Rain entering cabin - Page 2 - 986 Forum - The Community for Porsche Boxster & Cayman Owners

I have posted about this problem before but haven't been able to sort the problem. To recap, I have rain water entering the passenger footwell at the front of the car ( right hand drive) I have poured water down the front drains and this runs out ok, I have put an air line down them to make sure they are not blocked, I have replaced the missing rubber grommets to the drain holes. I have had the door membrane replaced even though the door card was dry, I have re sealed the cabin filter casing and have now run out of ideas. Is there anything I am missing. The water is entering from behind the dash but not through the screen, it runs down the bulkhead and onto the carpet. The carpet under the seats always remains dry so it isn't the rear drains. Fed up and at the moment defeated. HELP

Are all the frunk cowl covers properly installed and present? Battery drain working properly? Fuel overflow draining properly?

A/c evaporator drain clogged ?

[QUOTE=Flavor 987S;488759]Are all the frunk cowl covers properly installed and present? Battery drain working properly? Fuel overflow draining properly?[/UOTE] Yes all installed properly and all drains clear

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No not clogged, and car gets wet when sitting outside the house not being used.

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Can you replicate by using a hose? If so I've heard of folks putting dry food coloring in certain areas then doing the hose test and seeing what color water shows up. Mike

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Are you sure it's not getting in somewhere round the side windows? I had to get my passenger side windows adjusted to stop water getting in past the front edge and running down the inside front of the door.

Are both of the door liners in good shape and in place? I am talking about the ones between the metal door and the inner interior panel.

Could the seal around your windshield be the problem?

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Yes both are In good shape, passenger side is new and fitted by porsche

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No, I have water tested from below the windshield line, the water drains away ok from the skuttle panel through the drains but some ends up running down the cabin side of the bulkhead at the very front.

I have tried with a hose and also more specific placement of water to try to locate point of entry. When pouring a jug of water in the skuttle tray, it drained down the drain hole but then seeped through where the heater box passes through the bulkhead. I do not know what is the other side of this and how to get to it. Sent from my D6603 using Tapatalk

Just so you know you aren't alone. I get water behind my passenger seat, every time it rains. Drives me bat******************** crazy. Did the hose test, made sure all drains were free and clear, checked seals, and yada yada yada. I finally just gave up, and keep the carpet pulled up behind the seat. If it rains, I keep a small white towel under the carpet. It soaks up the water, and when the weather is nice, I leave the top down during the day and it dries out nicely. Not the fix your looking for, but I feel your pain!!!!! Best of luck!

check the front wheel fender liners... perhaps water splashing up from the tires.

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Thanks, it is very frustrating, I am starting to feel that way. I have bought a storm cover for when the weather is bad.

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Unfortunately no, it leaks when standing outside the house not being used.

Walshie, you have probably seen this link already, but sending it along in case you haven't. Mike is a member on this forum. You might try a PM to him. https://sites.google.com/site/mikefocke2/drainsdiagram

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Hi need for Speed. From this it looks like there is 4 drains fuel filler, one either side of battery and no 3 that I didn't know about, is this correct

I count 6 total: 2 behind the seats, 2 in front (near battery), fuel and a/c.

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Oh ok no 3 on the schematic is the AC drain. I take it this is only a problem if the AC is running and not while it is sitting unused.

Walshie, here's another thread -- water entering via the side mirror, running down the wire harness through the bottom of the door and into the footwell. http://986forum.com/forums/general-discussions/22781-drivers-side-footwell-wet.html?highlight=Wet+door+panel You would only have water building up in the a/c drain if the a/c was running. I don't think this is the problem. Good luck my friend!

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Thank-you, need for Speed for all your help. I will investigate further and post my findings. Thanks again Walshie

To get to the bottom of this you really need to pull the carpet out. The backing is about 2" thick foam. This absorbs and retains water. You might think it is coming from the front but I could be anywhere. To pull the carpet the seats and centre console need to come out but once you have a bare tub you can dust it with talcum powder and then follow the tracks to where the leak is. This also gives you the chance to get the carpet dry. You won't otherwise. Even leaving the roof down it will stay damp. Trust me on this. Tracing water leaks is tough. The Boxster isn't designed well to keep the rain out but if you take your time and trace and seal the leaks you will get this.

