Managed to strip down the scuttle panel and replace the plenum foam this morning.

Found this on the passenger side:

Didn't get as far as removing the panel above the driver side to see inside the pollen filter housing on the side - I think it needs the wiper mechanism removing.

Cleaned up all the mating faces of scuttle panels, windscreen etc and put them all back. Replaced all the missing screws (several missing along the bottom of the scuttle panel and the A-pillar trims. Filled all the screw holes near the pollen filters with silicon before putting the screws back in and siliconed around the pollen filter covers. It looks like I need to get 4 replacement plastic clips for the lower windscreen trim too, some are missing.

Then I moved inside and stared removing the glovebox to get a better look inside the dash to try and find where the water was coming in.Grabbed a jug of water and started pouring over the windscreen. I couldn't see any new drops coming in so I think it's sorted.

This was about the time heavens opened up again so I couldn't continue with the plan hoover up as much water as I could. Left large bundles of tissue paper covering the carpet weighed down with the rubber floor mat in the mean time.

I hate the glovebox in this car! Tried putting it back in and it wouldn't close. Was in a rush as it was pissing down with rain but managed to get it to a state where I can smack it hard to close. I think I figured out how to adjust the glovebox to adjust the panel gap though, so that's now a new task fore when the rain stops.

RutlandRover wrote:

I think I figured out how to adjust the glovebox to adjust the panel gap though, so that's now a new task fore when the rain stops.

I'd be happy to see how you do it, as you know the fit on mine is pretty crap too.

Just be careful when adjusting 'cos if you go too far aiming for the perfect gap and the catches jam it's a complete pain in the ar$e to get open again. ask me how I know!
Fortunately I had a spare :)

There are a couple of adjustment screws which are reachable with the glovebox door open.

As a side not on the sealing up - I usually undo all the screws holding that plastic pollen filter holder in, and remove that whole unit. You can then fold up the rubber seal that is under the pollen filter housing, and clean out any crud under there.

I reassembled mine with silicone under the rubber seal aswell, which then gets clamped to the bodywork when the plastic housing is refitted.

Hopefully you've got it sealed up though - with the glove box in, but the footwell trim removed still, you can reach up behind the glove box and feel the blower housing/recirculation flap, and see if there's any moisture there too.

I really do wish the sporadic rain would stop. It makes this process so much longer than it should be.

Went back out and flipped the seat up on to the rear seats and started going at it with the wet vac. Not much came out from the top but I lifted the carpet and went at the foam from the bottom. Got it to a stage where I can no longer squeeze water out by hand. Luckily it's only wet on the edge by the door, it gets drier the further inboard you go so I don't think the whole carpet has to come out.

Then it started raining again! Packed it with tissue under the foam, closed the doors and headed inside for a cup of tea until it stops again...

Gilbertd wrote:

RutlandRover wrote:

I think I figured out how to adjust the glovebox to adjust the panel gap though, so that's now a new task fore when the rain stops.

I'd be happy to see how you do it, as you know the fit on mine is pretty crap too.

I had no luck with improving the fit. The screws I found did adjust the gap but I couldn't make the glovebox close with a good gap. I settled for a bad gap but a closed glovebox.

If you'd like to try with yours, the adjustment screws are right next to the catch on each side, inside a semi-circular cutout. It's a bit of a pain to get the screwdriver to locate properly with the glovebox still installed.

Fingers crossed, looks like the leak is solved and the carpet feels dry now. I think next weekend I'll tackle the carpet on the driver's side. It's nowhere near as soggy but I know I've had a little bit of moisture on that side.

Just been out on my lunch break to open the windows and sunroof to take advantage of the sun today and dry out any residual moisture and found the carpet is absolutely sodden again :(

Bugger.

I now have a better idea of where my water is coming from. I just took out the black plastic panel below the glovebox and had a prod around.

There's a plastic pipe that I assume supplies air to the various vents around the car just above the panel, almost directly above the OBD socket.

If I move that water pours out from where it joins the next section of pipe. I think the black panel under the glovebox presses this section when installed, releasing water.

