Service Manual."

17. Apply a medium bodied leak check sealer such as Kent Industries Leak Chek (P/N HT - B 10070) or equivalent, to the lap joint(s) that has been found (by watertest) to leak and let sealer cure according to manufacturer's recommendation.

#### NOTE: The area most likely to leak in lap joint 1 is shown in the highlighted circle in the illustration on the facing page. If sealer is missing behind the taillamp assembly, it will be necessary to partially remove the taillamp assembly to properly gain access when applying sealer to lap joint 1.

18. Repeat Steps 14, 15 and 16 to verify repair. When it is confirmed that waterleak has been repaired, install spare tire.

PARTS REQUIREMENTS: 21121827 Liftgate Inner Panel Drain Hole Plug

CLAIM INFORMATION: To receive credit for this repair, submit a claim through the Saturn Dealer System as follows:

Labor Case Operation Type Description Code Time ---- ----------- --------- ---- VW Trim Portion of Outer Lip from T9645 1.0 hrs Seal, Install Drain Plug and Watertest

#### Add if required:

A. To Seal and Watertest Lap Joint(s) 0.3 hrs

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.