Body, A/C - Water Leaks to Vehicle Interior
TSB 05-13-307/11/05
WATER LEAKS AND/OR A/C CONDENSATION LEAKS
AT FRONT FLOOR AREA - SERVICE TIPS
FORD:
2000-2005 Focus
This article supersedes TSB 02-25-1 to update the vehicle model years and service procedure.
ISSUE
Some 2000-2005 Focus vehicles may exhibit a difficult to diagnose or difficult to repair water leak or AC system condensation leak condition in the front floor area. This may be caused by sealer skips, loose grommets, mis-positioned seals or condensation leaking from the A/C evaporator case.
ACTION
Determine if the concern is an A/C condensation leak or a water leak and repair as necessary. Some common water leak locations and repair recommendations are listed in this article to help reduce repair time and increase repair effectiveness.
SERVICE PROCEDURE
1. If possible, ask the customer the following questions to help determine when the leak occurs.
a. Does leak occur only when A/C is on in high heat/humidity conditions?
(1) If yes, proceed to A/C Condensation Leak Inspection/Repair Procedure.
(2) If no, or customer is unsure, proceed to question b.
b. Does leak occur when it is raining or when the vehicle is taken through a car wash?
(1) If yes, proceed to Water Leak Testing and Water Inspection/Repair Procedure.
(2) If no, or customer is unsure, proceed to A/C Condensation Leak Inspection/Repair Procedure. If no problem is found proceed to Water Leak Testing and Water Leak Inspection/Repair Procedure.
A/C Condensation Leak Inspection/Repair Procedure
1. Start the engine and run vehicle with A/C on, in the recirculated air position, with the blower at high speed.
2. Inspect for condensation leaks coming from the evaporator case area.
3. If condensation leaks are present replace the evaporator case with Part Number 5S4Z-19B50-BB. Refer to Workshop Manual, Section 412-02.
NOTE
DO NOT REPLACE THE EVAPORATOR CASE IF A CONDENSATION LEAK CANNOT BE VERIFIED.
Water Leak Testing Procedure
1. Using a high pressure water hose or a pressure washer, run water onto the windshield being sure to direct water over the roof ditch moldings, and down onto the cowl (Figure 1).
2. Open the hood and direct water (from the side of the vehicle) into the base of the A-pillar in the hood hinge area (Figure 2).
3. Remove right front inner splash shield and direct water into the back of the right front wheel well area (Figure 3). Refer to Workshop Manual, Section 501-02.
4. Proceed to Water Leak Inspection/Repair Procedure.
Water leak Inspection/Repair Procedure
Inspect the following areas for visible signs of leaks and follow the appropriate repair steps.
Water is visible at Blower Motor Connector, Blower Motor Resistor, Blower Motor Mounting Flange, or Foot Air Duct:
NOTE
THE MOST LIKELY SOURCE OF THE LEAK IS THE FRESH AIR INTAKE. WATER ENTRY INTO THE AIR INLET HOUSING MAY BE VISIBLE BY LOOKING THROUGH THE RECIRCULATION DOOR AS IT IS OPEN AND CLOSED. TO DO THIS, REMOVE THE GLOVE BOX, TURN THE IGNITION KEY TO THE ON POSITION AND PUSH THE RECIRCULATION BUTTON.
1. Remove the cowl panel grille and inspect for gaps between the pollen filter housing gasket and sheet metal plenum (2000-2003 model years) or skips in the sealer around the pollen filter housing (2004-2005 model years).
2. If gaps are present inspect for bent plenum sheet metal flanges and repair as necessary.
3. Seal around the pollen filter housing perimeter using Clear Silicone Rubber (TA-32).
Water is Visible on Evaporator Case Seal at the Heater Core Inlet/Outlet:
1. Inspect for a mis-positioned evaporator case seal at the heater core inlet/outlet. Repair as necessary (Figure 4).
2. Inspect for loose evaporator case housing attachment nuts. Repair as necessary.
Water is Visible in the Right Kick Panel/A-Post Area
NOTE
IT MAY BE NECESSARY TO REMOVE THE INSTRUMENT PANEL TO FULLY ACCESS AND REPAIR SOME LEAK SOURCES. FOLLOW WORKSHOP MANUAL SECTION 501-12 IF INSTRUMENT PANEL REMOVAL IS NECESSARY.
1. Inspect for sealer skip behind roof ditch moldings. Fold the ditch molding back and inspect for a pinhole in the body seal just above the windshield. Reseal as necessary with Motorcraft Roof Ditch Sealer (TA-15) (Figure 5).
2. Inspect for wire harness body grommet loose or mis-positioned. Reposition or reinstall grommet as necessary (Figure 6).
3. Inspect for skip in windshield urethane. Reseal as necessary.
4. Inspect for sealer skip in A-post to cowl joint. Reseal as necessary (Figure 7).
5. Inspect for sealer skips between cowl top to bulkhead, just above main harness grommet (Figure 8).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
19850 68
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