Passat (B5) :: Front Passenger Compartment Water Leak Every Time It Rains
Apr 18, 2012
My VW mechanic and I have been working on and off over the past year to try and determine why my front passenger compartment gets flooded with water every time it rains. I've done some research determined it's not my sunroof drains (already clipped long ago) and it's nothing inside my engine bay (battery tray, underneath master cylinder). Those drains are clear.
Last night, we had another soaker and my front passenger compartment was more flooded than I've ever seen it. It looked like somebody dumped an entire bottle of water in there. However, this morning I noticed something different. I noticed a few drops of water leading down from just beneath the door speaker and into the front passenger carpet. I've circled on the following photo where I saw the drops of water:
When I opened the front passenger door, some water had built up and splashed out. I showed my mechanic this and he looked at my door. He used a screwdriver and started poking around up inside the drainage holes. 3-4 tiny pieces of broken glass fell out. My car had been broken into in 2009 and I had my front passenger door window replaced. These were the remnants of the old broken windshield. He kept poking around and knocking the door to try to get any other loose impediments out. Not much more than those 3-4 tiny pieces came out, though.
He suspected the door was filling up with water and overflowing into my car. I'm not sure if those few pieces could have caused that much water to back up. So I'm posting here to make sure I've covered all my bases. Could it possibly be anything else? We've checked the rest of the car out again in the usual suspect places (under the hood, beneath the car) and couldn't find anything. This leak is mind-boggling.
Additional reference images below .....
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The picture below shows underneath the passenger dash the two locations where I've seen leakage:
The test setup:
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