Well would you believe it, I FINALLY found my leak! Actually two leaks, I'd never bothered checking the driver foot-well because it wasn't causing me a problem, but it was wet there as well.
I started to suspect water coming in from under the car, even though I couldn't see anywhere it could come in when looking under the carpet. I decided to try and inspect the underside of the car and luckily a friend of mine knew the manager at a local Kwick-Fit centre who let me put it up on the lift for a few hours.
I removed the underside panel, which is held in place by a number of plastic 10mm nuts and a few 8mm bolts. Under the panel are LOADS of rubber drain bungs, I mean, there must be more than 10. 6 of them were along the sill and then various others in other positions.
Unfortunately, these rubber bungs can perish. There are four very big ones, about 30mm across, two at the back of the car (you can see these from under the carpet) and another two just at the front of the foot-well, which cannot be seen from inside the car and are much harder to see from underneath, even with the under-panels removed. These front two bungs are on the front edge of the foot-well and so they are under constant attack from road spray. In my case, the drive side bung was perished and spilt so that the centre part opened like a flap (see below), the passenger side bung was missing altogether, most likely it’d come out when I went through some standing water at speed once.
Enclosed is a picture of the hole and the split bung. Why it’s necessary to have quite so many places water can get in I have no idea, but there they are. With the front bungs out (or damaged) water from the road goes through the hole and collects in the foot-wells, eventually casing all manner of electrical malfunctions etc.
So, it seems there are many places water can get in, rubber bungs in the floor is definitely one more to add to the list
I started to suspect water coming in from under the car, even though I couldn't see anywhere it could come in when looking under the carpet. I decided to try and inspect the underside of the car and luckily a friend of mine knew the manager at a local Kwick-Fit centre who let me put it up on the lift for a few hours.
I removed the underside panel, which is held in place by a number of plastic 10mm nuts and a few 8mm bolts. Under the panel are LOADS of rubber drain bungs, I mean, there must be more than 10. 6 of them were along the sill and then various others in other positions.
Unfortunately, these rubber bungs can perish. There are four very big ones, about 30mm across, two at the back of the car (you can see these from under the carpet) and another two just at the front of the foot-well, which cannot be seen from inside the car and are much harder to see from underneath, even with the under-panels removed. These front two bungs are on the front edge of the foot-well and so they are under constant attack from road spray. In my case, the drive side bung was perished and spilt so that the centre part opened like a flap (see below), the passenger side bung was missing altogether, most likely it’d come out when I went through some standing water at speed once.
Enclosed is a picture of the hole and the split bung. Why it’s necessary to have quite so many places water can get in I have no idea, but there they are. With the front bungs out (or damaged) water from the road goes through the hole and collects in the foot-wells, eventually casing all manner of electrical malfunctions etc.
So, it seems there are many places water can get in, rubber bungs in the floor is definitely one more to add to the list