This is the same exact problem I'm having (I think) I bought my 06 HHR used in January (had 20K) miles on it. Loved the car, the first thing I noticed was the blower fan only ran on low or high nothing in between. The dealer fixed that, I noticed the floor matte was a little wet but wasn't sure if it was from snow (we havent had a lot of rain till now) I smelled a slightly musty smell and suspected it may be leaking in the passenger front. Last night we had a downpour and I opened the car, the passenger car mat was SOAKED. I didn't see any water leaking from the seams of door, looked like it was dripping from somewhere behind/under the glove compartment.
I had my husband get an appointment for the dealer and came on this forum to investigate. I hope they find and fix problem the first time. I love the car and after swearing by Fords for years, I was hoping my luck would hold out with the new Chevy. Will see what they say next week.

 

Here Blondie cut and paste the below into Word, notepad or whatever you use and print them out. These are the official GM Bulletins regarding your issue. Or just print the thread, but would take less paper and ink if you copy and paste them.

Subject: Passenger Floor Wet/Blower Motor Inoperative (Install New Cowl Air Inlet Butyl Patch) #07-08-57-001 - (01/24/2007)



Models: 2006-2007 Chevrolet HHR




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Condition
Some customers may comment about water leaking on the front passenger side floor of the vehicle or that the blower motor is inoperative.

Cause
This condition may be caused by a poor fitting butyl patch at the cowl air inlet.

Correction
Replace the cowl air inlet butyl patch.

Open the hood.
Remove the left and right wiper arms. Refer to SI if necessary.
Remove the four 7 mm screws and the two push-in retainers from each side of the grille panel.
Remove the five wire harness retainers from the grille panel.
Lift the panel up and place it on the engine.
IF THE PATCH IS IN PLACE AND SEALING PROPERLY, REFER TO BULLETIN NUMBER 05-01-38-016B.
Remove the butyl patch and clean the area with a 3M™ General Purpose Cleaner, or equivalent.
Install the sealing patch to the cowl opening and apply pressure to the outer edge of the patch.
Install the air inlet grille panel and tuck the weatherstrip into the side weatherstrip that runs down the fenders.
Install the four 7 mm screws and the two push-in retainers to each side of the grille panel.
Tighten
Tighten the four 7 mm bolts to 10 N·m (89 lb in).

Install the left and right wiper arms. Refer to SI if necessary.
Close the hood.


Subject: Water Leaking on Front Passenger Side Floor of Vehicle, Water Blowing Out of Vents (Seal Heater Core Cover) #05-01-38-016B - (08/16/2006)



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).


--------------------------------------------------------------------------------
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.

 

Thanks ^^ I copied and pasted in word.
I'm sure the dealer "should know" the hit list but I'll print it out anyway.

 

True they should, but it doesn't hurt to be well armed. I found that being well informed is better than being clueless. You would be surprised how much I find out from my customers when they come to see me at the dealer.

 

Nite31.....

I wish to be the first to commend you. You appear to be an excellent service tech.

And, I'm really a vocal guy in regard to the lack of current dealer technician abilities.

Thanks for posting the TSB, etc. Because AllData, which is providing some service, does not list all of them.

 

My husband and brother were both ASE certified state insp. mechanics in PA/DE awhile ago.
Don't worry, I go in fully armed! LOL.
The reason why some of the newer dealer techs are not as knowlegeable as few years ago, the dealers keep hiring new blood at lower rates and the older guys get squeezed out.
The flat rate system can be great or hell depending on if the shop is busy or stuck with warranty work. Feast or famine sometimes. That is why they both got out of auto biz.

 

Well Snoopy, you might be surprised, but I am not a tech, but thank you for the comment. I am an Assistant Service Manager, but most time do feel like a tech.

 

I have a small water problem and can’t find where it is coming from? I took it to the dealer they cleaned it a little and told me to bring it in next time it gets bad. Here is a photo of the damage after they cleaned it. Any ideas??

 

Oh yea this is on the passenger side door. I never use that door or open the windows.

 

You don't have roof rails or a sunroof so, just some thoughts.....

The water appears to be concentrated to the upper rear of the front passenger door. Since water "runs" downhill, I would look at the weather stripping BACK and assure it is positioned correctly and secure. I believe someone once had a leak problem with the roof and structure seal. Although I believe it was in the rear above the lift gate.

There are trouble shooting methods to locate these types of problems. Did your dealer employ any of these or did they just clean the material?