Heater box removal

[Meir]

Hi welshie.
I just went over your previous posts, an I'm sorry I missed the one you posted back in April.
I have no intention of braking your spirit, but I think you didn't need to remove the dashboard.
The air box is meeting the firewall in two places.
On the passenger side there is the cabin air filter, and in the center, the heater core.
Focus on the "heater core removal" document, and I'm sure you will solve your issue.
My guess is that the foam part that covers the heater core, is either torn, or not sealed.
Another option is that the heater core is leaking, but then you whould notice coolant lost.
Do you have A/C in the car, or just heat?

[Walshie]

Originally Posted by Meir

Hi welshie.
I just went over your previous posts, an I'm sorry I missed the one you posted back in April.
I have no intention of braking your spirit, but I think you didn't need to remove the dashboard.
The air box is meeting the firewall in two places.
On the passenger side there is the cabin air filter, and in the center, the heater core.
Focus on the "heater core removal" document, and I'm sure you will solve your issue.
My guess is that the foam part that covers the heater core, is either torn, or not sealed.
Another option is that the heater core is leaking, but then you whould notice coolant lost.
Do you have A/C in the car, or just heat?

Hi Meir. Thank you for taking the time to help. As you say the heater core is in the centre of the car. But I am not sure this is the problem. The car does have AC but it doesn't work( another project) the rain water comes in approximately centre of the passenger side( Rh drive) around the extrusion that I believe houses the AC pipes going to the matrix. I have found this while running a hose into the scuttle panel as just a trickle. The scuttle panel area does not flood. I am hoping that in removing the heater box that I can replace any seals.
I am hoping this makes sense to you.

[Meir]

Originally Posted by Walshie

Hi Meir. Thank you for taking the time to help. As you say the heater core is in the centre of the car. But I am not sure this is the problem. The car does have AC but it doesn't work( another project) the rain water comes in approximately centre of the passenger side( Rh drive) around the extrusion that I believe houses the AC pipes going to the matrix. I have found this while running a hose into the scuttle panel as just a trickle. The scuttle panel area does not flood. I am hoping that in removing the heater box that I can replace any seals.
I am hoping this makes sense to you.

got it.
in that case, it could be from this seal:



if the seal is fine, pay attention to the lower bolt.
i didn't have any leaking issues, but you can see from the picture that the bolt is a bit rusted at is base, evidence of it being in contact with a lot water.

good luck, and keep us posted.
i'm really curios to see where the lick is coming from once you find it (and i'm sure you will).

[Walshie]

Thanks, yes I am sure this is the seal. I am carrying on again this weekend so will keep you posted.
Walshie

[Walshie]

Originally Posted by Meir

got it.
in that case, it could be from this seal:



if the seal is fine, pay attention to the lower bolt.
i didn't have any leaking issues, but you can see from the picture that the bolt is a bit rusted at is base, evidence of it being in contact with a lot water.

good luck, and keep us posted.
i'm really curios to see where the lick is coming from once you find it (and i'm sure you will).

Found it. The leak is coming in around the black steel panel that is bonded to the bulkhead, has anyone ever tried to remove this.. Thanks to meir for all his help. We couldn't have done this without you.# legend

[Walshie]

Hi Meir
With your help, we have found the leak. It is coming in through the black steel panel that is bonded to the bulkhead. A small water test has proved this now that everything is out. I am not sure if anyone has attempted to remove this in the past. I wouldn't want to risk damaging the bulkhead. Second option is to try and seal the panel and test again before putting the heater box back. Any advice would be welcome.
Nick

[Meir]

Originally Posted by Walshie

Hi Meir
With your help, we have found the leak. It is coming in through the black steel panel that is bonded to the bulkhead. A small water test has proved this now that everything is out. I am not sure if anyone has attempted to remove this in the past. I wouldn't want to risk damaging the bulkhead. Second option is to try and seal the panel and test again before putting the heater box back. Any advice would be welcome.
Nick

Hi Nick.
Are you talking about the part I show in the picture? I have to be hunest and say I don't remember any part that can be detached from the box. But then again I never looked for any leaks.
This way or the other I'm sure you can fabricate a foam seal or just use good old silicon.

[Walshie]

Hi Meir I am not sure if it is the same on left hand drive cars but it seams to me that porsche manufactured the same chassis for both Lh and Rh drive cars but where your pedals, steering rack etc pass through the bulkhead I have a black steel panel bonded to the bulkhead which in turn has the holes where the AC pipes etc pass through. It is around this panel that the water seeps into the cabin. Apparently this panel is very hard to remove as it is bonded. I do not know how to attach a photo otherwise I would attach for you to see.