Evaporator Case/Cowl - Interior Water leaks

Article No.
01-9-2

05/14/01

^ WATER LEAK - WATER LEAK AT FRONT COWL
AREA AND/OR FROM EVAPORATOR CASE AREA

^ CLIMATE CONTROL - WATER LEAK FROM
EVAPORATOR CASE AREA AND/OR FRONT COWL AREA

FORD:
2000-2001 FOCUS

ISSUE
Some vehicles may exhibit a water leak at the cowl or evaporator case area. This may be caused by water leaking from around the cowl grille seal to the windshield, the inlet housing seal to sheet metal sheet or the evaporator case seal to the lower dash panel.

ACTION
Repair the leaks to the body or cowl area or replace the evaporator case assembly. Refer to the following Service Procedure for details.

SERVICE PROCEDURE

If an interior water leak at the front of the vehicle is verified, proceed as follows:

1. Dry Vehicle Interior:

a. Pull back carpet to expose floor pan in area of leak. Run heater at highest heat setting in recirc mode with the A/C off. Direct the air to the floor with the blower setting on 4 until water stops dripping out of the heater case. Then dry the floor pan and carpet padding with a towel.

2. Test A/C-Equipped Vehicles for Condensate Leaks:

a. Start vehicle and run A/C in fresh air mode (not recirc) for 30 minutes in a warm and humid location. A/C should be set on coldest setting in floor mode with blower setting on 4.

b. If no leaks are found, proceed to Step 3. (Check and Reseal Cowl).

c. If a leak is found, check A/C drain tube for obstructions. If an obstruction is found, clear the obstruction and return to Step 1 (Dry Vehicle Interior).

d. If vehicle is leaking condensate and no obstruction is found, replace the Evaporator Case (YS4Z-19850-EA) per appropriate model year Workshop Manual procedure, Section 412-02.

3. Check and Reseal Cowl:

a. Remove passenger side cowl grille per Workshop Manual, Section 501-02.





b. Check sheet metal tabs for cowl grille clips. Measure distances from top surface of windshield to surface of sheet metal at clip locations (Figure 1). If distance is less than 11 mm (7/16", bend tabs back to 11 mm (7/16").





c. Visually verify that the outboard baffle is not bent and is positioned as shown in Figure 2. If and inboard baffle is present per Figure 2, remove and discard.





d. Remove and replace Filter Housing (Y54Z-19N619-EA) (Figure 3) per Workshop Manual procedure, Section 412-01.

NOTE
IF CLIPS FOR COWL GRILLE ARE BROKEN OR DAMAGED, REPLACE COWL GRILLE.








e. Remove white clips from sheet metal tabs as seen in Figure 4 and snap onto pins on backside of cowl grille. Next, if butyl seal is present, remove it and clean the surface (Figure 5). Replace the right side Cowl Grille (1S4Z-5402228-CA).





f. Reinstall cowl grille per Workshop Manual procedure, Section 501-02. Ensure the new cowl grille makes a good seal to the windshield glass (Figure 6).

4. Verify Repair:

Water test vehicle to verify the source of the leak has been repaired. If water appears to be coming from another source, discontinue this TSB and refer to the appropriate Workshop Manual.

Other potential root causes are windshield sealer skips, cowl sheet metal sealer skips or weld burn holes, dash panel electrical grommets, front floor grommets and front door sealing. Follow normal leak repair procedures for these sources.

PART NUMBER PART NAME

YS4Z-19850-EA Evaporator Case
YS4Z-19N619-EA Filter Housing - Fresh Air Inlet
184Z-5402228-CA Cowl Grille (RH)

OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 110000, 111000, 208999