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DIY: Fixing The Passenger Side Cowl Leak On A 90-93 Integra

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  • DIY: Fixing The Passenger Side Cowl Leak On A 90-93 Integra

    The common is a very very common problem on 90-93 Integras. The issue is that after 17yrs the seals are no longer in good enough shape to keep the water out and it ends up on your floor. This is after it goes through your blower motor and rusts it out.

    Before even starting, go to a Honda or Acura dealership and order 8 of the follow part number, 91608-SJ6-003. They are super cheap ($2.50 each, a buck something at cost).

    To do this you'll need basic hand tools, 14mm socket, flat head and #2 phillips screw drivers, panel poppers and needle nose pillars. You will also need a pair of scissors.

    I didn't take pictures of removing the wiper cowl but I will describe it the best I can.
    Step 1: First use the 14mm socket to remove the wiper arms.

    Step 2:Then use the flat head to pop up the little black circle covers and unscrew the clips around the white pegs. You have to unscrew them by hand, you can use the flat head but you may break one so be careful.

    Step 3: Now pull the plastic push pins from the cowl seal (they are under the seal). Use the needle nose pillars to squeeze the bottom and the panel popper to pop them out. Now you can remove the seal.

    Step 4: Remove the wiper cowl, be very very careful to not break the cowl. Especially were it goes around the hood hinges.

    Step 5: You will now see the cabin intake cowl, there are 8 plastic trim screws on the top and 2 on the side. Use the Phillips screw driver to remove them. They can be a bit of a bitch. The panel popped helps to get them out.

    Step 6: Now you can see the problem, the 8 black trim screw along the top have those seals you order. After 17yrs they are shot! So it's time to replace them. Pull them out by hand.


    Look how old and worn these things are.


    Step 7: Pop the new seals in.


    Step 8: Re-assemble? No no yet. Look at the cabin intake cowl, look at the bottom. I bet yours will look similar to mine.

    How am I going to fix this? one might think. Fear not, it's a simple fix. Go to any hardware store and buy foam tape (commonly used for sealing windows but also works in making a seal here. The stock seal is just foam too. Also, they make GREAT tail light seals and are much cheaper then the $20 per from the dealer).


    Step 9: Pull the old seal off and wash all the dirt and grim off the cowl. Now pull the backing off the foam tape and put it on just like the old factory seal.


    No need to cut the foam tape either, it does corners like a champ.



    Step 10: Assembly is the reverse of removal. Stand back and be happy that your windshield cowl will no longer leak.


    Hope this helps some people!!

  • DawsonB17A
    replied
    Garage isn't exceptionally hot I don't think? It only has some natural ventilation, and I do live in NC so it gets pretty damn hot in the summer.

    I'll post up photos when I replace the parts. Probably won't be this week. I thought the blower fan motor was burnt out, but oddly enough it worked for like 5 seconds this past weekend. Though all 4 speeds weren't available so I think the speed resistor is burnt out as well. Just ordered a replacement, so not doing this work until it arrives.

    Leave a comment:


  • escudogt2
    replied
    I had this problem before , heavy rain one night . the floor was soaked . I replaced the little white inserts everybody was talking about, but leaked again. I finally covered up the giant hole on top of the blower motor. Has never leaked again in over 13 years. Only draw back is I don't get the fresh air , when I have the fan running. Hope this helps

    Leave a comment:


  • Colin
    replied
    That does seem really strange. Post up some pics of what they look like. I can't imagine them failing that quickly but who knows. Does it get REALLY hot inside the garage?

    Leave a comment:


  • DawsonB17A
    replied
    I've got a big water leak again, and it burnt out the blower motor about a month ago. Over this past weekend I took things apart to find the culprit, and it would appear that all the clear rubber pieces had worn out again and cracked (allowing water to pass). This is particularly frustrating, since those parts are only 2 1/2 years old (and the car spent 6 months in my garage unused this past year). So roughly 2 years of being exposed to the elements and these parts failed again?

