Leak in Passenger Footwell

[HarryBock]

Hi, I've not long had my first Polo 9n. However I have one issue, this is that water is somehow getting into the front and rear passenger foot wells. The rear was a pond before I noticed .

We have had some heavy rain recently but the leak also occurs in normal amounts of rain. I believe I have found where the water is getting into the foot wells but cannot figure out why. I found the water seems to be seeping past a rubber bung which I would guess is to do the bonnet release for left hand drive models. There should be a picture of where I mean attached to this.
The problem is, I cant figure out how the water is getting into this section or why it builds up in there to the extent it is seeping past the rubber bung.

My initial thought after a lot of research into this was that the scuttle drains where blocked especially as when testing these did tend to take a while to drain away, however after cleaning these the best I can with the limited access I have it doesn't seem to have made any difference. the water drains form the scuttle quicker and out of the bottom of the car much better than before but water still seems to end up in the said hole.
The other thing I have tried is drilling a small hole next to the door hinge, behind the hole where the water is, to at least drain the water out of there before it can get into the cabin, but I haven't completed this as this section appears to be double skinned and if I drill through this internal centre layer, the water will end up in the sill which seems even worse to me.

I hope somebody can help because I'm completely out of ideas and am struggling to find anything else on the internet that helps me.

Also the car is a 2002 VW Polo 3dr with no sunroof.

Thanks,

Harry

[littlepolo]

That's a puzzle. The scuttle drain at the front works well normally. I'm wondering if there could be an obstruction diverting the flow. I had the black plastic scuttle cover off when I changed my wiper motor but cannot recall if there is good access to the drains. If you have not yet tried that it might be worth looking into.

[HarryBock]

It's possible there is some sort of obstruction but after pulling most of the muck out form around the drains I would expect there not be an obstruction.

After having the Scuttle cover off its not the best access but enough to use a bent fork and some wire to pull most of the muck and leaves out from around the drains.

The one thing I didn't try when i had it in bits is to poke a thin wire through the drain holes and see where it comes out at the bottom of the car that should definitely clear any muck from inside the drains. So I might try that later.

I'm planning on taking it to a local VW dealer later today or tomorrow if they are not open when I finish work and I'll see if they know anything.

Thanks again,

Harry

[littlepolo]

I guess you don't want to pour lots of water in to check the flow of the drains (aka watering can test) but it should be pouring out the bottom of the drain exits under the car. I can't imagine there would be a bung in the flow of the water down the drains (that would be poor design) but if there was and it was missing/damaged...

The only other thing I can think of is a Friday afternoon spot welding job leaving seams adrift. Are there any signs of longstanding corrosion?

[HarryBock]

I have been doing quite a few watering can tests but don't seem to be getting anywhere with them. I stuff tissues around the hole and stop pouring water when they get wet. When doing these tests water definitely pours out from underneath the car.

I can't be certain if there would be any bungs that are in the flow of water from the drains but like you say, it would be a bad design if their was. The only way I could think of to find this out is to dismantle the hole dashboard and plenum/scuttle assembly, and I don't really fancy that, especially as I haven't sourced a Haynes manual yet and need the car daily.

I'm not to sure about what you mean with the spot welding, what is there to weld? Especially as there are no major spots of corrosion/rust. The only place a have found rust is on the wings, right on the edge where the metal is thinnest and I wouldn't think that is anything to do with my leak.

[littlepolo]

I mean the quality of the welding when the car was built.

[HarryBock]

Maybe that could be it but I wouldn't know where to start. I can weld, but wouldn't have a clue on what seams need to be welded and what don't.

This morning at about half 7 I noticed that water was again standing behind the hole. And I'm sure it didn't rain in the night. The only thing that would produce moisture is the dew but surely it wouldn't produce enough to fill the hole to the point of overflowing. (this is without the bung in place).

[lwi004]

Do you have a sunroof?

If so check the 4 sunroof drain holes and make sure they are GENUINELY going outside, If they're blocked, it will flood inside the car. If you're lucky they're just blocked but worse still if they come disconnected from the nipples which connect the pipes to the outside world and are attached to the body. PIA of a job.

I ended up extending my hoses to make sure they can't fall back inside.

[HarryBock]

Hi, the car does not have a sunroof, so cannot be the sunroof drains.
I did have it at the local "VW specialist" garage and they couldn't come up with anything and suggested that the only way that water could get into the section it is doing is through the windscreen seals so today I am having a new screen fitted.

I will keep you all informed on the outcome.

Thanks again for all of your suggestions

[HarryBock]

Hi again,

After having the windscreen replaced the car is still leaking.
I now know for definite that the water is not coming form the windscreen seals or any of the drains under the scuttle.
Therefore I am still open to any ideas you may have as I am at a complete loss as to how the water is getting where it is.

Thanks again,

Harry

[chevmat08]

Hi does it ever leak if left sat? Or is it leaking after a drive? Is there any water behind the dash i.e. is it only the bottom of the carpet wet, or does it leak through anywhere else


Is it 100% coming from the bung?

[HarryBock]

Hi,

The car will leak when it is sat or moving. There is no water behind the dash, only the bottom of the carpet gets wet.

Water does not seem get into the car elsewhere and I have proved this by stuffing a tissue in the hole and using it to direct water into a bowl. The bowl will contain the water and nothing gets wet inside the car. So that bung hole is the only place water is getting into the car.

Thank you,

Harry

[chevmat08]

It's figuring out what's feeding that bung hole (heh heh). I know 9n's are known for s**t door rubbers so perhaps it isn't leaking from the front but rather the side. It's hard obviously to see where the water is filling from. Anyone got any idea what else may allow water through that pillar?

[HarryBock]

Your right, the problem is finding what feeds the bung hole.
It is entirely possible the water is coming from the side, I wouldn't say the door seals but maybe somewhere behind the wing. I'm pretty certain that section is doubled skinned though.

And to repeat was has been said, has anybody else got any sort of idea what else may allow water into that pillar.

Thanks again,

[chevmat08]

Just found this link, maybe of some use?