Hoping that it's just filled up with water from the leaking pollen filter housing and needs removing and emptying. Had a look through RAVE but I can't find mention of the vent pipes in the "heating and ventilation" or "air conditioning" sections.

Would a blocked AC drain cause water to fill this pipe or would that water go elsewhere?

Water in the ducting hasn't come from the AC, that's definitely left over from what got in through the pollen filter housing. If the weather stays like it has been today, leave the car parked in the sun so it's at cooking temperature inside then run the engine for 10 minutes. If the AC drains are clear, you'll find a big puddle underneath the centre of the car. I parked mine for a couple of minutes this afternoon and came back to it to see a stream running out from underneath and that was with the engine off.

Tbh, I have been working on the assumption that the AC drains were clear. I nearly always get one or two streams of water when I park and Fiona gets embarrassed when I crawl under the car in public to make certain it's clear water from the AC and not something more serious :P

Figured it was worth asking if the AC water was able to make its way in to the vent pipes just in case though.

Mine were blocked up enough to get water in the passenger side ducting - the bottom of the duct is level with the bottom of the air handling box. The drain channel for condensate is in theory lower... till it gets full!

It hasn't rained since late Saturday and I've still got water pouring in. AC drain vents are definitely next on the list.

If I were to pull it over a pit at work and get an airline to the outlet - would blowing air up the drain pipe cause damage to anything?

Shouldn't think so although it might fill your car up with very dirty, smelly, water and dead leaves. Giving them a squeeze from underneath will usually result in a shirt sleeve full of dirty water. They are a conical shaped bit of rubber with a slit in the end so water can get out but not in. Dirt will clog them so they can't get the water out fast enough. When mine clogged up the water was running out of the side of the transmission tunnel cover and forming a puddle on the passenger side rubber overmat.

Hmm...I'll start by giving them a squeeze first then. If it seems like there's an internal blockage I can look at puffing air up them - I don't mind having to clean the interior if I can be sure the issue is gone.

Pry with a small screwdriver underneath on either side of the box, that usually gets them running.

So, I think the AC drain vents are fine. Drove the 50 or so feet across the work car park and over the workshop pit. Checked the drain vents and they looked like this:

And:

They were flowing pretty freely and dripping on my head but I stuck a finger in each one anyway, found some dirt but nothing too bad. A little water came out of each but not a lot.

Checked the pollen filter and it's completely bone dry - it's definitely not coming in there.

I then drove home and when I parked I got a small flood of water surge in to the footwell. I've been driving around with the panel below the glovebox removed for easy viewing.

The water is coming from the bottom of this pipe:

If I push/tip the pipe even more water comes out. It's pretty cold and completely clear which makes me think it is the AC drains even though they appeared clear.

So...with this in mind, is there any other way that the AC water can make its way in to this pipe?

I tried removing the pipe as it doesn't seem to be fixed with any screws but there wasn't enough wiggle room to get it out. One end attaches to the box that the fan motor screws to but I'm not sure what the other end is attached to. I couldn't see a way to remove the box the fan motor is screwed to.

If it's come adrift at the top, it might find it's way in from there. With the side off the centre console you can see them where they fit to the bottom of the heater box.

Have a look at the AC drains from the top.

They are a bit of a concertina'd rubber idea that come off the evaporator tray and then go down through the transmission tunnel and end up where you've found them.

However, it is possible (I've seen it a couple of times) for the concertina part of the drain tube to get pinched up, so they might seal up, and just be letting drips through..

With that trim off, and if you take out the footwell vent (triangular thing that clips in - bottom/right ish in the background of your picture) then you can do a bit of a visual on the drain tubes themselves - it could also be possible that the outlet from the evaporator is blocked, rather than the drain tube (again because of the kink that sometimes occurs in the drain, residual silt etc could build up in the bottom of the tray and block the outlet...

Does the lower end of the big black pipe I showed attach to the heater box?

I couldn't see any evidence of the water falling on the pipe from elsewhere so I believe it's flowing in from where it attaches at the lower end.

Sorry Marty, you posted at the same as I did. I'll check the tops of the drains tomorrow, as you and Richard suggest.