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Old 09-13-2005, 09:24 PM   #1
ST170FOCUSRS
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Join Date: Aug 2005
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Location: Port Saint Lucie, Fl
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Tsb Water leak!

Article No.02-25-1

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WATER LEAK AT FRONT PASSENGER FLOOR AREA-SERVICE TIPS



FORD: 2000-2003 FOCUS


ISSUE:
Some vehicles may exhibit a difficult to diagnose or difficult to repair water leak condition in the front passenger floor area. This may be caused by sealer skips, loose grommets, mis-positioned seals, etc.

ACTION:
Some common water leak locations and repair recommendations are listed below to help reduce repair time and increase repair effectiveness.

SERVICE PROCEDURE
Using a high-pressure water hose or a pressure washer, run water over the roof onto the windshield being sure to direct water over the roof ditch mouldings, and down onto the cowl (Figure 1). From the side of the car with the hood open, direct water into the base of the A-pillar in the hood hinge area (Figure 2). With the right inner fender splash shield removed, direct water into the back of the right front wheel well area (Figure 3).

After Water testing is complete, inspect the following areas for visible signs of leaks.

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.



If Water Is Visible At Blower Motor Connector, Blower Motor Resistor, Blower Motor Mounting Flange, Or Foot Air Duct:
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 opened or closed. To do this, remove the glove box, turn the ignition key to the on position and push the recirculation button.)

Inspect for the following:

Inspect for visible gaps between the windshield and the cowl grille (Figure 4). 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 5).
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 Water Is Visible On Evaporator Case Seal At The Heater Core Inlet/Outlet (Figure 6):
Inspect for a mis-positioned evaporator case seal at the heater core inlet/outlet. Repair as necessary.
Inspect for loose evaporator case housing nuts. Repair as necessary.
If Water Is Visible In The Right Kick Panel/A-Post Area:
Inspect for sealer skip behind windshield roof ditch mouldings. Fold the ditch moulding back and inspect for pinhole in the body seal just above the windshield. Reseal as necessary (Figure 7).
Inspect for wire harness body grommet loose or mis-positioned. Reposition or reinstall grommet as necessary (Figure 8).
Skip in windshield urethane. Reseal as necessary.
Inspect for sealer skip in A-post to cowl joint. Reseal as necessary (Figure 9).
Inspect for sealer skips between the cowl top to bulk head, just above the main harness grommet. (Figure 10).
Rerun water test after repairs, to verify all possible leak sources are sealed.



PART NUMBER PART NAME
YS4Z-19N619-EA Pollen Filter Housing
1S4Z-5402228-CA Cowl Grille
F7AZ-19554-CA Clear Silicone Rubber


OTHER APPLICABLE ARTICLES:
01-9-2, 02-15-6

SUPERSEDES:
01-9-2

WARRANTY STATUS:
INFORMATION ONLY

OASIS CODES:
110000, 111000
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NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by "do-it-yourselfers". Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle.


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