Leak Help

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Water leaks.

AND its leaking again.... totally out of ideas. With the amount of sealant Ive used I cant imagine anymore will help. Its getting to the stage where If I cant fix it soon it will have to go and it seems such a stupid thing for me to get rid of it over but it will have expensive tools in it and i cant have them getting soaked.

Water leaks are often very difficult to find & then go on to fix successfully. (When I worked for an Audi dealer in the 1970's we used an Ultra Sound generator placed in the vehicle, a microphone was then run round the outer edge of the door frame to listen for excessive noise leaks on a Electronic Display. It was an expensive bit of kit that rarely worked!! lol)

It is often something less obvious that has been missed like a rust pin hole or even a broken upper door frame that moves when it is shut, poor accident repair in the past? The post reads as though you can see where the water is coming through but that is probably not where the actual issue is it will be further up somewhere. If you have lots of sealant in place that could actually make it worse.

Most door seals do not actually completely seal the gap between the door and the body frame as this would not work for very long as the seals would soon loose compression and it would leak all the time when a car is a few years old. Most door seal designs act as a sort of flexible channel where the seal fit. The seal then acts like a sort of guttering directing the water away. Some door seal designs have inner and outer seals so you can have a seal on the door and also on the body frame. I can't remember my Terrano design but I would concentrate on the fit of the seal. I would then thoroughly clean all the paintwork and give it some wax polish and the proper silicone weatherstrip grease that helps the seal repel water rather than absorb it.

I would check the less obvious such as does it look like the original door? Checking the hinges usually is a give away if it has been replaced in the past. Is the bodywork sound and rigid as rusty sills can cause body flexing. Has the vehicle been on a wheel free ramp recently?

I am not aware of the vehicle history have you had it long? Has the leak started after an MoT etc ?

I am just trying to think of ideas outside the box.
 
Finding the start of the problem might help.

When I had a rear door door water leak many years ago on a Mk 1 Astra that would fill the rear footwell I ended up putting some Duct Tape along the door gap on the outside along the top of the door frame. If you try that and the water stops that might help you locate where the issue is as you increase the taped up area.

I was convinced my leak was from the top of the door seal. When I tapped the top of the door frame off it still leaked. Mine only leaked when driving, eventually found it was the front edge door seal and water was blowing up to where the door seal had a joint .
 
Chalk

Water is notorious for appearing a distance away from the leak. A technique that works is to remove the carpets/ trims and dry the area, the coat the area with a chalk based solution and allow to dry (there are commercial sprays that can be used but I can not remember their names). When it next leaks you should see the track where the fluid comes in.

I have had 4 Terrano over 23 years and I have found 1 that had a leak from the rear side window tracking down behind the trim, this appeared to be from the rear door.

One of the most effective fixes I have found is to use the Sealant tape used in caravan/ motorhomes (https://www.leisureshopdirect.com/caravan-accessories/caravan-maintenance/caravan-sealant-and-tapes :thumb2) place under door seal and boot trim.

This tip is also useful for finding engine fluid leaks
 
Thanks for all the help. Need to check in more often. once again I'm calling it fixed but I will let the next heavy rain to be the judge.

I removed all my se4alent and re did it, adjusted the door so it shuts better (I think that was my issue all along) and replaced the top gutter? the one that sits on the vehicle above the door.

Any way it passed the hose test so fingers crossed.
 

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