Rain entering cabin

[Earnest]

Originally Posted by Walshie

Hi Scott
Yes I did use all 3 posts. My advise is buy some zip lock food bags and a sharpie and put each set of fixings from each step in a different bag. Label them with the items and number them . Then reassemble in reverse order. I also took photos to remind me. It was actually quite fun in the end.
Good luck and let me know how it goes.
Walshie


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Hello Walshie! Great advice--thank you. Got all dismantled Friday evening and Saturday, and confirmed the leak points with some focused tests. I found your forum conversation with Meir from 2016, and the culprit is just where you found as you described to him. Waiting now for the Wurth Bond & Seal to arrive, so spending time cleaning under the dash and re-taping all the wiring harnesses. Also repairing the interior of the heater box, cleaning the evaporator and re-foaming (or taping up with aluminum tape--not sure which way to go yet) the flaps. By the way, were you able to track down the part# of the foam gasket between the heater box and the bulkhead--the one that goes around the evaporator tubes as they pass through the bulkhead to the expansion valve? One of the previous owners tried to fix the leak by putting a bunch of sealant around the tubes (maybe it was leaking there as well--that lower screw is rusted just like yours was), and I would like to replace that gasket. Unfortunately no part number on the gasket and none of my searches yield anything...

I spent considerable time trying to clean out the small crevice right below the expansion valve. Tons of gunk in there and it was like flossing teeth because the car body at the base of the right strut mount (LHD car) has an outcropping just forward of the bulkhead plate that obscures visibility to the joint of the plate with the body. Also creates a channel where water accumulates thus causing this whole leak problem. Ended up using toothpicks and the end of a zip tie to get in there to scoop the gunk out, then flushed with water, and then dried with a heat gun and compressed air. It should be ready for the seal.

Anything else you did or parts that you replaced in the process that I should pay attention to? Once again, thank you SO much for your experienced guidance!

Best, Scott

[Walshie]

Hi Scott , if I am totally honest , I cannot remember what I did about the foam seal, although I know I didn’t buy a new one. I did however use the bond and seal to re stick the foam cover over the matrix in the fronk. One hood thing about the bond and seal is that it works if the surfaces are damp.
I am glad all appears to be going well. Good luck with the re build
Walshie

[Earnest]

Originally Posted by Walshie

Hi Scott , if I am totally honest , I cannot remember what I did about the foam seal, although I know I didn’t buy a new one. I did however use the bond and seal to re stick the foam cover over the matrix in the fronk. One hood thing about the bond and seal is that it works if the surfaces are damp.
I am glad all appears to be going well. Good luck with the re build
Walshie

Hello Walshie! Just wanted to give you an update: Got the leak sealed up a couple of weeks ago, and mostly all put back together last week. Still have yet to re-charge the a/c, but it's nice to be able to drive it again! Unfortunately it's now throwing emissions-related misfire codes, so now I have another problem to solve...

Anyway, thank you SO much for the help in sorting out the leak problem--I couldn't have done it without you and Meir! I hope all is well in the UK and that you're staying out of the cross-hairs of the coronavirus.

All the best,
Scott