Hi there, can any one help with my leaky roof.....

Woodster100 · May 5, 2021

Hi folks,
I have been a member here for a while but this is my first post. I was after a little help with a leaky roof and don’t know which is the best category to post in.........
I have owned my 2010 Cali for the last 5 years, I love it even though I had the CFCA engine problem at 50k miles so £5k on a new engine (I think this why the guy sold it to me in the first place.....should have done more research....), just had a new mechatronic unit fitted (£3k) but gear box still clunky as you like (back in to DSG specialist for this) ......on the plus side had the roof corrosion fixed on warranty
I am getting the damp patches on the head lining on both sides by the grab handles.
Pulled down the head lining and used copious amounts of blue paper roll to spot water leaks.
I have cleaned the drain tubes as advised everywhere they are fine, run water on the windscreen seals and also on the wedge holding the pop top motor and these all seem fine with the roof up. when I put the roof down it seems to leak in......
It is getting in and dripping from the metal roof bracket just forward of the drain hole connector and running down the A pillar in the well described way.
I have identified these two rubber grommets (photo below) at the end of the roof seal (fixed to the outside van roof, running parallel to the windscreen) and think maybe they are leaking when compressed by the roof?
has any one got any experience with this problem and could share any solution?

thanks in advance!

KGCali · May 5, 2021

The previous owner of my 2010 T5.1 SE had the front cowl replacement done in 2017 with a three year warranty. I purchased it in 2019 then in 2020 I noticed water ingress into the cab roof lining and saw the sealant was cracked around the cowl so I contacted the VW dealer who had arranged the original repair, Breeze Southampton via VW Heritage Bristol, and Breeze contacted VW Customer Services who approved the cowl removal and replacement which was done via Claridges Southall who collected and returned my Cali via the AA. Claridges did a great job and touched up a few other minor rust spot with VW approval and all free of charge! They whole process took about a month with VW approval causing the most delay but I'm very happy with the result. Apparently VW has specified an improved cowl sealant since 2019 so hopefully no more issues.

Woodster100 · May 5, 2021

Nice one, thanks for the reply. I will take it down to Martins van centre in basinghole and see what they say

Cali1 · May 6, 2021

Hi,
I’ve just had the same problem which through lots of calls and complaints VW customer service approved to have the front cowl fixed.
My headliner came away from the roof and I’m currently in talks to get that replaced all through warranty.
It was found when I had my cap replaced initially they screwed up. Hence to be redone.
Definitely photo ID everything and send to Vw customer care,they will only do the basics and try fob you off for anything else.

Perfectos · May 6, 2021

Woodster100 said:
Hi folks,
I have been a member here for a while but this is my first post. I was after a little help with a leaky roof and don’t know which is the best category to post in.........
I have owned my 2010 Cali for the last 5 years, I love it even though I had the CFCA engine problem at 50k miles so £5k on a new engine (I think this why the guy sold it to me in the first place.....should have done more research....), just had a new mechatronic unit fitted (£3k) but gear box still clunky as you like (back in to DSG specialist for this) ......on the plus side had the roof corrosion fixed on warranty
I am getting the damp patches on the head lining on both sides by the grab handles.
Pulled down the head lining and used copious amounts of blue paper roll to spot water leaks.
I have cleaned the drain tubes as advised everywhere they are fine, run water on the windscreen seals and also on the wedge holding the pop top motor and these all seem fine with the roof up. when I put the roof down it seems to leak in......
It is getting in and dripping from the metal roof bracket just forward of the drain hole connector and running down the A pillar in the well described way.
I have identified these two rubber grommets (photo below) at the end of the roof seal (fixed to the outside van roof, running parallel to the windscreen) and think maybe they are leaking when compressed by the roof?
has any one got any experience with this problem and could share any solution?

thanks in advance!

View attachment 77955

View attachment 77956

Hi Woodster,

In your first photo (off side) the rubber seal and drainage vent cap look to have been deformed causing a channel depression in the rubber seal ?
The other side is what I would expect to see!
from the limited photos the deformation does not look correct.

can you take a couple of photos showing the cross section along the front rubber seal and roof cap (one from each side). & a photo with the roof closed locking at the closed roof where it meets the front cap (viewing front to rear )

edit marked up photo showing two areas