Body - Preventing Water Entry Onto Passenger Side Floor
BO93-009NOVEMBER 5, 1993
Title: PREVENTING WATER ENTRY ONTO PASSENGER SIDE FLOOR
ES 300
On some ES 300's, the front passenger floor carpet may become wet or damp after a heavy rain. Two sources of water entry have been identified:
(1) Water travels down SRS wire harness and enters through SRS wire harness grommet located on RH outer cowl side panel subassembly, (side kick panel).
(2) Water, flowing on the back side (underside) of cowl outer panel, enters by dripping into fresh air intake plenum.
PRODUCTION COUNTERMEASURE:
To prevent water entry into front passenger compartment, the following production countermeasures have been implemented.
(1) Water entry at SRS wire harness grommet
Figure 1:
SRS wire harness grommet has been modified to prevent water from entering vehicle (See Figure 1).
PRODUCTION EFFECTIVE:
VIN P/D
JT8GK13T# R0001033 8/93
(2) Water entry through fresh air intake plenum
Figure 2:
Stamped formation (drain channel) added to RH cowl outer panel to prevent water flow along back side of panel. (See Figure 2)
PRODUCTION EFFECTIVE:
VIN P/D
JT8VK13T# N0117382 7/92
REPAIR PROCEDURES:
Should preliminary inspection confirm wet/damp passenger side carpet or silencer pad, the following repair procedures are recommended:
(1) For water entry at SRS wire harness grommet, seal SRS grommet to body panel
1. REMOVE RH FRONT TIRE
2. REMOVE FRONT FENDER WHEEL OPENING MOULDING. Remove four screws and the moulding.
Figure 3:
3. REMOVE RH FRONT FENDER LINER. Remove fasteners (12) RH front fender liner (as shown in Figure 3) to gain access to SRS wire harness grommet.
4. CLEAN AREA FOR APPLICATION OF SEALER. Clean area around SRS wire harness grommet opening in RH cowl side panel subassembly.
5. POSITION SRS WIRE HARNESS GROMMET
Ensure grommet is properly seated to opening in RH cowl side panel subassembly.
6. SEAL SURFACE BETWEEN GROMMET AND BODY PANEL
Recommend using 3M Ultrapro Auto Body Sealant (Clear) P/N 08302 or 3M All Around Auto Body Sealant (White) P/N 08500 or equivalent.
Figure 4:
Apply sealer to surface between SRS wire harness grommet and body panel, (as shown in Figure 4) to prevent water entry.
7. RE-INSTALL FENDER LINER
Figure 5:
Install three clips so that the screw can be inserted in the manner shown in Figure 5.
8. RE-INSTALL FRONT FENDER WHEEL OPENING MOLDING.
(2) For water entry through plenum fresh air intake, install countermeasure seal
1. REMOVE RH COWL LOUVER (SCREEN)
Operate windshield wiper and stop the arm at the upper position.
Figure 6:
Using a clip remover7 remove attaching clips (5) for RH cowl louver and hood to cowl top weather-strip. (See Figure 6).
Figure 7:
Using clip remover, remove additional clip securing RH cowl louver to LH cowl louver and cowl top, (See Figure 7). Pull the cowl louver out forward to remove clip.
2. CLEAN AREA FOR INSTALLATION OF SEAL
Figure 8:
Clean the back side of the cowl outer panel with isopropyl alcohol to promote adhesion. (See Figure 8)
3. APPLY SEAL TO COWL OUTER PANEL
Recommend using Quarter Window No.2 Glass Seal (PN 68177-12020, Toyota Supply Part)
Cut strip of seal approximately 130 mm (5.12 in.) long.
Apply the seal to the back side (underside) of the cowl top panel as shown, starting from the front end of the cowl top panel.
Figure 9:
Align the edge of the seal strip with the edge of the opening in the cowl top panel (See Figure 9).
4. REINSTALL RH COWL LOUVER (SCREEN)