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Under-dash water leak
HRG,
My 2004 struggled with a passenger side underdash leak that started about a year. I first discovered it after washing it; then it started happening during rain storms. The dealer I bought it from tried fixing it several times, having the vehicle for upwards of 3 weeks total. I even corresponded with Chevrolet to no avail.
Then I took it to a different dealer that a friend suggested and half a day later it was fixed. Here is what it was:
A piece of sealer used at the factory to seal sheetmetal joints broke loose and lodged in the HVAC plenum drain, partially blocking it. When there was a lot of water, it overflowed into the HVAC blower and dripped down under the dash. Removing it fixed the problem even in a deluge.
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