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2003 Pontiac Bonneville Question: AC water drains to the int. passenger floor repeatedly & shorts electrical?

 

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dsjordahl, 3.8L V6, Moorhead, MN, June 05, 2014, 17:21
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We have had a continuous battle with water from the AC system draining to the interior passenger floor. What may be the best solution to clear this up?

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    June 05, 2014, 17:37
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    Has a professional mechanic ever checked it out?

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    dsjordahl, June 27, 2014, 15:35
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    Yes.

    My research so far finds problems with the cowling seal just below the front windshield that closes off the HVAC system. I've just found out the original GM cowling is not available. Another issue I have found in my research is a diversion piece is required that sits under the front windshield's gasket & the HVAC access opening thru the cowling.

    In photos I've found online showing the second issue & how to solve it, I note the cowling is flashed under the front windwhield's lower gasket. My cowling has a rubber strip (broken) that sits above the window's gasket on top of the lower windshield. I'm not sure how this discrepancy fits into the whole issue, but if the rubber strip is broken as ours is, rain filters under the cowling & into the HVAC system instead of being drained out to each side of the car & then down & out.

    I believe my next step is to call a friend next week who owns a local auto body repair shop & discuss the whole issue & availability of replacing the cowling & how it flashes out.

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  • Answer #2

    December 13, 2014, 06:18
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    Had the same problem, fixed now. The process is documented on my thread here:
    http://www.pontiacbonnevilleclub.com/forum/2000-2005-other-than-gxp/topic38953.html

    It turns out GM designed an AC drain tube that goes right through the firewall and into the interior passenger floor. Someone might know why. You can see photos halfway down the page here -
    http://www.pontiacbonnevilleclub.com/forum/2000-2005-other-than-gxp/topic38953.html
    Meineke got at my tube from under the car on a lift, cheap fix.

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