Me too. Only had the car about 2 weeks so we just had our first hard rain. Take to the dealer and they can't find anything wrong. Said that they soaked the car with the garden hose and nothing. So I go home an turn the hose on it and my passenger floor board fills with water. I'm getting it both ways

 

#05-01-38-016B: Water Leaking on Front Passenger Side Floor of Vehicle, Water Blowing Out of Vents (Seal Heater Core Cover) - (Aug 16, 2006)


Subject: Water Leaking on Front Passenger Side Floor of Vehicle, Water Blowing Out of Vents (Seal Heater Core Cover)


Models: 2005-2006 Chevrolet Cobalt

2006 Chevrolet HHR

2005-2006 Pontiac Pursuit (Canada Only)




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This bulletin is being revised to provide the part number of the screw that is required for the Cobalt and Pursuit models. Please discard Corporate Bulletin Number 05-01-38-016A (Section 01 -- HVAC).


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Built Prior to the Following VIN Breakpoints: Model
VIN Breakpoint

Cobalt/Pursuit
67661747

HHR
6S551004

Condition
Some customers may comment on water leaking on the front passenger side floor of the vehicle. This leak would occur under high ambient temperatures and high humidity situations when the customer has the air conditioning on high. Leaks will appear to be coming from the HVAC module where the heater core cover and lower case come together. Also, some customers may comment on water droplets blowing out of the vents when the A/C is on high.

Cause
This condition may be due to water condensing in the HVAC case that adheres to the upper surface in the tongue and groove area of the lower case and then leaking out.

Correction
Install the foam gasket between the heater core cover and the lower HVAC case at the location of the leak using the procedure listed below.

•Remove the right side insulator/closeout panel retainers and the panel, if equipped.




•Remove the 5 screws (1) (HHR) or break the 4 welds (2) (Cobalt/Pursuit) from the heater core cover at the specified locations.




•Carefully pry apart the heater core cover and the lower HVAC case to achieve a 12.7 mm (0.5 in) gap.







•Install the foam gasket, P/N 15878211, using a flat rigid tool (feeler gauge shown) into the sump area (1) of the heater core cover.
•Reassemble the case using the 5 screws that were removed (HHR) or with new screws (Cobalt/Pursuit), P/N 11609829. For Cobalt/Pursuit, add an additional screw (2) at rear of sump area.
•Install the right side insulator/closeout panel and retainers, if equipped.
Parts Information
Part Number
Description
Qty

15878211
Gasket, Heater & A/C Evaporator Module Drain Tube
1

11609829 (Cobalt/Pursuit Only)
Screw
5

Warranty Information
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

D9714*
HVAC Case -- Reseal
0.5 hr

*This is a unique labor operation number for bulletin use only. This number will not be published in the Labor Time Guide.

GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the information.

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I had a lake in my pass side,I found the leak colin from the twonpieces O plastic that are solderedtogether,I put some blac caulk on it and it minimized the prob to jus a dampsopt after a few hr I use and minimized the water on my dash but water stil does condensate,I'm gonna take it in for repAir once I quit bein lazy if it's not covered I'll use more caulking

 

I had the same problem with my 05 4dr. The fix per TSB was about $75.00. However when they did it they made it worse, alot worse. The fix was to remove the dash and install a gasget in the whole A/C unit. There is no gasket from the factory, just pressed and glued. That cost was $850+. GM did not cover anything. I did get a $500 voucher toward the purchase of a new GM car.

Good luck, it's not cheap.