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Water on driver's Side Flooded carpet

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  • [Corsa C] Water on driver's Side Flooded carpet

    I recently discovered that my 2002 Corsa C has a water leak into the interior cabin. The first sign was the front windscreen was fogging up and hard to remove since the car doesn't have air conditioning. Second clue I discovered was the carpet was soaking wet. I could press down the carpet and water would cover my hand, plus the foam insulation in the footwell is completely soaked too. I parked the car outside and my wife used the garden hose to wet window. I still could not see where the water was coming from but knew it was coming in on that side. I don't have a coolant leak and the passenger side is dry, but I double checked just to make sure. After doing some searching on the internet and this forum I have an idea that the leak might be coming from the brake booster or around the clutch master slave cylinder.
    Here is what I have done so far:
    Removed the drivers seat and some interior trim in order to peel back the carpet allowing it to dry.
    Checked the floor for holes and signs of rust, everything looks good.
    Removed the wipers and cover and wiper motor assembly.

    Removed the battery and battery tray, to check for holes under the battery. Not likely because I have no water on that side.
    Removed the cabin inlet filter housing to check the seal. This also makes it easy to clean.
    Removed the water bottle.
    Removed the brake booster.
    Inspected drain holes at the bottom.

    Removed the cover on the electrical to inspect for infiltration.
    I cleaned the entire area with soap and water. It looks like someone has tried to seal this before because there is a yellowish-white coating over everything and there is a sticky black putty around the brake booster and plate. I removed all of this a plan to reseal it after it has time to dry. I'm also going to clean and seal around the electrical box.

    I have a suspicion that the water is coming in around the clutch master slave cylinder so I'm going to save that for last. Here are a few photos of where I'm at now and I'll let you know what I find. And yes folks this is a left-hand drive.

  • #2
    You certainly seem to be doing a thorough inspection. The brake servo (booster) plate is the most common source I believe. And some folk still have leaks even after quite elaborate attempts at sealing it with various mastics and putty. I dont think daubing it on the outside works very well. Things have to be done properly by separating parts . (Even Opel got it wrong originally. )

    It would be great if you continue to take detailed photos of the work. If it stops the leak you could possibly make it into a tutorial. I dont know how different the plates and things are on left hand drive cars but it will still help , especially for the many who have left hand drive cars. (my own corsa D is left hand drive)


    • #3
      I just found out to seal the clutch cylinder I have to remove the steering column. I think I'll wait to do that and test what I have done so far. Thanks for the words of encouragement. I think the plates are just reversed stamped. I find that the cars are the same right hand or left hand.


      • #4
        Found out where the water was coming in!! Left hand drive car has a lever and a cable that opens the hood "bonnet". Water was coming in through the grommet and near the electrical entrance. Now I'm deciding whether to do a temp fix with sealant or take the dash completely apart, maybe the first.


        • #5
          Wow. You must really love this car , or enjoy doing the work. I can fully understand both.

          I too would be inclined to go the 'temp fix' sealant route , unless the area is structurally dangerous, or its necessary to pass the local technical inspection (MOT) But sealant may not bond very well to rusty, rough or dissimilar surfaces . You may find specialist automotive semi flexible seam sealant works best .or something more flexible might be better.

          Or a ' belt and braces' approach. See if there is also a way of preventing so much rainwater actually reaching the area at all, Such as diverting water that might flow down the firewall into some sort of drain pipe ,or diverted away. If water is pooling somewhere in the engine compartment a new drain away might help . Be careful not to block drainage or create a new water trap with sealant. .

          I have also heard that rather than 100 % seal it can sometimes be better to leave a small area unsealed at the bottom. That way any water that does seep through the sealing can escape more easily back into the engine compartment than it can into the car. I dont know. it might depend on design and capillary action. If one method doesnt work you could try the other. And the same could apply if you seal it both on the outside and inside the car . If water can get past one barrier but not the next it might increase rusting. Or this might be the best way. I dont know

          The adage " If a jobs worth doing its worth doing well " does have its limits. Unless you really believe the cars overall condition is so good it will eventually outlive most of the many other corsa c's and become a rare collectable classic with rising values. A harder call than with some other cars (such as an MX-5)