Windows - Windshield/Cowl Water Leaks

91honda02

Model 90-91 ACCORD

Applicable To ALL


File Under BODY

Bulletin No. 90-020

Issue Date MAY 17, 1991





Accord Windshield/Cowl Water Leaks (Supersedes 90-020, dated July 20, 1990)


PROBLEM Water leaks into the cowl and onto the floor in the area behind the right or left side of the dashboard. This may happen while the car is parked or being driven.

PROBABLE CAUSE Incomplete sealing around windshield locating blocks, or not enough sealer on frame panel seams in the cowl area.

DIAGNOSIS First check the windshield; if it's OK, check the seams in the cowl.

Windshield leak check

1. Open the hood and remove both wiper arms (2 cap nuts).

2. Remove the cowl cover (7 caps and screws, 6 expansion clips).

3. Pour a solution of liquid dishwashing soap and water along the base of the windshield.

4. From inside the car, blow compressed air along the base of the windshield and watch for bubbles on the outside.
- If bubbles appear, go on to CORRECTIVE ACTION, on the next page.

- If no bubbles appear, go on to step 5.

Cowl leak check

5. Park the car in a wash area, then raise the front end about 12 inches.

WARNING Using an inadequate lack or an
Improper jacking procedure can cause the car to fall and you can be seriously injured.

Use a hydraulic or scissors jack of the proper weight capacity and insert safety stands to support the car.


6. Run a heavy stream of water along the lower edge of the windshield, then check inside the car for leaks under both ends of the dashboard:

- If water is leaking into the car on the left side, go on to CORRECTIVE ACTION.

- If water is leaking in on the right side, remove the glovebox. First remove the ECU, then remove the blower as follows:





Remove these nuts, then remove the ECU-and-cover with wires still attached and set it aside.











7. Remove the blower:

- Without A/C: Remove the heater (3 screws) and blower (3 nuts).

- With A/C: Remove the blower as follows.


8. Run more water on the windshield, then check for leaks again under the right end of the dashboard.


CORRECTIVE ACTION

If bubbles appeared when you checked the windshield, follow the steps under Repair Windshield Leak.

If you found leak(s) when you checked the dash, follow the steps under Repair Cowl Leak(s).





Repair Windshield Leak

1. Mark the section of windshield seal that's leaking, then rinse the soap off, and blow the area dry.

2. Seal the leak with 3M Window-Weld Resealer (3M part number # 08633), or equivalent.

Repair Cowl Leek(s) Seal any cowl leaks as noted in the following drawings (all cowl area drawings show the right side; the left side is a mirror image):


1. Remove the fender by removing the

- front bumper

- mud guard

- side sill panel

- front parking light

- inner fender liner

- seven bolts in the fender





2. Apply 3M Brushable Seam Sealer (3M part number # 08656) or equivalent to the external seams shown.











3. Apply sealant such as Auto Armor Outside Coating to the spot welds and seams inside the cowl.

NOTE: As an alternative, 3M Window-Weld Resealant (3M part number # 08633) can be applied through the top hole (not shown) by using a 3M Applicator Gun (3M part number # 8994), and a length of windshield washer hose. To help you see the seam you are sealing, use a flexible flashlight.





4. Insert a straight nozzle up the drain hole, and apply sealant while moving the nozzle up and down to cover all internal seams. Be sure the sealer does not plug up the drain hole, as this will cause the seam to leak.


5. Run water over the entire area again to make sure it's watertight.

6. Reinstall all parts you removed. If you removed the blower:

- tape its bulkhead-mounted band to the evaporator so it won't fall out of place as you reinstall the blower.

- after you've reinstalled the blower, turn the fan on HIGH and make sure no air is leaking from the blower housing.


WARRANTY CLAIM INFORMATION

In warranty: The normal warranty applies.

Out-of-warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Service Manager. You must request consideration, and get the DSM's decision, before starting work.


Operation numbers:

- Leak-check windshield, reseal as necessary: 831020

- Leak-check cowl seams, reseal as necessary: Right side - 812025

Flat rate times:

- Leak-check and reseal windshield: 1.0 hour

- Leak-check and reseal cowl seams: Right side - 3.1 hours

Failed Part:

For windshield leak: P/N 73111-SM4-A00 H/C 3246790

For cowl leak: P/N 74200-SM4-A00 H/C 3288024

Defect code: 060

Contention code: B99