There is a drain you can clear from under the car that causes the car to flood on the passenger side when it clogs. Way up against the firewall on the passenger side. There's some pictures somewhere that show this.

 

That if the Ac or defrost was on.

 

That's the condensate drip.

 

Found the problem, lol. Wasn't expecting it to be torn so bad

 

Nasty looking!

A discussion about the patch

https://www.chevyhhr.net/forums/main...l-patch-58597/

 

It was repaired in the past. Most just cut a piece of sheet metal or plastic and RTV it on.

 

Your photo explains why the cowl wasn't fitting well.
I used aluminun tape to repair mine

 

Get a sheet of rubber at the hardware store, rtv'd it on. While I was at it, cleaned a handful or two of leaves and debris out the area under the patch. While I was at it, I checked my wiring loom boot, but it was tight and in good shape. Thanks all for the tips and links 🙂

 

That was a hack job they did prior. That's why it blew again.

 

BTW, the patch is needed on 2006 an very early 2007 models ONLY. If you have a later model don't do it.