WATERLEAK - FRONT PASSENGER FLOOR (RESEAL PLENUM/COWL. Chevrolet Malibu 1997

SUBJECT: WATERLEAK - FRONT PASSENGER FLOOR (RESEAL PLENUM/COWL WATER DEFLECTOR)

MODELS: 1997-98 CHEVROLET MALIBU 1997-98 OLDSMOBILE CUTLASS 1999 PONTIAC GRAND AM

BUILT PRIOR TO THE FOLLOWING VIN BREAKPOINTS:

VIN VIN MODEL LOCATION BREAKPOINT DATE ========= ====================== ========== =======

MALIBU OKLAHOMA CITY PLANT 6 W6229091 4/16/98 WILMINGTON PLANT Y WY178047 4/16/98

CUTLASS OKLAHOMA CITY PLANT 6 W6339883 4/16/98

GRAND AM LANSING PLANT M XM726868 4/20/98 LANSING PLANT C XC503367 4/20/98

CONDITION:

SOME CUSTOMERS MAY COMMENT ON THE PASSENGER FRONT FLOOR CARPET BEING WET OR WATER LEAKING FROM THE BOTTOM OF THE INSTRUMENT PANEL AND/OR HVAC MODULE.

CAUSE:

CONDITION MAY BE DUE TO WATER LEAKING INTO THE HVAC MODULE THROUGH THE SEALER BETWEEN THE WATER DEFLECTOR AND THE BOTTOM OF THE PLENUM/COWL.

CORRECTION:

RESEAL THE WATER DEFLECTOR TO THE PLENUM. THE PRODUCTS LISTED IN THIS BULLETIN ARE TAKEN FROM THE TECHNICIANS HANDOUT OF "ADHESIVES, SEALERS AND RELATED ITEMS", JULY 1995 REVISION (ITEM #22009.01-3). FOLLOW THE MANUFACTURERS DIRECTIONS OF EACH PRODUCT FOR APPLICATION AND DRYING TIMES.

PROCEDURE:

1. REMOVE AIR INLET GRILLE, FOLLOWING THE PROCEDURE IN THE SERVICE MANUAL.

2. REMOVE ANY EXCESS FOAM SEALER THAT MAY HAVE OOZED OUT FROM THE PERIMETER OF THE WATER DEFLECTOR AND CLEAN AREA.

3. APPLY ONE OF THE PUMPABLE SEALERS, LISTED LATER IN THIS BULLETIN, TO THE PERIMETER OF THE DEFLECTOR. A FLAT BLADED TOOL OR BRUSH WILL HAVE TO BE USED TO APPLY SEALER TO THE AREA UNDER THE WINDSHIELD.

4. REINSTALL AIR INLET GRILLE, FOLLOWING THE PROCEDURE IN THE SERVICE MANUAL.

5. CHECK CARPET FOR WETNESS OR WICKING OF WATER TO OTHER COMPONENTS AND REPAIR/DRY AS REQUIRED.

PUMPABLE SEAM SEALERS OR EQUIVALENT:

- 3M(R) #08360 OR 61 ULTRA PRO SEAM SEALER - DOMINION SURE SEAL(R) #9005 HIGH TECH SEAM SEALER - KENT(R) #10095, 10130, 10567 HIGH TECH SEAM SEALER

WARRANTY INFORMATION:

FOR VEHICLES REPAIRED UNDER WARRANTY, USE:

LABOR OPERATION LABOR OPERATION NUMBER DESCRIPTION TIME =============== ================================== ===============

C0010 COWL AREA - RESEAL 0.5 HR

FIGURES: 00 ATTACHMENTS: 00

GENERAL MOTORS BULLETINS ARE INTENDED FOR USE BY PROFESSIONAL TECHNICIANS, NOT A "DO-IT-YOURSELFER". THEY ARE WRITTEN TO INFORM THOSE TECHNICIANS OF CONDITIONS THAT MAY OCCUR ON SOME VEHICLES, OR TO PROVIDE INFORMATION THAT COULD ASSIST IN THE PROPER SERVICE OF A VEHICLE. PROPERLY TRAINED TECHNICIANS HAVE THE EQUIPMENT, TOOLS, SAFETY INSTRUCTIONS AND KNOW-HOW TO DO A JOB PROPERLY AND SAFELY. IF A CONDITION IS DESCRIBED, DO NOT ASSUME THAT THE BULLETIN APPLIES TO YOUR VEHICLE, OR THAT YOUR VEHICLE WILL HAVE THAT CONDITION. SEE A GENERAL MOTORS DEALER SERVICING YOUR BRAND OF GENERAL MOTORS VEHICLE FOR INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THE INFORMATION.