Bulletin No.: PI0096B
Date: Nov-2015

Subject:

Water Leak into Driver/Passenger Footwell or Within IP and/or Lower Dash Panel Insulators (Hush Panels)

Models:

2010-2012 Chevrolet Malibu

Attention:

This PI also applies to any of the above models that may be Export vehicles.

This PI has been revised to add the 2012 Model Year and update the Labor Operation to the Global Labor Code (GLC).
Please discard PI0096A.

Condition/Concern
Some customers may comment on finding wet carpet in the driver or passenger footwell area. Upon further inspection, a technician may note water spotting or
water accumulation within the IP structure and/or hush panel.

This condition may occur due to incomplete sealing within the roof to windshield header, A-pillar and/or B-pillar seams.

Recommendation/Instructions
Inspect the vehicle for accumulated water or water spotting in two common areas:

1

•

Remove the IP outer trim cover and inspect for water/spotting within the end opening on the IP (1).

•

Repositioning the front carpet, inspect for water/spotting between the carpet and the floorboard.

If evidence of water is found in either of these locations, inspect the affected side roof ditch for possible voids in the sealer at any of the following locations:

•

At the windshield header and between the roof panel to A-pillar seam

2

•

Between the roof panel to B-pillar seam

To inspect for, and correct this leak, complete the follow repair steps:
1.

Remove the roof ditch molding on the side affected. Refer to Roof Weld Joint Reveal Molding Replacement in SI.

2.

inspect for voids/gaps (1) in the seam sealer along the outboard edge of the roof ditch.

3.

Seal all gaps with *Kent Automotive High-Tech™ Clear Seam Sealer, P/N 10200 (5 oz tube), or equivalent. Avoid excess sealer build up within the ditch
while assuring any voids in the factory seal are filled.

4.

Also inspect the forward-most edge of the ditch, assuring any gaps in the factory sealer are filled. Inspect and seal all the way to and below the rubber
windshield lace (1).

3

5.

Allow the seam sealer to adequately set-up, then water test by placing a water hose mid-roof near the ditch, allowing water to run forward to the A-pillar.
Visually inspect for any water leaks along the inner roof and A-pillar areas.

6.

Replace the ditch molding and dry the interior of the vehicle as needed. Refer to Roof Weld Joint Reveal Molding Replacement in SI.

*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse,
indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other
sources.

Parts Information
Contact Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com.
Part Number

Description

P10200

Kent Automotive High-Tech™ Clear Seam
Sealer

25905615

Molding Asm – Rf Pnl Qtr Rvl (LH)

25905616

Molding Asm – Rf Pnl Qtr Rvl (RH)

Warranty Information
For vehicles repaired under warranty, use:
Labor
Operation

Description

Labor Time

1480588

Reseal Roof Ditch Molding Seam

0.8 hr

Add

To Reseal Other Side

0.5 hr

GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions that may
occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools,
safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that
your vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the information.

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