Canada - Body - Water Leak At Cowl Area

Bulletin
1318

Issue Date
February 02, 2004

Market
Canada

Title:
WATER LEAK AT COWL

Component
BODY COMPONENT

Model
'02 - '06 Camry (TMMK), '04 - '06 Solara Coupe & '05 - '06 Avalon

TSB REVISION NOTICE:
- June 13, 2006: The engine type for the Avalon has been updated to 2GR in the Production Change Information table.
- February 23, 2006: 2002 -- 2006 model year Camry, 2005 -- 2006 model year Solara Coupe, and 2005 -- 2006 model year Avalon vehicles have been added to Applicable vehicles. The VINs in the Production Change Information table have been updated.
Previous versions of this TSB should be discarded.







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

APPLICABLE VEHICLES:
- 2002 -- 2006 model year Camry (TMMK Production) vehicles produced BEFORE the Production Change Effective VINs in this TSB.
- 2004 -- 2006 model year Solara Coupe vehicles produced BEFORE the Production Change Effective VINs in this TSB.
- 2005 -- 2006 model year Avalon vehicles produced BEFORE the Production Change Effective VINs in this TSB.







PRODUCTION CHANGE INFORMATION:







WARRANTY INFORMATION:







REQUIRED TOOLS & MATERIAL:

REPAIR PROCEDURE:
1. Raise the vehicle. On the side of the vehicle that has the water leak, remove the front wheel and the front fender plastic liner.







2. Examine (with flash light and mirror) the body sealer condition on the engine compartment rear wall, near the upper door hinge. Also examine the sealer condition inside the inner fender box frame structure with access holes (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 install the removed wheel.

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

Other potential sources of water leaks into the front floor area:
- Water can be splashed into the vehicle from the tires, if the rubber body plugs were not installed during Pre--Delivery Service.
- 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.

NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.