Body/Trim: Wet carpet all the fixes plus new ones

[binty]

I think I may have found a new source of a water leak that can wet the drivers (right hand side) carpet.
Firstly thanks to everyone who gas posted previously and given a load of good advice, could not have sorted it without you.
My problem on my 2006 model was the drivers carpet was wet underneath after winter. It had also brought on a load of fault codes. The suspect was a wet CEM.
To cut a long storey short, everything was dried out by me. The codes cleared by the main dealer and they checked everything and could find no faults with any electrical components.

In summary I had checked:-
CEM cover in the scuttle, it is the upgraded type but was re sealed with silicon just to be sure.
Flexible ducting checked and new cable ties fitted.
Steering shaft seal checked.
Door seals checked.
Aircon drain runs clear.
Bonnet release grommet checked.
A pilar cover removed and windscreen checked for leaks, all dry and it is the original windscreen.
Scuttle drains rains checked, cleaned and running free.
I do not have a sunroof.

Everything under the centre console was dry, and the car has never lost any coolant.
(the water was clean not coolant).

I ran the car with no carpets, through carwashes, rain and soaked with a hosepipe but it remained dry.

Everything was re fitted and the car has run great, being a bit OCD I do check under the carpet regularly to ensure all is good.

Three weeks ago, a drove for 2 hours on the motorway in a torrential downpour. When I checked the day after the carpet was again wet underneath, Not soaking like it had been previously, but the foam at the front inner corner wet, it had not spread to the rest of the foam.

To trace the problem I spent a good hour plying the car with water from a hose at full volume, (no nozzle just running from the pipe). I put the windscreen wipers on to replicate he conditions of driving and then commenced a full strip down to find where the water had gone.

Firstly I noticed that under heavy conditions water pools in the centre of the plastic scuttle. There is a small drain hole, bit it can overflow to the open grid.

I then found that directly under this area are the cables that go to the CEM. They run in an open plastic tray, not a sealed loom,and seems designed for water to run through the wires and then along the tray. The wires were soaking wet, and over the years debris had built up between them, so water did not run through, but ran along the wires.

Following the wires further along they were wet all the way into the ducting that goes to the CEM. There was also moisture inside the ducting. So whilst the ducting was sealed well, the water was running along inside it.

I considered giving everything a thorough clean out, but separating and tugging dozens of wires on a 10 year old car seemed risky, so opted to cover the open tray but still allow air flow from either end.

TIP, remove the wiper mechanism, very easy, 2 x 8mm bolts, slide out, disconnect multi plug.

I lifted the tray up, covered it with some 10mm (4 inch) builders damp proof course 760mm long and cable tied it in place.

Before refitting I replaced a broken white clip that holds the trim to the windscreen to ensure a good seal.

I also noticed a foam block was missing from the scuttle trim which sits under the corner of the windscreen. It seems to divert water away from the CEM cover.

Since refitting everything is dry, we have had a torrential downpour and driven in motorway rain.

Only time will tell if it is fully cured but I am hopeful. One to consider if you have tried everything else.

Loads of photos attached.

[gmonag]

I think picture 2 shows the problem. There should not be a hole there. Mine doesn't have one anyway (MY2005)

IMAG0710.jpg

[binty]

Thanks Greg,
That is interesting.
I have just had a look at my brothers XC90 (2010) and that also has the same hole where mine (2006) does.

Wonder if the design was changed at some time, perhaps to stop the water pooling in that area, but causing another issue

[gmonag]

I think we need a straw poll everyone -

Do you have a hole or not?

[gmonag]

Aw crap! There is a hole after all. It was just bunged up and camouflaged.

IMAG0712.jpg

So that's not the cause

[SwissXC90]

It pays to keep the water drains free of dirt and debris

On any car. Regardless of make and model