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2009 XC70 with mysterious leak

427 Views 3 Replies 2 Participants Last post by  zircular
Hey all, just bought my first Volvo wagon after many years of admiration. It's getting old, but I'm hopeful it has some good years still ahead of it. The car has 200k km (125k miles) and in many ways seems to be in great shape. It had a few issues that I knew about when I purchased it, and I'm working my way through them (bad wheel bearing, front flex pipe leak). One issue I didn't know about is that the car seems to have a leak.

We had a crazy rain storm that started the day I bought the car and lasted a couple of days. The next morning the headliner was wet near the windshield and the cabin light assembly had water dripping out of it. And, since then, it sounds like there is about a quart of water under the dash (or under the carpets way up front?) that sloshes back and forth when I go around corners.

My first thought was that it could be the sunroof drains, but I've poured water down them and the seem fine. I sent a blast of air from my compressor down for good measure. I suppose the rain could have overwhelmed the diameter of the tubes?

My second thought is a windshield leak, but the windshield itself has not been wet on the inside, and after another big rain last night there is water in the cabin light again but the headliner feels dry.

My third thought is that the water in dash (or floor) and the water in the headliner might be unrelated... and maybe I have an AC drain clog? I'm going to try hitting that with compressor later today.

I'm not in a great position time-wise or money-wise to chase this issue around the car forever. I'd love any advice from the group about this, including whether people feel it's worth trying some kind of sealant at the top of the windscreen (I'm hoping to avoid having to get it pulled and risking it getting broken in the process).

Thank you in advance! Like I said, I've always wanted one of these, and I'm hoping to slowly convert it to a low-intensity overlander/camping base camp over the next couple of years... provided it doesn't turn out to be riddled with these kids of small issues.

Cheers.
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Props to the recommendation engine on this forum. It pointed me to this post: Water in the map/roof lights... already replaced drain tubes

Which sounds similar to my issue. My driveway is sloped such that when I park nose-in (as I normally do) the front of the car is downhill. It's not super steep, but steep enough that if water gets past the sunroof seal, it should be flowing towards the front drains (again, could the flow be overwhelming them?)
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So, to close the loop for any future readers: the top of the windshield was the source of the leak. The glass installer showed me how he believes the top of the windshield was not properly installed at the factory. His guess was that the [catalyst? Primer? Activator?] was never applied at the top of the glass. On the sides and bottom, the seal "tore" away from the car leaving a ragged remnant on the car and the glass. On the top, the seal separated completely cleanly with ZERO stuck to the glass, and an almost polished upper surface (which would have been against the glass). Sadly the factory windshield broke on removal so this ended up being a $500 repair.
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