    WTF?!?

    Leave a comment:


  • DawsonB17A
    replied
    Hope you stay leak free!

    Leave a comment:


  • GSG2Teg
    replied
    I'm in the same boat. Blower motor finally went out and my floor is soaked. I had installed just the clear gaskets a couple years ago and it was fixed but not anymore. Took the two panels below the windshield off, took off the "third" plastic piece surrounding the vent and installed a new gasket in it, got all new plastic clips (picked up some extra as well), and also picked up some really thin plastic cutting boards. I cut a sheet of cutting board to fit over top of that vent surround and then drilled matching holes in each and clipped it down with the extra clips. Since it didn't line up perfectly I lined up the "bubbles" of the cutting board to match the corners in the front. It looked like there was a channel on one side anyway, I was thinking more airflow since I'm blocking most of it. I then installed the modified vent cover/surround, and installed new clips to hold it down. It's been on there for almost a week without any replacement of the gaskets, plastic covers, or the passenger side wiper above it and I haven't had any water issues yet. I haven't installed any covers since I'm in line for a new windshield.

    Leave a comment:


  • DawsonB17A
    replied
    So it turns out this method DID work, but when I reinstalled the smaller plastic panel piece the foam seal got moved inward somehow, creating a gap through which water could flow. I diagnosed this by removing the lower dash assembly and fan blower assembly, then positioned a garden hose to dump water onto the windshield cowl cover. After a few minutes it was easy to find the leak.

    So I disassembled everything at the base of the windshield again, repositioned the foam, and added a little insurance by Krazy gluing the section that had previously moved. Reassembled everything and waited 24 hours to check for a leak - no leak!

    Then replaced the blower motor and put everything back together inside the car. 45 days later, and during a very wet Fall here in NC and no leak! Hooray!

    Leave a comment:


  • DawsonB17A
    replied
    Did the procedure described in this thread, and after 2 days of fairly steady rain (though garaged overnight) there's still a small leak in the passenger footwell, dripping from the same place as before. It's much improved, but still leaking.

    Dammit, on to plan B.

    Leave a comment:


  • DawsonB17A
    replied
    Originally posted by G2Again View Post
    It depends on the condition of your car/parts already on your car. For example, I ordered 5 or 6 of the 91608-SJ6-003 that were rotted or damaged on my car, but I only needed like 3 of the 91502-SK7-013. (Also that OP was not me...) Good luck!
    Thanks. In that case I might order 5-6 of the main parts and then 3-4 of everything else.

    Sidenote, does anyone know the part # for the entire windshield cowling piece? I need to have my replaced.

    Leave a comment:


  • G2Again
    replied
    Originally posted by DawsonB17A View Post
    G2Again, what is the required quantity of each part listed in the photo above? In your OP you said we need part # 91608-SJ6-003 in a quantity of 8. But what about the rest of these parts?
    It depends on the condition of your car/parts already on your car. For example, I ordered 5 or 6 of the 91608-SJ6-003 that were rotted or damaged on my car, but I only needed like 3 of the 91502-SK7-013. (Also that OP was not me...) Good luck!

    Leave a comment:


  • DawsonB17A
    replied
    G2Again, what is the required quantity of each part listed in the photo above? In your OP you said we need part # 91608-SJ6-003 in a quantity of 8. But what about the rest of these parts?

    Leave a comment:


  • DawsonB17A
    replied
    Bless you for this write-up, and for making it so easy to know which parts to buy. I definitely need to do this within the next month.

    Leave a comment:


  • G2Again
    replied
    I'll just leave this here... feel free to link to it as needed. Sorry for the lo-res image.

    Leave a comment:


  • dhettinger
    replied
    Thanks so much for the write-up! Here is SoCal it has only been a issue every now and then however we are soon going to be moving up to the Pacific North West and it would surly be a much greater problem at that time. So ya, thanks!

    Leave a comment:

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