Vista Cruiser
Dedicated Enthusiast
Posts: 5514
Loc: Erie Canal
Reg: 10-01-99
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04-21-11 06:07 PM - Post#2080059
HHR owners, if your HHR is'nt leaking now,....it will be. The cover for the HVAC air intake is a rubber patch with a byutal bead. It's under the wiper/cowl trim. Four 7mm screws, 15mm wiper nuts, a few wire loom reatiners, and two small push plugs in the corners and it's off.
Re-seal the rubber patch, maybe get a new HVAC air filter while your there, and seal it tight with high quality seam sealer or urethane. Seal it to the bottom (slightly under) the bottom of the glass. The foam under the carpet will hold probably up to a half gallon of water before it's really noticed. There is a drain hole in the front of the rubber patch by a screw hole.....leave that open. This is very similar to the issue that 2000-2005 Impalas have.
Also, with the hood open, you'll see a one inch hole in the top of the fender, that is also punched throuh the upper frame rail. Tape it shut. And while you have the sealer in your hand, seal the pinch weld flange just to the inside of the hood hinge.
These are notorious leakers, and these are the most common problems. There are a ton more secondary players, but this should prevent 90% of potential leaks.
The HHR's really drive me crazy. My stomach drops if i know one is coming in for a leak. There is a bulletin for them to rmove the dash and re-seal the entire cowl. Pays 7.5 hours. I've yet to do this. But an HHR is the only one to ever beat me, and probably needed this done.......but i built a gutter and drained it through the rocker.  Made it look like it was from mother GM too. 
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spoiled
Contributor
Posts: 106
Loc: New York
Reg: 01-16-09
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05-30-11 05:55 PM - Post#2097204
In response to Vista Cruiser
Thank You!
My wife and I just bought a 2009 HHR with 31,000 miles on it. I haven't seen any leaking yet even with the record breaking rain this month. Your thoughtful advice will help me to keep it dry.
I have enough water woes to last me for quite a while and I don't want any more.I am currently replacing the seam sealer around the roof of my '64 Bel Air wagon due to leaking. The wagon is staying close to the garage for now. My pick-up truck is leaking also, some well placed tape is holding the water to a minimum until the wagon is done.
Would you happen to know where I can get a good price on a drivers door seal for the HHR? No luck on E-Bay so far.
Thanks again!!! David. 
Edited by spoiled on 05-30-11 05:56 PM. Reason for edit: No reason given.
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57ORG
Senior Member
Posts: 625
Loc: Brookfield,Illinois
Reg: 12-24-02
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05-31-13 06:11 AM - Post#2350623
In response to Vista Cruiser
What year HHR are these known for leaking? I have an 08 and lately got a lake on my inside driver side with all the rain we having here in IL. Friend has an 06 should he be worried it may leak too?
Tim
1957 Belair 4 door 38,000 actual miles on it.
1977 Firebird Formula 400 4speed
1989 Firebird Formula (sons car) 350 Holley Stealth ram
1990 GMC Jimmy 350 350 trans 6" lift on 35s
2006 HD Softail
2013 Sonic
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JackieB
Contributor
Posts: 270
Loc: Louisville KY
Reg: 08-13-10
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05-31-13 02:50 PM - Post#2350755
In response to 57ORG
I have not noticed any leaks in my 07. It took a jolt right in the cowl area on the right side, but you never know about these unibodies. My son in law hit a deer on the left front of his Sonata and his door opened up easy, but the passenger door could not be pried open. JB
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models916
Valued Contributor
Posts: 4776
Age: 67
Loc: Addison, IL
Reg: 05-28-10
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06-04-13 06:10 AM - Post#2351795
In response to JackieB
All HHRs have the problem. Remove the wiper cowl and reseal the cover over the cabin filter. That's it. Just a bead of sealer. If it leaks too much it will burn out the heater motor and rot the floor. Factory used butyl rubber for the seal so you could easily remove the cover and change the cabin filter, but the seal comes loose and leaks water into the cabin right on to the fan motor.
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57ORG
Senior Member
Posts: 625
Loc: Brookfield,Illinois
Reg: 12-24-02
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06-09-13 01:00 PM - Post#2353512
In response to models916
Ok finally got weekend off to work on the dreaded water leak I am having. Well behold the butyl patch was not there? Not sure how come, maybe not put on from the factory? Any suggestion where to get one?
Here link below of pics on how to get to the seal.
Link: http://www.chevyhhr.net/forums/showthread.php?t=14...
Tim
1957 Belair 4 door 38,000 actual miles on it.
1977 Firebird Formula 400 4speed
1989 Firebird Formula (sons car) 350 Holley Stealth ram
1990 GMC Jimmy 350 350 trans 6" lift on 35s
2006 HD Softail
2013 Sonic
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Edited by 57ORG on 06-09-13 01:02 PM. Reason for edit: No reason given.
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models916
Valued Contributor
Posts: 4776
Age: 67
Loc: Addison, IL
Reg: 05-28-10
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06-10-13 06:44 AM - Post#2353762
In response to 57ORG
It's just a piece of flexible plastic sealed with butyl rubber. Get something from Ace Hardware and silicone it down. Change the cabin filter while you are there.
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57ORG
Senior Member
Posts: 625
Loc: Brookfield,Illinois
Reg: 12-24-02
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06-10-13 09:55 AM - Post#2353811
In response to models916
Ok cool I work at Ace part-time  I will see what they have and also get the sealant while I’m there too. Guess got lucky didn’t flood the fan motor and didnt burn it out with no seal there??
Thanks for the info.
Tim
1957 Belair 4 door 38,000 actual miles on it.
1977 Firebird Formula 400 4speed
1989 Firebird Formula (sons car) 350 Holley Stealth ram
1990 GMC Jimmy 350 350 trans 6" lift on 35s
2006 HD Softail
2013 Sonic
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mself61
Forum Newbie
Posts: 1
Reg: 01-02-17
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01-02-17 03:44 PM - Post#2669023
In response to Vista Cruiser
the cowling isn't the only leak problem as you might want to check the sun/moonroof if you have one, there is a youtube video on that and I'm hoping compressed air trick works in the 2 front tubes so I don't have to take the whole headliner out. I'm getting leaks through the airbag/seatbelt area and don't see how it could get that far back even if the front 2 tubes are plugged  , if they are not connected then thats going to suck. the sunroof seal looks in pretty good shape but maybe I'll have to run some water over it to test for echo. I also have the problem of the windshield cowling leaking and it's not the patch fix under it, it has got to be something blocking the drain system backing it up enough where it's getting inside. I did the patch with aluminum and clead a wad of leaves out of the drain hole and used a vacuum because I dont have a compressor to blow it out at this time. I may have to go back in before I flexseal and test for leaking there as well. also I am thinking I'm going to drill 3-4 screws in cowling to hold it against the windshield and then use the flex-seal. 2007 hhr made in mexico... well I thought it was American ! lol
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