I went out this morning to head to work and found that the floor on the passenger side of my HHR was soaked! The windows were up and the sunroof didn't have any moisture. Anyone heard of this?

 

Use the search function and type in BUTYL PATCH. You will find many threads on solving this issue.

 

Thanks! I'll be taking it to my Chevy dealer in the morning. I did notice the fan was not working earlier on the way to get dinner, but it started working again on the way back. I will tell them to take a look at that as well.

This is going to be its 3rd time in for warranty work since early January. Most people would have a problem with that, but it is okay to me since I'd rather have everything fixed before the warranty is up, and since they put me in a car so I don't have to worry about transportation I pretty much figure that stuff simply happens.

 

That BUTYL PATCH is above the fan motor, at the base of the windshield,
so fan motor musta dried out a bit when it began working again..

Check the cabin air filter, it is likely soaked/wet also..(in the glove box)..

I agree, Warranty is a wonderful thing..

 

Yep, the Chevrolet dealer will have it until Tuesday is what the service writer said.

 

They fixed the same problem on our 06 about three years ago. From the paperwork: installed cowl inlet deflector patch 19 W94, replaced the deflector (25785783) and the cabin filter (52493319). This was done as per bulletin 07-08-57-001B. I'm not sure if that was a recall or just a TSB as we were still under warranty at the time.

 

I had the same problem on mine. The patch was bad. My 2006 was out of the original warranty and I was told my extended warraty would not cover the repair. The part is roughly $10.00 and took me about a half an hour using help from this forum. The dealership wanted $300.00 for the repair. Water leak has most likely caused your heater motor problems and like mentioned earlier your cabin filter has probably gotten wet. Both the motor and filter are directly below the patch. Pretty easy repair

 

I got it back with the repairs performed per the TSB, a new cabin air filter, and new blower motor too.

 

I read about these and cant help but wonder how the patch moves in the first place or does it deteriorate and leak.

 

Don- maybe deteriorate...IDK ?

GM did do away with this "patch" for the '08 model year & later..