For 1990-2009 cars

# WATERLEAK A RIGHT AND/OR LEFT FRONT FOOTWELL AREA

#### SUBJECT: Waterleak at Right and/or Left Front Footwell Area (Seal Frame Rail and Hood Hinge to Body Bolts)

Due to addition of 1996 Saturns, a change in Step 7, and a change in the recommended sealer, this bulletin supercedes bulletin 93-T-16A, which should be discarded

#### MODELS AFFECTED: 1992 and 1993 Saturns built between and including vehicle identification numbers NZ150003 and PZ150021.

CONDITION: Water leaks past sealer in upper motor frame rail or down hood hinge bolts and enters right or left front body hinge pillar.

CAUSE: Sealer skips in frame rail sealer (inside frame rail), and/or possible gaps between layers of metal at hood hinge area.

CORRECTION: Perform the following procedure to diagnose and correct leaks.

PROCEDURE: To verify water leak originates at previously stated locations, perform the following procedure.

1. Raise the hood.

2. From inside the vehicle, pull carpet back from beneath sill/garnish molding at front corner of footwell.

3. Direct an unrestricted flow of water over upper rear fender attaching bolt and hood hinge to body bolts of affected side.

4. Inspect for water at front inside corner of footwell. If water is present in this area, go to Step 5.

If water is not present in this immediate area, refer to "Waterleaks" in the "General Information" section of the "Body/Collision Repair Service Manual."

5. Remove fender to wheelhouse liner fasteners from affected side.

6. Remove all fasteners from top and rear of upper fender. Pull fender away from body to allow access to area to be repaired.

7. Using Kent Industries Wet/Dry Re-Sealant Pump Grade sealer (P/N 10590) or equivalent, and hand pump applicator (P/N 90010)

a. Remove scre-on tip and replace with a 203 mm (8 in.) length of 1/4 inch diameter hose.

b. Insert end of hose for sealer into the J-nut slot at the rear of the rear of the fender, towards rear of vehicle.

c. Pump sealer around the perimeter of the frame rail baffle.

#### IMPORTANT: It is important to pump sealer towards the rear of the car, at the perimeter of the baffle shown in the illustration, and that a liberal amount is used for proper flow of the sealer into voids. Raising the front of the vehicle will promote flow of the sealer against the baffle.

8. Allow sealer to cure (according to sealer manufacturer's recommendations)

9. To seal hood hinge to body bolts, remove one bolt at a time to avoid movement of hood hinge adjustment, and apply 3M Bedding and Glazing Compound (P/N 8509) or equivalent to threads of bolt.

10. Install bolt and torque.

Torque: 25 N-m (18 ft-lbs)

11. Repeat steps 8 and 9 for remaining bolts.

12. Water test the area to make sure that no other waterleaks are present.

13. Install upper fender fasteners and align fender as necessary.

Torque: 10 N-m (89 in-lbs)

14. Install wheelhouse liner to fender fasteners.

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 Seal Left Frame Rail and Hood T9623 1.1 hrs Hinge to Body Bolts

VW Seal Right Frame Rail and Hood T9624 1.1 hrs Hinge to Body Bolts

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.