Interior - Water Leaks Onto Front Floor Area

BODY
BO025-03

December 11, 2003

Title
WATER LEAK AT COWL

Models
'04 Solara

Introduction





Some customers may experience a water leak condition at the front floor area. Water may be entering the body through a body sealer void on the engine compartment rear wall, near the upper door hinge.

Applicable Vehicles
^ 2004 model year Solara vehicles produced BEFORE the Production Change Effective VINs shown below.





Production Change Information





Warranty Information

Applicable Warranty:

This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.

* Warranty application is limited to correction of a problem based upon a customer's specific complaint.





Required Tools & Material

NOTE:
Please visit www.3m.com/automotive to locate the nearest store that sells 3M automotive products.

Repair Procedure

1. Raise vehicle. Remove front wheel and front fender plastic liner on the side of the vehicle with the water leak.





2. Examine the body sealer condition (with a flash light and mirror) on the engine compartment rear wall, near the upper door hinge (A). Also examine the sealer condition inside of the inner fender box frame structure with access holes (B) (see illustration).

3. If sealer appears misaligned, missing, or has gaps, apply body sealer (3M Ultrapro Urethane Seam Sealer) to that area and other panel edges. Use a long tip applicator to reach inside the inner fender box frame structure.

4. Once the sealer repair is complete, reassemble the vehicle and the removed wheel.

Torque: 103 N.m, 1050 kgf.cm, 76 ft.lbf

Other potential sources of water leaks into the front floor area:

^ Confirm the HVAC evaporator drain hose is not plugged with debris and it is properly routed through the hole in the floor.

^ Confirm front sunroof drain tubes are properly routed and not plugged with debris. To confirm sunroof drain tubes are clear, insert a flexible wire (such as a long speedometer cable) into each drain hose.

^ Confirm there are no gaps in the body sealer under the roof molding. Confirm there are no gaps in the windshield sealer.