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Old 09-28-2007, 11:44 AM   #1
Shoreman
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Water in passenger foot well after heavy rain 2003 ZX3

No leak apparent during car wash. No telltale signs to point to door fit, glass fit, area under glove compartment. A goodly pool of water will collect after a steady rain, say 1 and a half full size bath towels' worth. Yes window tightly
closed.
Anybody else have this prob or have an insight into its' solution?


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Old 09-28-2007, 12:09 PM   #2
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have you checked the around the windshield or the cowl
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Old 09-28-2007, 12:10 PM   #3
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Yup, it's a known problem. You need to reseal the plastic cowl under the passenger side wiper...
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Old 09-28-2007, 12:32 PM   #4
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Try this:

FORD: 2000-2005 Focus


This article supersedes TSB 02-25-1 to update the vehicle model years and service procedure.

ISSUE:
Some 2000-2005 Focus vehicles may exhibit a difficult to diagnose or difficult to repair water leak or A/C system condensation leak condition in the front floor area. This may be caused by sealer skips, loose grommets, mis-positioned seals or condensation leaking from the A/C evaporator case.

ACTION:
Determine if the concern is an A/C condensation leak or a water leak and repair as necessary. Some common water leak locations and repair recommendations are listed in this article to help reduce repair time and increase repair effectiveness.

SERVICE PROCEDURE

If possible, ask the customer the following questions to help determine when the leak occurs.
Does leak occur only when A/C is on in high heat/humidity conditions?
If yes, proceed to A/C Condensation Leak Inspection/Repair Procedure.
If no, or customer is unsure, proceed to question b.
Does leak occur when it is raining or when the vehicle is taken through a car wash?
If yes, proceed to Water Leak Testing and Water Inspection/Repair Procedure.
If no, or customer is unsure, proceed to A/C Condensation Leak Inspection/Repair Procedure. If no problem is found proceed to Water Leak Testing and Water Leak Inspection/Repair Procedure.
A/C Condensation Leak Inspection/Repair Procedure

Start the engine and run vehicle with A/C on, in the recirculated air position, with the blower at high speed.
Inspect for condensation leaks coming from the evaporator case area.
If condensation leaks are present replace the evaporator case with Part Number 5S4Z-19B50-BB. Refer to Workshop Manual, Section 412-02.
NOTE: DO NOT REPLACE THE EVAPORATOR CASE IF A CONDENSATION LEAK CANNOT BE VERIFIED.



Water Leak Testing Procedure

Using a high pressure water hose or a pressure washer, run water onto the windshield being sure to direct water over the roof ditch moldings, and down onto the cowl (Figure 1).





Open the hood and direct water (from the side of the vehicle) into the base of the A-pillar in the hood hinge area (Figure 2).



Remove right front inner splash shield and direct water into the back of the right front wheel well area (Figure 3). Refer to Workshop Manual, Section 501-02.
Proceed to Water Leak Inspection/Repair Procedure.





Water leak Inspection/Repair Procedure

Inspect the following areas for visible signs of leaks and follow the appropriate repair steps.

Water is visible at Blower Motor Connector, Blower Motor Resistor, Blower Motor Mounting Flange, or Foot Air Duct:

NOTE: THE MOST LIKELY SOURCE OF THE LEAK IS THE FRESH AIR INTAKE. WATER ENTRY INTO THE AIR INLET HOUSING MAY BE VISIBLE BY LOOKING THROUGH THE RECIRCULATION DOOR AS IT IS OPEN AND CLOSED. TO DO THIS, REMOVE THE GLOVE BOX, TURN THE IGNITION KEY TO THE ON POSITION AND PUSH THE RECIRCULATION BUTTON.



Remove the cowl panel grille and inspect for gaps between the pollen filter housing gasket and sheet metal plenum (2000-2003 model years) or skips in the sealer around the pollen filter housing (2004-2005 model years).
If gaps are present inspect for bent plenum sheet metal flanges and repair as necessary.
Seal around the pollen filter housing perimeter using Clear Silicone Rubber (TA-32).
Water is Visible on Evaporator Case Seal at the Heater Core Inlet/Outlet:

Inspect for a mis-positioned evaporator case seal at the heater core inlet/outlet. Repair as necessary (Figure 4).