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Thanks I am off work this week so I will set about it. I have to re colour the leather so that would be a good time while the seats are out. I will post result Walshie

At last it looks like I have found the point of entry for the rain water. After extensive stripping out and water testing I have found water coming in around the lower extrusion of the heater box as it passes through the bulkhead. I am not sure what is on the frunk side of this but I think it's going to involve shipping the dashboard out to re seal it. Has anybody else had this problem. Walshie.

Check the drain in the center of the frunk - it is like 5-3 in this diagram linked in this thread: http://986forum.com/forums/general-discussions/61272-someone-please-explain-986-drainage-system.html It is near the heater core. If it is blocked it might be allow water to seep through the firewall.

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Walshie, Did you ever get this sorted? The passenger footwell of my '97 Boxster gets soaked similarly to yours, and today I sleuthed out the pathway as you describe here. Have no idea how to fix it. The drains in the frunk work just fine, but regardless there is seepage around the bulkhead pass-through grommet or seal that goes to the heater box under the dash. Would love to hear how you solved this! Thanks so much in advance if you don't mind taking the time to share! - Scott

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Hi Scott Yes I did The water was coming in through a blanking panel bonded to the bulkhead on the passenger side. I had to remove all of the dash and centre console. I then had to remove the heater box assembly complete to get to the panel. I then re bonded the panel with Wurth bond and seal and for an extra measure, I then applied dynamat to the whole area before putting the carpet back. It never leaked again Walshie Sent from my iPhone using Tapatalk

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Thank you! And--oh my--it sounds like a ton of work. How long did it take you to do all that? I clearly have some research ahead of me in order to get it right. Have recently done the center console so not worried about that, but the entire dash seems another thing entirely... Thank you so much again, and cheers!! - Scott

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It took best part of a day for me to remove everything but it was well worth it. The longest job was plucking up the courage to start it. There was a fantastic post that I used to help me . I am not sure how you re send something like that but it must still be in the thread somewhere. I was from meir. You may need to search for him but it is brilliant . Check all other remedies first. Good luck and let me know how you get on . I am here if you need help Walshie Sent from my iPhone using Tapatalk

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I think I found the post from Meir--fantastic indeed! Do these look right? Step 1 - heater core removal/replacement: https://www.dropbox.com/s/6bi2dlsy47ygaky/step%201%20heater%20core%20removal.pdf?dl=0 Step 2 - dashboard cover removal: https://www.dropbox.com/s/lcthesknynmqaaz/step%202%20Dashboard%20cover%20removal.pdf?dl=0 Step 3 - replacing the evaporator and re- foaming the flaps: https://www.dropbox.com/s/gja11v6yi6h6sq9/step%203%20Evaporator%20replacement.pdf?dl=0 And did you do all three steps or just #2? I understand entirely the daunting prospect and the need to pluck up the courage, but I think I'm sufficiently psyched up to give it a go this weekend. Will let you know how it goes. I'm certain water is seeping though the heater box pass-through, but there might also be an accompanying source more toward the car's midline in the vicinity of the heater core. Am likely to attempt all of Meir's three steps for good measure. The car is throwing a "temperature flap" code, and I believe that is associated with missing flap insulation so I may as well do it all at once... Any other advice/recommendations before I proceed? Thank you so much for the brilliant guidance so far! Best, Scott

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Walshie, Thank you so much! I think I found Meir's posts--there were actually three different documents he put on DropBox. One for removing the heater core, one for the dashboard, and the last one for removing and repairing the heater box. Does that sound like what you used? Did you do all three steps? I actually responded to this post a couple of days ago but included the DropBox links to see if they looked familiar to you, but the forum said a moderator needed to review it before posting... I must have done something wrong because the response never posted. Anyway, thanks so much again for the help. I completely understand the daunting prospect this project presents and the need to muster courage--definitely there myself, but I think I'm sufficiently psyched up to make a go of it this weekend. I am sure of the leak through the heater box pass-thru, but there might also be an additional leak source more toward the midline, possibly the heater core, so I'm likely to attempt all of Meir's three steps. Will let you know how things go, and once again I appreciate your help! Best, Scott

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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 Sent from my iPhone using Tapatalk

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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

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

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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