ION L4-2.2L VIN F (2004)
Evaporator Case: Customer Interest
A/C - Water Leaks Onto Vehicle Floor
File in Section: 01 - HVAC
Bulletin No.: 03-01-38-020
Issue Date: November, 2003
Subject:
Air Conditioning (A/C) Condensation Leaking onto the Vehicle Floor During
Times of A/C Usage (Remove Foam Block Obstruction From Evaporator
Drain Hole)
Models Affected:
2003-2004 ION Vehicles with Air Conditioning (RPO C60) built prior to
VIN Breakpoint 4Z131776
Attention: Technician
Condition:
Some customers may comment on moisture leaking onto the floor of the vehicle when the A/C system is running.
Cause:
During assembly of the HVAC module, a foam block used to isolate the evaporator core from the HVAC module case may fall off and float over the top
of the drain causing blockage.
Correction:
Remove foam block from drain area and discard.
Service Procedure:
Important:
Prior to performing the following procedures, ensure that the heater core cover front of dash condensate drain is not obstructed.
Important:
The evaporator core is contained in its own compartment with its own unique drain hole (the drain hole is approximately 5 mm (0.20 inches) in
diameter). This drain hole allows condensation collected by the evaporator core to flow from the evaporator compartment down to the heater core
compartment at which time it exits the vehicle through the heater core cover front of dash condensate drain. The evaporator compartment drain hole
is located about 25.4 mm (1 inch) inside and down from where the access hole is being drilled.
Important:
Keep copies of the original template for future use.
1.
Locate the area of passenger side of HVAC module on the right side of the console.