Bulletin No.: 03-01-39-011B
Date: November 22, 2005
Water Leaks Into Passenger Compartment Through HVAC Module Condensate Drain Tube When Parked on Incline/Uphill Position (Install Auxiliary Drain Tube Extension)
2003-2006 Saturn ION Sedans and Coupes
This bulletin is being revised to include the 2005 and 2006 model years. Please discard Corporate Bulletin Number 03-01-39-011A (Section 01 - HVAC).
When vehicle is parked on an incline with the front end up during a rainstorm or when driving uphill during a rainstorm, water may leak into the passenger compartment through the condensate drain tube opening of the HVAC module.
Water may drain out of the cowl drain, then drain down the front of the dash panel in the engine compartment and seep into the HVAC module condensate drain tube opening. The water then collects in the heater core cover and upon acceleration may leak into the passenger compartment through the heater core cover seams.
Open the hood and locate the HVAC module condensate drain tube in the engine compartment on the right side of the dash panel.
During installation of the auxiliary drain tube, do not make contact with the HVAC module foam gasket located at the base of the HVAC module condensate drain tube. If the auxiliary drain tube is pushed on too far and makes contact with the foam gasket, water may leak into the passenger compartment.
Slide the auxiliary drain tube onto the HVAC module condensate drain tube and make sure that the auxiliary drain tube is angled downwards after installation.