Procedure
1. Test for leakage the side sill areas on both sides as follows:
a. Run the A/C at maximum blower speed with the ventilation set at the fresh air position. Be sure all the doors, windows, and sunroof are completely closed.
b. Raise the vehicle.
C. Apply soapy water (solution of 20% dish soap) on both sides in the area shown. Check for air bubbles.
NOTE:
It is normal for air to be escaping from the side sill drain openings.
d. If air bubbles appear in any area of the side sill except the drain openings, turn the blower off and apply 3M 08370 sealant to all sealant gaps where air bubbles appear.
CAUTION:
DO NOT SEAL THE SIDE SILL DRAIN OPENINGS.
(1) Dry the area to be sealed.
(2) Use kerosene or mineral spirits to clean the surface.
(3) Apply a 3/8" bead of sealant to the gaps, overlapping the original sealant 1/2 inch to 1 inch.
(4) Allow the sealant to set for at least 45 minutes, then apply black spray undercoating over it.
e. Lower the vehicle.
2. Test for leakage at the dash as follows:
a. Use a hose to run a full stream of water into the opening in the windshield garnish as shown. Run the water for about three minutes.
b. Confirm that the water drains behind the front tires.
c. Lift the lower edge of the sound insulation pad (where the carpeting ends) and feel for moisture under the dash on both driver and front passenger sides.
d. If moisture is detected, dry the affected area. Then use kerosene or mineral spirits to clean the surface, and apply sealant 3M 08370 to any sealant gaps in the bulkhead.
The blower assembly must be removed in order to access the bulkhead and apply sealant. (It is not necessary to remove the blower assembly to inspect for leakage.)
3. If there has been water entry into the passenger compartment in any area, thoroughly dry the affected areas.
4. If sealant is applied to either the bulkhead or the side sills during this procedure, instruct the customer not to wash the vehicle for at least four hours, to allow the sealant to completely set.
5. Inspect oxygen sensor connector D-31 as follows:
a. Raise the vehicle.
b. Use a trim stick to remove the grommet. Pry the trim stick in the areas indicated to disengage the claws.
Gently pull out the connector, using care to prevent damaging its terminals. To ease harness removal, use the trim stick to push up on the carpeting.
c. Disconnect 4-pin connector D-31 and inspect its terminals.
d. Go to Step 6 if:
^ moisture is observed outside or inside the connector, or on the harness tape
^ there is rust, corrosion or discoloration on the connector's terminal(s)
^ the connector is discolored inside or outside
e. If one of the above conditions are found, reinstall the connector and grommet. Then go to Step 7 to complete this campaign procedure.
6. If any of the conditions described above are evident, replace the heated rear oxygen sensor and install the subharness as follows:
NOTE:
The oxygen sensor and subharness kit are listed in the PARTS INFORMATION section of this bulletin.
a. Replace the heated rear oxygen sensor.
b. Cut five inches from the harness outer tubing and peel it away from the wires. Use care to prevent damaging the wires.
c. Cut the harness wires at one inch intervals.
d. Solder the subharness to the body harness, matching the wire colors.
e. Wrap butyl tape (provided in the kit) to the soldered sections.
f. Wrap electrical tape around the butyl, reaching 10 mm beyond the butyl on both sides.
g. Wrap electrical tape around all of the wiring as a bundle.
h. Reinstall the connector and grommet. Go to Step 7.
7. FOR VEHICLES REGISTERED IN CALIFORNIA ONLY - Complete and provide to the vehicle owner a VEHICLE EMISSION RECALL - PROOF OF CORRECTIONS FORM (p/n MSSF-106D-00), available from Standard Register at 1-877-227-6115).