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Door seal leaking

18K views 76 replies 15 participants last post by  torqueit  
#1 ·
So, after assuming my water leak in the roadster was coming from the back and running forward to the drivers foot well I discovered today that its coming in the door seal near the curve of the door at the speaker grill. I checked the seal and there's no tears or splits in it. Removed the door card expecting the bottom of the door to be sitting in inches of water but although it was damp there was no standing water.

So my question is - how does the water find its way in past the door seal when where the water is coming in is higher than the bottom of the door ? Inside of the door card is dry and I've cleaned out the drain holes in the bottom of the door and when I put water in there it is running out. I'm stumped. Also the drain tubes were changed last year and after inspection today with an inspection camera they are both intact and not blocked.
 
#3 ·
Are the TT doors sealed behind the door card with a one piece plastic film?

I had a troublesome leak on a Passat saloon which sounds similar to your issues. In my case a previous owner had ripped the door card sealing film. When it rained water would enter the drivers door cavity, drip off the bottom edge of the window glass and run down the inner door skin due to the curvature of the door panel and leak through the torn plastic trim. Some duct workers aluminium foil tape over the torn film solved it.
 
#4 ·
I know what you mean used to have the polythene barrier on mk1/2 golfs, Sciroccos etc. The door cards on the 8n TT do not have this. Once the card is off it's just all the electrics etc on view. There is a type of foam on the rear of the card, don't know if it stops water ingress. Going out tomorrow for another look. Was too cold today my hands were frozen ! This has taken me all week so far. Will post any findings tomorrow.
 
#5 ·
At the top of the front windscreen on the drivers side there is a drain - if I pour water down that drain it goes all the way down to that curve in the seal at the bottom near the speakers and I can see the water leak out the side - but to the right towards the outside of the car

I pulled the carpet and plastic trim away from the floor next to the door and that all looks dry

I'm confused cause I too thought the puddle in my drivers footwell was coming from this curve in the seal
 
#6 ·
I thought that's where the water was coming in on my car. I took the scuttle panel off and looked inside but it all looked ok. I will put some water down there tomorrow as that would make sense. Any water running in there and coming down the seal would wet the carpet. I couldn't understand why water in the door was coming in at that curve - water doesn't run uphill.
 
#7 ·
Back out this morning. No water inside. Ran water over scuttle tray which came out somewhere around the bottom of wheel arch but still nothing inside the car. Tried to refit the door card. Is it just me or is the triangular seal with the red reflector difficult to refit ? It must have taken me nearly an hour to get this seal on, a right pita ! So I have refitted the door seal and put some more paper towels down to see what happens. Need some rain which looks like it's not too far away. Will update soon
 
#11 ·
The rear of the drivers chair and all the back is completely dry - it's dry all along the seals and the carpet side. The only place it's soaking wet is right at the drivers foot well - not even the raised area at the pedals - just the flat floor but in front of the drivers seat

The drains however have also been checked by myself and a mate used his small camera down them and they were clear!

I just can't pinpoint where exactly the damn water is coming in from
 
#12 ·
I'm in the same position. Saw water coming in yesterday at the door seal/speaker grill but none overnight. Tried to replicate it today but couldn't. Waiting again overnight to see if we get some more rain and have a look in the morning. What I did notice however was the sides of my carpet at the cill were dry but there was a puddle under the pedals. The way the carpet is made with about an inch of foam insulation on the bottom means that the carpet on the cill is pulled off the cill making a void where water can run down the metal without touching the carpet and the foam then soaks it up causing the damp patch under the pedals. Hope this makes sense ? Have you removed your carpet ? It is absolutely dry under the dash above the pedals as well. It's a mystery but I will get there :?
 
#17 ·
Eric V. said:
Are the big 40 mm rubber bungs still in the floorpan.
I do not know how but on mine one bung was no longer in the floorpan.(lost)

You can use a garden hose to check,no need to wait for rain.

Eric V.
Hi Eric - being that i'm a complete newbie to the TT Roadster yet i'm having the same issue with my drivers footwell being soaked - where exactly are those 40mm bungs your mentioning? Do they go right through the floor of the car? Any chance of photos please?
 
#19 ·
Arh - ok yes those are in place in fact on my car the big rubber bungs are in place so the previous owner must have Dont the mod shown in your link :)

I can't see what's causing my dampness so I've resorted to a ÂŁ30 waterproof car cover . So far no more wet and carpet is dry.
 
#21 ·
SO I sat there in the drivers seat just 'thinking' about this and whilst the rain poured down I notice a small droplet get through the rubber door seal at the top and slowly drop down the black small pillar between the front small triangle window on the door and the main window (that goes up and down)

Ive noticed before that when I put the drivers door window up it moves the top of the door away by about 2mm. When I put the window down it brings the door back in (including that black small pillar) and touches the seal.

I may have now seen where my water on the drivers floor is coming from. Question is how do you adjust the window to stop it maybe a few mm lower than it does at present when its fully up??

And of course this may also be a red herring
 
#22 ·
That is a well known area for water leaks. Mine leaks there regularly but its not very much and it runs down the window and inside the door where presumably it exits through the drain holes in the o/s side of the door seal. Was out again today with a watering can but couldn't replicate the water running down past the speaker grill and into the car.

I don't want to put the carpet and all the trim back in until I'm 100% certain that the leak has been cured. But I'm still stumped :?
 
#23 ·
So after having a night of rain for the first time in ages I went out to check the car for water ingress this morning. Yep the rain had found a way in after I couldn't with a watering can ! This is what I found - drivers foot well was wet as usual. As you can see in the photo the water was filling up the door seal at the curve. The seal was only wet where you can see in the photo, its dry above and dry along the sill ! The seal was wet on the A pillar but only on the outside edge where it meets the door card. What is happening is the seal is filling up in that curve and overflowing over the top of the seal and into the car but I can't see where the water is coming from to fill the seal in that area ! The car sits nose down on my drive but its always been parked like that and been ok ? I know its a well known area for leaking and mine does sometimes but do you think its possible that its leaking at the junction of where the roof meets the windscreen frame/top of the door glass and dripping on to the that area of the door seal curve ? Its a lot of water that's getting in.
 

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#25 ·
black9146 said:
View attachment 1 More investigation - removed the fuse cover at end of dash. You can see water lying on the bottom edge ! Also when digging in further found rust above where the water is lying. Would this be coming in from under the scuttle cover or through the windscreen ?
 

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