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Discussion Starter #1
Haha, as funny as this sounds, its true. I took delivery of my brand new 09 LS yesterday from Criswell Chevrolet. It was raining like hell in the DC area but I went to pick up my girl and show her my new car anyways. As we were driving along, she casually pointed out to me that her legs were getting wet. When I looked down I noticed water coming out from under the dash!

Oddly, it would only do this when driving up hill, and it was just a little stream of water. After stopping to investigate, it appears it is coming out from a small hole in the housing of the blower motor behind the glove box. I had to drive from DC to Norfolk, VA in the rain last night, and this morning discovered that the towel I placed in the passenger footwell was soaked. Anyone ever heard of anything like this? Im gonna call the dealer back and schedule her for a warranty repair.
 

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hmm thats interesting. sometimes i hear water moving around after i start the car but i never had any leaks. maybe there is a hole in the fluid line from the AC? idk what its called.
 

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Discussion Starter #4
Something in the AC is quickly becoming my theory as well. My buddy and I went to the movies tonight (Terminator Salvation... not too shabby) and it pee'd on him to. And it was not raining out tonight. On the blower motor cover there is a bolt closer to the passenger and what looks like a small hole next to it. Its not a crack or anything, its a small round hole that was drilled or cast in, looks like it was meant to be there. That appears to be the source of the water. I just don't know if I should plug it... seems like a bad idea with the blower motor there. Maybe there's somewhere else in the system that needs to be plugged? Any other ideas?
 

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sorry bro i have no idea. i really really hope this doesnt happen to me though.
 

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Discussion Starter #6
Well, I may have already found a solution. Did some more focused research online, and came up with a TSB #05-01-38-016B. Seems like this isn't unheard of in the Cobalts, as well as a few other Chevys. From what I gather (and it's hard to find the TSB's spelled out, most sites want to charge you), you need to flush the AC drain line which is located somewhere on the passengers side of the firewall. From what I could gather, its hard to see from the top. Additionally, there is some gasket, somewhere in the system that may need to be replaced. I couldn't find anymore information than this, but if anyone has this problem or questions about it, I'd suggest talking to your dealer. I'll let you know when I get this resolved.
 

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Take it to criswell, and ask them you just bought the car so it will be under warranty. its just water coming out and not coolant or anything right? if its coolant it must be coming from the heater core.

Also, what color is the balt since there is a chance I'll see you on the street sometime.
 

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Discussion Starter #9
Yeah, I checked and its not coolant or anything. Like I mentioned, there is a TSB for this but it doesnt seem to be too common, at least not like the e-brake light and ignition switch issues.

Oh, the 'Balt is a Silver Ice Metallic coupe. Its a plain, base LS with no wing. You can tell it for the moment because my dad let me put his old silver/red/black Chevrolet Racing plate on the front till I get my real plates. It has graced such cars as his 1969 Z/28 Camaro with the full Can-Am spec race package, 1970-1/2 Z/28 Camaro, 1972 Corvette Sting Ray Convertible, and his 1996 Impala SS. :bigsmile:
 

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Discussion Starter #10
So this is totally out of the blue, but I got my 'Balt fixed... Finally. It took 3 trips to the dealer, but I ended up with essentially a whole new AC system. The first time they took the blower and everything under the dash apart and re-sealed it. It was fine for about a day, then it started to spray water out from under the dash AND fog was rolling out of my vents. People must have thought I was hotboxing my car while on the highway.

I took it back and they re-resealed everything and replaced the drain line thinking it might be plugged. They said they ran the car for a half hour and nothing happened. I get it back, drive it for an hour, and holy crap, it was like the dam burst. I had niagra falls under my dash. There was so much water it wasnt just coming out on the passenger side, it was backing up and spraying out on my feet too.

So back to the dealer it went, and they ended up replacing the whole AC system. New compressor, condenser, evaporator, and blower. Apparently there was something defective in the system and it was basically condensing too much and the evaporator wasnt working properly, so all the water had nowhere to go but out the emergency drain hole in the blower casing. At least its fixed and the car is running great now.
 

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With all that water in your floor and possibly on your seats you should make the dealer replace them as well because it will mold or possibly stain due to no fault of your own.
 

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I'm with these two^...they should have at the very least given you a full service interior detail and possibly looked into the carpets needing replacement if they can't clean it well enough.
 
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