Water leakage/passenger footwell

Hello,
Does anyone know if there is spesific Service Bullet from Ford how dealers should handle passenger footwell leakage problem. My 2 years old (European modell) Focus Ternd S 1.6i 5d has had this
problem from the very begining. Local dealer has so far made 4 attempts to fix this problem without success. After repair and careful drying it will take some time till the problem reoccur. First the apporach was to improve the sealing in ventilation channels and last attempt was to re-isolate passanger side mirror - didn't work. Most innoying part was that blame must be customers! E.g. parking position & angle was used as an excuse in the begining...
Does anyone have any success stories to solve this?
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On 10 May 2004 06:13:58 -0700, FocusTrend5D wrote:

The problem was solved at the second attempt on my Focus. The problem is the sealing around the pollen filter below the windscreen on the passenger's side.
--
MCC

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My daughter's 2002 Focus had the same problem, and the dealer had to call in a "Leak Specialist" that took the front cowl off, and probably sealed around the pllen filter like the above says, and the leak was gone! Had to take the car back, because the Specialist didn't do such a good job putting the cowl back. The dealer made it right.
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wrote:

So this sounds like uncompetent repair shop in my case. I have to check if there are "leak specialists" in the yellow pages :)
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Are you shore it's not a mini :)
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I'm quite sure but sometimes I hope it would be Mini instead...
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Had same problem, called my dealer and next day the booked me in a fixed the seal that was causing the problems. All covered by the warranty, no cost.
GL

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See Ford USA TSP below:
My local Ford dealer ignored that complicated procedure and simply inserted a piece of plastic sign material between the cowl cover and the air intake box (that holds the pollen filter). That solved the problem on both of my Foci. The plastic was cut slightly long so it folded in the middle, tent-like; air could get in on the sides, but water from above was stopped. This has held up for 3 1/2 years on my first Focus. I was a little ticked when I discovered what they had done, but I got over it because it worked. I suspect the dealer made a nice profit from Ford on this "repair".
03-18-02 a.. BODY - WATER LEAK - CLIMATE CONTROL - WATER IN HEATER BLOWER MOTOR CASE b.. ELECTRICAL - CLIMATE CONTROL - WATER IN HEATER BLOWER MOTOR CASE FORD: 2000-2003 FOCUS
ISSUE: Some vehicles may exhibit a difficult to diagnose or difficult to repair water leak condition in the front passenger floor area. This may be caused by sealer skips, loose grommets, mis-positioned seals, etc.
ACTION: Some common water leak locations and repair recommendations are listed below to help reduce repair time and increase repair effectiveness.
SERVICE PROCEDURE Using a high-pressure water hose or a pressure washer, run water over the roof onto the windshield being sure to direct water over the roof ditch mouldings, and down onto the cowl (Figure 1). From the side of the car with the hood open, direct water into the base of the A-pillar in the hood hinge area (Figure 2). With the right inner fender splash shield removed, direct water into the back of the right front wheel well area (Figure 3).
After Water testing is complete, inspect the following areas for visible signs of leaks.
NOTE: IT MAY BE NECESSARY TO REMOVE THE INSTRUMENT PANEL TO FULLY ACCESS AND REPAIR SOME LEAK SOURCES. FOLLOW WORKSHOP MANUAL SECTION 501-12 IF INSTRUMENT PANEL REMOVAL IS NECESSARY.
If Water Is Visible At Blower Motor Connector, Blower Motor Resistor, Blower Motor Mounting Flange, Or Foot Air Duct: The most likely source of the leak is the fresh air intake. (Water entry into the air inlet housing may be visible by looking through the recirculation door as it is opened or closed. To do this, remove the glove box, turn the ignition key to the on position and push the recirculation button.)
Inspect for the following:
1.. Inspect for visible gaps between the windshield and the cowl grille (Figure 4). If gaps are present remove and replace the cowl grille, (1S4Z-5402228-CA) per Workshop Manual Section 501-02. 2.. Remove cowl panel, inspect for gaps between pollen filter housing gasket and sheet metal plenum. If present, inspect for studs bent or off center. If off center, use a drill to slot the housing (Figure 5). 3.. Inspect for bent plenum sheet metal flanges - repair as necessary. 4.. Inspect Pollen Filter Housing gasket for damage. If damaged, replace Pollen filter housing (YS4Z-19N619-EA). If Water Is Visible On Evaporator Case Seal At The Heater Core Inlet/Outlet (Figure 6): 1.. Inspect for a mis-positioned evaporator case seal at the heater core inlet/outlet. Repair as necessary. 2.. Inspect for loose evaporator case housing nuts. Repair as necessary. If Water Is Visible In The Right Kick Panel/A-Post Area: 1.. Inspect for sealer skip behind windshield roof ditch mouldings. Fold the ditch moulding back and inspect for pinhole in the body seal just above the windshield. Reseal as necessary (Figure 7). 2.. Inspect for wire harness body grommet loose or mis-positioned. Reposition or reinstall grommet as necessary (Figure 8). 3.. Skip in windshield urethane. Reseal as necessary. 4.. Inspect for sealer skip in A-post to cowl joint. Reseal as necessary (Figure 9). 5.. Inspect for sealer skips between the cowl top to bulk head, just above the main harness grommet. (Figure 10). Rerun water test after repairs, to verify all possible leak sources are sealed.
PART NUMBER PART NAME YS4Z-19N619-EA Pollen Filter Housing 1S4Z-5402228-CA Cowl Grille F7AZ-19554-CA Clear Silicone Rubber
OTHER APPLICABLE ARTICLES: 01-9-2, 02-15-6
SUPERSEDES: 01-9-2
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 110000, 111000

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Thanks Gary,
Since local repair shop hasn't been too co-operative I think I can support them by sharing your inputs with them. I do hope that someone can read english there :)
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