Cowl Plenum - Water Leaks
NO: 23-78-95GROUP: Body
DATE: Dec. 22, 1995
SUBJECT:
Cowl/Plenum Water Leaks
MODELS:
1995 - 1996 (JA) Cirrus/Stratus
SYMPTOM/CONDITION:
Wet dash silencer pad/carpet in front seat, musty odor inside vehicle, or excessive condensation on inside of windows.
DIAGNOSIS:
Verify the carpet and/or the dash silencer pad are wet. Remove the left and right interior cowl side trim panels and pull the carpet back. Check the underside of the carpet for dampness. Disconnect the fasteners used to route the wire harness down the inside of the left and right interior cowl sides. Raise the dash silencer pad and check the under side for dampness.
If carpet or dash silencer pad are damp, confirm that the water is entering the vehicle through the outside plenum. Remove the windshield wipers and cowl cover. Raise the hood and spray water at the base of the left and right A-pillar into the cowl side/plenum floor area seams and up into the A-pillar/cowl baffle. In addition, spray water around the hood hinge relief pocket, hood hinge tap plate and load beam baffle attachment push pin (push pin is located just below the hood hinge tap plate). While spraying water into the areas listed, have the carpet and dash silencer pad raised off the floor and check for water entering the vehicle.
REPAIR PROCEDURE:
This bulletin involves sealing the cowl side/plenum.
1. Remove the hood by unbolting the hood from the hood tap plate. Reinstall the bolts in the tap plate to temporally seal the bolt holes.
2. The cowl side/plenum floor seams, hood hinge relief pocket, hood hinge tap plate and inner load beam at the load beam baffle attachment push pin must be free from dirt, grease and other contaminants. Clean these areas with Mopar Super Kleen, P/N 4318015, and compressed air.
3. Force Mopar Silicone Rubber Adhesive Sealer, P/N 4318025, as far as possible into the cowl side/plenum floor seams. Care must be taken not to close off the plenum water drain holes. Force a large amount of sealant up into the area of the A-pillar/cowl baffle. It may be necessary to completely cover the A-pillar/cowl baffle with sealant to be sure to close off all voids around the baffle.
4. Force sealant into the hood hinge relief pocket to close off voids that may exist. Care must be taken not to close off the hood hinge pocket water drain hole.
5. At Hood tap plate, force sealant into the seam between the load beam and plenum floor closure panel. Cover the load beam baffle attachment clip with sealant.
6. Repeat procedure for other side.
7. Allow sealant to dry for 30/45 minutes and retest cowl side/plenum for water leaks. Repeat procedure as necessary.
8. Dry carpet and/or dash silencer pad with heat gun or allow to air dry.
9. Reassemble vehicle.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 23-50-01-98 1.3 Hrs.
FAILURE CODE: XX - Service Adjustment