TSB's

Floorboard flood

Some owners of 2008-2010 Chevy Cobalt, 2008-2011 Chevy HHR, 2008-2012 Chevy Malibu, 2008-2009 Pontiac G6, 2008-2010 Pontiac G5 and 2008-2009 Saturn AURA vehicles may complain about a passenger-side wet floor carpet (front and rear). The condition may involve a plugged HVAC evaporator drain. In some cases, water from the HVAC system will drain back through the front of the dash.

Inspect the drain operation. Make sure that the drain is not plugged with small debris.

Reposition the heat shield in order to gain access to the HVAC drain (Note: repositioning the shield is not necessary on Cobalt and HRR vehicles).

Remove the white plug and verify that there is no debris in the drain tube and/or plug. If debris is found, pull debris from the drain tube. Do NOT force debris back into the evaporator case.

Mask off area 1 and 2 shown in the accompanying illustration (see blue masking tape) using high quality automotive masking tape.

Apply high tech seam sealer (Kent Industries P/N P10200 or equivalent) to the front of the dash area, around the base of the drain tube.

Remove the masking tape and reposition the heat shield to its normal position.

Lower the vehicle and run the engine with the A/C on and inspect to verify that the system is draining properly.

Remove the white plug from the drain tube and check for debris.
<p><strong>Remove the white plug from the drain tube and check for debris.</strong></p>

Mask off the end of the tube and the shield area.
<p>Mask off the end of the tube and the shield area.</p>
Apply seam sealer around the base of the tube.
<p>Apply seam sealer around the base of the tube.</p>

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