Repair Procedure

2.5L (4 Cylinder) Engine - Drain Tube Rework For Plastic Flashing:





NOTE:
If your dealer does not have the tools required for this repair, contact the Technical Assistance Hotline.





1. Set up drill in chuck as shown.

CAUTION:
Ensure paint mark stays at edge of chuck and does not creep out of chuck (drill in deeper), otherwise, an unwanted water drain hole will be created to drain in the passenger compartment.

2. Open hood.

3. Using gauge, check for presence of plastic flash in drain hole.

- Gauge check is OK if gauge can be completely inserted into hole until shoulder contacts end of drain tube. No flash is present. Proceed to "Campaign Label".

- If gauge check is NO GOOD (shoulder does not contact end of drain tube), then plastic flash is present. Proceed to next step.





4. Use 90 degree assembly (or standard cordless drill with 6 inch extension option) to clear the flash.

5. Flex the drill 90 degrees to the rear and insert in the drain tube (NO POWER to the driver yet.)





6. Using RH locate chuck and bit assembly and feed through drain hole.





7. Insert drill assembly behind engine heat shield.

8. Feed flexible drill hose through opening to gain access to drain hole.





9. To drill out plastic flash, insert bit into drain hole approx. 1.5 inches into tube as a loose engagement for proper alignment. While the drill is fully energized, drill and stroke forward until chuck bottoms out on drain tube, then back it out.

NOTE:
Clear drill threads of plastic shavings prior to inserting into next vehicle for repair.

10. To clear drain hole of all debris, cycle HVAC fan on full blower speed for 30 seconds.

11. Proceed to "CAMPAIGN LABEL".

3.7L (6 Cylinder) Engine - Drain Tube Rework For Plastic Flashing:





NOTE:
If your dealer does not have the tools required for this repair, contact the Technical Assistance Hotline.





1. Set up drill in chuck as shown.

CAUTION:
Ensure paint mark stays at edge of chuck and does not creep out of chuck (drill in deeper), otherwise, an unwanted water drain hole will be created to drain in the passenger compartment.

2. Using gauge, check for presence of plastic flash in drain hole.

- Gauge check is OK if gauge can be completely inserted into hole until shoulder contacts end of drain tube. No flash is present. Proceed to "Campaign Label".

- If gauge check is NO GOOD (shoulder does not contact end of drain tube), then plastic flash is present. Proceed to next step.





3. Use 90 degree assembly (or standard cordless drill with 6 inch extension option) to clear the flash.

4. Safely raise vehicle on hoist.





5. Rotate right front wheel fully to the "left turning" position.





6. To access the drain hole, relocate the plastic splash for the torsion bar by removing two (2) push pins.





7. To drill out plastic flash, insert bit into drain hole approx. 1.5 inches into tube as a loose engagement for proper alignment. While the drill is fully energized, drill and stroke forward until chuck bottoms out on drain tube, then back it out.

NOTE:
Clear drill threads of plastic shavings prior to inserting into next vehicle for repair.

8. To clear drain hole of all debris, cycle HVAC fan on full blower speed for 30 seconds.

9. Proceed to "CAMPAIGN LABEL".