Repair Procedure

Verify leak by inspecting right side carpet for wetness. Water test right side of vehicle to eliminate other leak paths. If the carpet is wet and no other leak paths are apparent, proceed with this repair procedure. This bulletin involves de-trimming the right side of the vehicle, as listed, inspecting and sealing the A" pillar area.

1. Record all radio pre-sets and disconnect the negative battery cable.

2. Remove the glove box.

3. Remove the glove box under frame and disconnect the wire for the light switch.

4. Remove the right hand instrument panel under cover.

5. Remove the right side scuff plate.

6. Remove the right hand cowl side trim.

7. Peel back the right hand floor carpeting to gain access to the ABS control unit cover.

8. Remove the control unit cover and ABS-ECU bracket. The ABS controller can remain connected to the bracket with wiring attached.

9. Remove the automatic compressor ECM (A/C equipped vehicles). The controller can stay connected to the wiring.

10. Remove the right side instrument panel corner bracket (under cover mounts to this bracket).

11. Twist the bulb socket from the instrument panel bracket.

12. Remove the glove box locating pin bolt.

13. Disconnect the blower motor and resistor wiring.

14. Pull wire harness down from dash panel to access HVAC mounting bolts.

15. Cut the right side sound deadner from the floor pan area. Cut the deadner as close to the HVAC case as possible. Remove the deadner panel.

16. Remove the passenger side air bag module for access to upper blower housing fasteners.

17. Disconnect the recirculating door cable.

18. Remove the blower housing to upper dash mounting nuts (2). These are partially accessible through the air bag opening.

19. Remove the HVAC housing upper mounting bolts (2).

20. Remove the HVAC and blower housing lower mounting nuts (2).

21. Remove the HVAC housing clips and screws that hold the halves together. This will allow easier removal of the blower housing.

22. Remove the blower motor housing clip and 4 screws. These fasteners hold the blower halves together.

23. Remove the lower half of the blower assembly.

24. Remove the upper half of the blower assembly.

25. Peel back the deadner to expose the body seam along the inner bulkhead and A-pillar.





26. Inspect the seam along the bulkhead and A-pillar for sealer void and evidence of water entry (Figure 1).

27. Using a body filler squeegee, apply the sealer P/N 04856952 to the corner where the cowl seam meets the A-pillar seam. Apply the sealer 6 inches to the right and left of the A-pillar seam and 6 inches down the A-pillar seam. Work the sealer in with the squeegee.

28. Re-install components in reverse order.

29. Re-connect the battery negative cable, reset the radio pre-sets recorded in step 1, and set the clock to the appropriate time.

30. Test the HVAC system for proper operation.