Waterleaks Into Spare Tire Well. Saturn Saturn 1993

For 1990-2009 cars

# Waterleaks Into Spare Tire Well

Subject: | Waterleaks into Spare Tire Well (Install Liftgate Inner Panel Drain Hole Plug, and Trim Porting of the Outer Lip from the Weatherstrip and/or Apply Sealer to the Spaceframe Lap Joint.

Models: | 1993 Saturn Station Wagons built before and including VIN PZ23933

### 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 of the following causes:

• | Water directed at the bottom center of the rear liftgate, latch, area forces water into the enter drain hole, up and over the water barrier, down the latch and into the spare tire well.

• | The outer lip of the rear liftgate weatherstrip funnels water into the seam of the weatherstrip flange at the bottom of the rear liftgate opening.

• | The sealer skips at the rear liftgate opening spaceframe lap joints.

### Correction:

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

• | Trim a portion of the outer lip from the weatherstrip and apply weatherstrip adhesive to the weatherstrip, and/or;

• | Apply seam sealer to the spaceframe lap joints.

### Procedures

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

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.

3. Pierce the center of the left liftgate inner panel drain hole plug, located 305 mm (12 in) to the left of center, by using a cotter pin removal tool or an awl. Carefully pry the liftgate inner panel drain hole plug from the hole and discard.
4. Remove the spare tire.
5. If necessary, dry the spare tire well.
6. Close the rear liftgate and run an unrestricted flow of water at the top center of the rear liftgate and inspect the rear of the spare tire well for water.

6.1. | If water is present, go to step 7.

6.2. | If no water is present from the 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 in) to each side of the butt joint at the bottom of the liftgate opening and make a mark on the weather strip. Refer to the illustration.
8. Remove the bottom third of the rear liftgate weatherstrip from the metal flange.
9. Starting at the marks on the weatherstrip, trim the outer lip from the bottom third of the weatherstrip on each side of the vehicle.
10. Remove the rear liftgate opening sill plate trim molding.
11. Turn the weatherstrip over 180 degrees. Using 3M® Weatherstrip Adhesive P/N 08008 or equivalent, apply a 3.18 mm (1.8 in) bead inside the bottom third of the weatherstrip retention channel as shown in the illustration and re-install the weatherstrip, press down firmly to make sure the seal is fully seated.

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

12. Install the rear liftgate opening sill plate trim molding over the top of the inner lip of the weatherstrip.
13. Close the rear liftgate and run an unrestricted flow of water at the top corner of the rear liftgate and inspect the rear spare tire well for water.

13.1. | If a leak is present go to Step 14.

13.2. | If a leak is not present, install the spare tire, the repair is complete.

14. Dry the spare tire well, open the 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 the spare tire well. Refer to the illustration on the facing page.

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

14.2. | If a 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 the spare tire well. Refer to the illustration on the facing page.

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

15.2. | If a 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 the spare tire well. Refer to the illustration on the facing page.

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

16.2. | If a leak is not present at any of the lap joints, install the 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 joints that have been found , by watertest, to leak and let the sealer cure according to the 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 tail lamp assembly, it will be necessary to partially remove the tail lamp assembly to properly gain access when applying sealer to lap joint 1.

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

Claim Information | To receive credit for this repair, submit a claim through the Saturn Dealer System as follows:
--- | ---
-- | Case Type | Description | Labor Operation Code | Time
-- | VW | Trim Portion of Outer Lip from Seal, Install Drain Plug and Watertest | T9645 | 1.0 hrs
Add if required:
-- | A. | To Seal and Watertest Lap Joints |  | 0.30 hrs