Inspect for loose evaporator case housing attachment nuts. Repair as necessary.
Water is Visible in the Right Kick Panel/A-Post Area

NOTE: IT MAY BE NECESSARY TO REMOVE THE INSTRUMENT PANEL TO FULLY ACCESS AND REPAIR SOME LEAK SOURCES. FOLLOW WORKSHOP MANUAL SECTION 501-12 IF INSTRUMENT PANEL REMOVAL IS NECESSARY.



Inspect for sealer skip behind roof ditch moldings. Fold the ditch molding back and inspect for a pinhole in the body seal just above the windshield. Reseal as necessary with Motorcraft Roof Ditch Sealer (TA-15) (Figure 5).




Inspect for wire harness body grommet loose or mis-positioned. Reposition or reinstall grommet as necessary (Figure 6).





Inspect for skip in windshield urethane. Reseal as necessary.
Inspect for sealer skip in A-post to cowl joint. Reseal as necessary (Figure 7).





Inspect for sealer skips between cowl top to bulkhead, just above main harness grommet (Figure 8).






PART NUMBER PART NAME
5S4Z-19850-BB A/C Evaporator Case
TA-32 Clear Silicone Rubber
TA-15 Motorcraft Roof Ditch Sealer
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Old 09-28-2007, 12:36 PM   #5
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Or this:
FORD: 2000-2003 FOCUS


ISSUE:
Some 2000-2003 Focus vehicles may exhibit water in the Climate Control Heater Blower Motor Case, which can be associated with an inoperable heater blower motor resistor, blower motor, or a blown blower motor fuse.

ACTION:
Inspect and seal the cowl area for water leaks when servicing a blower motor resistor, blower motor, or a blown blower motor fuse. Refer to the following Service Procedure.

SERVICE PROCEDURE

Perform Workshop Manual Section 412-00: Climate Control System - General Information, Diagnosis And Testing, Climate Control System, Blower Motor Inoperative Pinpoint Tests.
If the blower motor RESISTOR is determined to be inoperable, then replace the blower motor resistor and the blower motor assembly. Proceed to Step 2.
If the BLOWER MOTOR is determined to be inoperable or the blower motor fuse is blown, then replace the blower motor assembly. Proceed to Step 2.
Inspect for water leaks into the fresh air inlet.
For vehicles built before 01/02/2003, inspect for visible gaps between the windshield and the cowl grille (Figure 1). If gaps are present remove and replace the cowl grille, (1S4Z-5402228-CA) per Workshop Manual Section 501-02.
Remove cowl panel, inspect for gaps between pollen filter housing gasket and sheet metal plenum. If present, inspect for studs bent or off center. If off center, use a drill to slot the housing (Figure 2).
Inspect for bent plenum sheet metal flanges, repair as necessary.
Inspect Pollen Filter Housing gasket for damage. If damaged, replace Pollen filter housing (YS4Z-19N619-EA).
If no water leaks are found, then install a Pollen Filter (XS4Z-19N619-AA).

PART NUMBER PART NAME
YS4Z-19805-AB Blower Motor
YS4Z-18591-AA Blower Resistor
XS4Z-19N619-AA Pollen Filter
1S4Z-5402228-CA Cowl Grille
YS4Z-19N619-EA Pollen Filter Housing


OTHER APPLICABLE ARTICLES:
02-25-1

WARRANTY STATUS:
Information Only




Figure 1 - Article 03-18-2




Figure 2 - Article 03-18-2
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Old 09-28-2007, 12:37 PM   #6
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If you need the pics to go along with that, shoot me your email addres on a PM and ill send you the whole TSB
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Old 09-28-2007, 01:28 PM   #7
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^^Ummm, yeah.....what he said.....lol. Mine did the same thing but only once so I dunno. I might do that when I install the cabin filter.
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Old 09-28-2007, 02:47 PM   #8
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Quote:
Originally Posted by Mr.Bergner View Post
^^Ummm, yeah.....what he said.....lol. Mine did the same thing but only once so I dunno. I might do that when I install the cabin filter.
same here
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Old 09-28-2007, 02:59 PM   #9
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i had the same thing happen on my old '03 ZX3 as well. happened about 3 times. took it in to have it fixed and it didn't do it again. . .
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Old 09-29-2007, 07:02 PM   #10
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I have the same problem, one time I had almost an inch of water!
I siliconed the cowl on the windshield and it solved the problem.
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