SUBJECT: Water Leak In Passenger Compartment Under Instrument Panel
NO: 23-48-94
GROUP: Body
DATE: Jul. 15, 1994
MODELS: 1995 (PL) Neon
NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JULY 1, 1994 (MDH 07-01-XX).
SYMPTOM/CONDITION:
Water leak from under instrument panel onto front floor area. Water may also be noticed in the glove box. Sloshing noise may be heard from instrument panel on turns. Water may leak on passenger floor area on left hand turn.
DIAGNOSIS:
1. Remove instrument panel top cover and cluster bezel assembly by lifting up on the bottom outer areas of the cluster bezel and along the rearward edge to disengage the clips. Pull the top cover and cluster bezel rearward until the forward pins disengage from the instrument panel.

2. Remove both right and left A-Pillar trim mouldings by pulling outward on the moulding to disengage clips.

3. Run water on the windshield starting at the bottom and working up around the sides and around the top of the glass. Inspect for water dripping or running down the A-Pillars or front part of the windshield through the urethane bead. If a windshield water leak is found, repair as necessary before proceeding to the repair procedure.
PARTS REQUIRED:
AR 4318088 Butyl Rubber Sealer (Or Equivalent)
AR 4467708 Silicone Windshield & Glass Sealer (Or Equivalent)
AR 4655021 Cowl Screen Assembly (With Lip Seal)
AR 4783100 Cowl Drain Tube
AR 4655604 Cowl Top Patch
REPAIR PROCEDURE:

This bulletin involves sealing the cowl plenum, installing a cowl screen, and a cowl plenum drain tube.

1. On the inside of the vehicle, on the left top corner of the dash,fold back the cowl top silencer pad and temporarily retain it under the VIN plate pad on the instrument panel. Fold back the cowl top patch to gain access to the dash panel access hole.Refer to Figure 1 and 2.

2. Look through the access hole in the cowl top and inspect for any water remaining in the cowl plenum. Remove any water that is present by using a vacuum through the access hole. Refer to Figure1.

3. Remove the wiper arm assemblies.

4. Open the hood and remove the cowl-to-hood seal and the cowl screen assembly.

5. Disconnect the wiper motor electrical connector and the three bolts holding the wiper assembly then remove the wiper motor assembly.

6. Apply Butyl Rubber Sealer P/N 4318088 (Or Equivalent) to the following areas of the cowl plenum. Refer to Figure 2, 3 and 4.


A. Horizontal & vertical seams in the cowl plenum.
B. Upper corner of the cowl plenum to cowl top extension(Right and Left sides).
C. Bottom corner of A-Pillar transition (Right and Left sides).
D. Horizontal and vertical seams under hood hinge attachment area (Right and Left sides.)

7. Force Silicone Windshield & Glass Sealer, P/N 4467708 (Or Equivalent), beneath the windshield edge to seal possible sheet metal leak covered by glass. Refer to Figure 4.

8. Install the wiper motor assembly.

9. Install a new Cowl Screen Assembly, P/N 4655021.

10. Install the wiper arm assemblies.

NOTE: IF THE VEHICLE BUILD DATE IS AFTER 6/15/94 (MDH 06-15-XX), THE COWL DRAIN TUBE IS ALREADY INSTALLED IN THE VEHICLE PROCEED TO STEP 18.

11. Remove the left front cowl trim panel.

12. On the inside of the vehicle, locate the rubber plug in the left cowl plenum, which can be seen through the left access hole. Refer to Figure 1.

NOTE: MAKE SURE THAT THE WIRING HARNESS IS MOVED OUT OF THE WAY BEFORE CUTTING THE DASH SILENCER.

13. On the inside of the car, on the underside of the dash panel,directly below the rubber plug, cut a hole with a utility knife in the dash silencer to gain access to the rubber plug. Remove the plug.

14. From the top side of the plenum, insert the Cowl Drain Tube, down through the access hole and seat the grommet by pulling down on the grommet, (not the tube) from below. Refer to Figure 1.

15. Route the drain tube, through the wiring slit on the left front cowl silencer plug. Make sure the tube is routed down into the sill as far as it will go without kinking the tube. Refer to Figure 5.


16. Pour water through the cowl top access hole, for several minutes,to cover the drain tube assembly. Inspect from underneath to ensure there are no leaks around the grommet. If leaks are noted,re-seat the drain tube grommet.

17. Install the left front cowl trim panel.

18. Install the cowl top patch over the dash panel access hole. If the patch cannot be re-used, use a new Cowl Top Patch, P/N 4655604.

19. Install the cowl top silencer pad over the cowl top patch.

20. Install the instrument panel top cover and A-Pillar trim moldings.
POLICY: Reimbursable within the provisions of the warranty