Interior - Water Leaks In the Floor
91saab03
CATEGORY
Body
SECTION PAGE
8 24
ISSUE CODE
07/91-0125 800
Supersedes: PSI 02/91-0086
Subject: Correcting Water Leaks
Into the Floor Area
Application: All 900 Models
Water leaks into the floor area of a 900 are often difficult to diagnose because there can be several possible points of entry. This PSI presents a diagnostic procedure for determining the point(s) of entry, as well as repair procedures for rectifying some of the possible causes of wet carpets and floors in 900 models. Water leaks around doors and windows are, in most cases, easily diagnosed and are not covered in this PSI.
Determining the Point of Entry
1. Remove the seats, the center console, the carpets and the foam padding under the carpets.
2. Temporarily replace the three screws on each side for the carpet trim pieces along the front of the door openings.
3. Hang the carpets and padding up to dry. Wet carpets and padding will not dry completely If left in the car.
4. Dry off the floor of the car and close the doors, windows and sunroof (if equipped).
5. Direct water onto the sunroof area, the windshield and the cowl gutter ahead of the windshield (beneath the rear edge of the hood). Water testing is most effective if carried out by standing outside the car and observing the accumulation of water through the windows. Note carefully where the water is coming from.
Possible Points of Entry and Repair Procedures
Figure 1:
1. Fuse panel/firewall connection (Figure 1). Install a new seal, P/N 85 52 671 and additional body putty as necessary.
Figure 2:
2. Wiring harness entry at the bottom of the right slde A-Pillar (Figure 2). Make sure that there is a foam seal, P/N 40 62 048, in the grommet and that it is correctly positioned. Also check the integrity of the grommet and the tightness of the cable tie. Correct as necessary.
3. A/C evaporator housing seal. Check the position of the water tray and seal. Correct as necessary.
Figure 3:
4. Body sill panels.
a. Seal possible entry points and install the additional drain plug as specified in SI 05/90-1238. One frequently overlooked place that water can leak into the sill area is a small gap located in the sill just below the leading edge of the front door (Figure 3). This gap can exist because of incomplete seam sealing, either from original production or from collision repair. Gaps in any body seam should be sealed using 3M All-Around Autobody Sealant (-08500).
Figure 4:
b. There are also four small drain channels, two on each side (Figure 4) which can allow water to drain from the sills into the floor area. Water which enters the sill is supposed to exit the car via the front and rear rubber drains. Depending on the angle of the car when parked, this does not always happen. Seal these channels with 3M strip caulk.
Also check the front lower corner of the door opening for possible incomplete seam sealing.
Figure 5:
5. Hood drain channel (Figure 5):
Install two drain tubes, P/N 41 54 258, into the drain channel at the back edge of the hood. Install one tube on each side as shown, making sure that the tube drains through the open area at the bottom of the wheel housing. On Convertibles, route the tube into the extension of the A-pillar. Press the tube firmly down so it is flush with the drain channel. Plug the hole next to the drain tube with body putty (Figure 5).
Warranty Information:
For warranty claims, use Failure Code(s) showing the cause of any leaks and the applicable labor operations (see also page 8-78 in the 900 Flat Rate Manual) and/or straight time. Use the following guidelines for straight time:
^ Fuse panel/firewall connection: about 0.3 hour to replace the seal and putty.
^ Wiring harness entry at the bottom of the RH A-pillar: about 0.2 hour to correct.
^ Evaporator housing seal: about 0.3 hour to correct.
^ Body sill panels (step a): about 0.1 hour to seal.
^ Body sill panels (step b): about 0.2 hour to seal.
^ Hood drain tubes: about 0.2 hour to install.