Leaks At Right Side Front Floor Pan/Carpet:
RIGHT SIDE FRONT FLOOR PAN/CARPET:
The most probable cause of this water leak is sealer skips at the cowl behind the right front fender, cowl (panel) fasteners, plugged water drain, and/or mispositioned grommets. Proceed as follows:
1. Run the water from the top of the right front "A" pillar, allowing the water to flow down the windshield, the cowl, the door weatherstrip and mirror and also out onto the right front fender and hood area. Allow the water to run a minimum of 15 minutes.
2. The person inside the vehicle should remove the right side kick panel and pull the carpet back to observe for water entry.
3. If water is observed coming into the kick panel and carpet area or through the heater case, remove the heater blower motor and use a light to see up into the air opening. The air recirculation door may have to be moved for clear access to the air opening. See Step 8 for procedures.
Figure 1:
4. Raise the hood and determine if the cowl water drain is plugged or not sealed properly, see Figure 1. If the water drain is plugged, water can dam up and enter the air intake to the heater from under the baffle cover.
5. If the drain is plugged and requires replacement, obtain a new drain, (E92Z-16758-B) and use silicone sealer on the foam gasket to provide additional sealing to the cowl.
Figure 1:
Figure 2:
Figure 3:
6. Water can also enter around the "push pins" at the right side bottom of the lower windshield molding. See Figure 1, use the parts as listed in this TSB. The arrows in Figures 2 and 3 point to possible sources of water leaks coming from grommets and/or push pins.
Figure 2:
Figure 3:
Figure 4:
7. Remove the wiper arms, right side baffle and lower windshield molding. Inspect for push pin/grommet damage, poor sealing or improper position. Replace the push pins, fasteners or grommets as needed, see Figures 2, 3, and 4.
8. If water was observed coming into the blower motor area of the heater housing as noted in Step 3, inspect the welds and sealer around the air opening.
Figure 5:
a. This operation will not be as easy as resealing with silicone sealer. It must be performed from inside the heater case, reaching up into the air opening. See Figure 5.
b. On the engine compartment side of the cowl, check for cross-threaded bolts/screws or loose/missing grommets and repair/seal as needed.
Figure 1:
9. Before installing the baffle, inspect the baffle foam seal. If damaged or missing, replace the baffle and/or apply silicone sealer under the baffle. This will reduce the possibility of water entering the blower motor opening. See Figure 1.
10. Inspect the right side fender grommet/plug as shown in Figure 1. It is about 1" from the water drain. If the grommet is missing or not installed properly, water can enter the heater case and right side kick panel area. Use silicone sealer under the grommet.
11. After reassembly of all components, water leak test the right side of the vehicle again to confirm that the repairs performed resolved the concern.