Hi- Ive read of many leaks, my 2009 HHR, no sunroof- has been leaking in heavy rain since I got it in 2012. My first question, I opened up the cowl cover at bottom of windshield, and there was no butyl patch. Just read that the patch was stopped in 2007, so any one have a 2009 solution to this strange leak, seems like its the whole life of the car- on guy wrote in saying he was a service tech, and you just have to clean the leaves out, I did, still leaks. I wonder if you couldnt just silicone the whole thing that covers the cowl and windshield, the big plastic cover that the windshield arems come out of- I had a honda did similar games, old cars were better sealed.

 

Welcome to the site, 2009 didn't have the patch, check the wiring harness loom from the door to the door jamb. You might need to speak up the grommet with some silicon sealant

 

Thanks, Old Blue! Ill try that. Seems odd the leak is like the others described, where the butyl patch sat is a big hole , funneling down, you can see the cabin air filter, pretty dysfunctional design!

 

to the forums!! It could be the windshield itself.

 

Sealing the cowl is a waste of time and silicone.

You did not mention which side is wet.

Did you suspect the A/C drain? The A/C runs when the defrost is on.

Possible that the seal around the windshield has a break in it.

 

Thanks, Donbrew, and RJ RS, it has stopped raining, now going out to check doorjam wiring gasket. It was passenger side, sorry I didn't specify, as that was the thread. The door wiring bridge-gasket flex part is tight, and fresh, the water is in the front right facing front quadrant of the floor. The cabin air filter is dry, indicating a not dashboard leak source. Have no sunroof, at a quandary, do these cars just leak, no matter what you do? c I must wonder- does the plastic cowl return its shape, as it stretched out in the removal process, and the seal to windshield near the wiper has a 1/4" gap now.
Donbrew, I dont understand, the windshield leaking, it is factory, saw no gaps. The water only appears on serious rain, and last time it was parked nose downhill, so it did not come from below. However, driving thru puddles also got water on passenger side floor, I looked and in the fender, when door open, there is some kind of fiberous insulation that is soaking wet, seems like a bad design, maybe plastic fenders don't rust but mildew seems a real potential problem. Really like the HHR, but shocked at the sinking Blu Book value, seems DIY is the way to go for these repairs. Try for the water leaks, now, as Im allergic to mildew, so thats the priority! Then, the "under drivers side bump- activated "thunk" later. Or if thats only a sound, but not dangerous, something to tolerate? Thanks again for any clues to stay on the road!

 

A/C drain, do you use the defroster in rain? Have you thought to use the water hose test?

How about the door gasket/door adjustment?

The windshield is held in by black silicone caulk, it is possible to have leaks.

The door windows don't seal very good, water can get inside the door then inside the car.

If none of those then there must be magic at work.

 

Maybe rust pinholes in the floorboards? The AC drain is near the heater core, isn't it? So as to location that makes sense, but I would think it would leak all summer too.

I agree, spend some time with a water hose.

 

The A/C drain is my next suggestion to investigate if it is clogged with debris the water will spill over into the carpets