wet passenger side footwell

[jtmccue]

my 2001 s80 2.8T developed a leak showing puddling in the footwell of the passenger side.
I figured some condensate hose was plugged or cracked.

I pulled up the p/s carpet. there was a drain hose on the firewall p/s corner just forward of the door. I think this is the A column drain for the sunroof tray but it curved up towards the center of the glove box. is this another drain to the HVAC??

I thought there would be some similar drain hose on the p/s center console side. I removed the cover panel along side of the exhaust hump - still no visible drain hose. I do see alot of metal brackets for the center console

Looking around online, other volvo models have the condensate hose drain to center of the D/S foot pedal. Maybe so , but how is it that i have water on the p/s not the D/s.

Before i try yank out the radio section i am hoping somebody can better direct me. how to attack this hose where it is

Im expecting to see a nipple with a "z" shaped hose ($10) with the same type of thru body plug as the A column drain on the lower end.

[volvolugnut]

Try this link.
viewtopic.php?f=9&t=92152&p=526429&hili ... ak#p526429

I believe it still has photos of what I found for a PS leak and my fix. 2001 V70.

volvolugnut

[jtmccue]

thanks volvolugnut.

Took off the vinyl shelf at the base of the windshield. and removed the subtray with the little down spout on the ends to feed water to the small rectangular forward drain on each side.Those rectangular drains have holes at their base and were clean.

Pulled back the 5 flange clips holding the larger plastic cowl opening (about 5x8) above the cage fan..
Cleaned it up of grit and replaced it. Then used that Duct waterproofing tape (foil with one side of stickem on the other) to surround the "outside" base and cover up the side of the cage fan cowl. The spongy bottom seal on the bottom foot of the cowl was in good shape so i cleaned and left it on. Seems to me, I pretty well surrounded the cowl on the outside.

But I wonder if i should have put the same around the inside of the cowl ?????? BECAUSE after i put it back together and hosed it - i had water leaking to the floor inside -dripping down from the glove box frame 3/4 of the way towards the door.

I pulled that drain hose coming from the bottom of the white plastic cage fan housing seen in picture - it was on tight and not cracked.
Some water did piddle out but nothing much. I stuck a 12 awg wire in there to try dislodge any debris. nothing piddled out. I pulled the entire hose out of it which goes to the door corned thru chassis fitting- and flushed it out. - no debris.. Put it back on this time with a hose clamp at the upper end. Then dribbled water onto the windshield-

I had put a few paper towels on the floor and found it still dripped at that spot on the glove box frame. I dont feel or sense any water on the white cage fan housing. But the drip is next to the motor you can see just behind the glove box frame.

Im going nuts now.. Could it be that the those lower corners of the windshield rubber gaskets that cracked off in removing windshield cowl tray is the cause of water getting it???

And should i have Duct waterproof taped the" inside" circumference of the cage fan cowl. One youtube poster didnt do the outside seal - he did the "inside" upper lip.

What am I overlooking here????



.

[volvolugnut]

My windshield bottom corner seals have been bad, but did not seem to cause a leak.

My shop made sheet metal cover/deflector over the air intake has prevented wet floor after many downpours in several years. You may want to try a temporary cover/deflector to see if your drip stops.

volvolugnut

[jtmccue]

well I' m gonna try find new rubber fittings for the lower corners. dealer part for this year model. FCP has them for the newer s80.

I took it apart this morning. This time i put the adhesive foil to line/seal the aft lip of the cage fan intake col. See picture.

intake cowl foil surround and inner aft.jpg (266.05 KiB) Viewed 1671 times

Put it back together and poured a 1/2 gallon of water on that side - it made it in but not as much as i thought would. a couple of drips.

so then i used the adhesive foil to straddle the bottom of the windshield corner and the broken rubber windshield weatherstrip fitting as there is now a 3/8 opening between the 2. It looks crappy for now with the foil showing some- but i hope to find new ones Monday.(tomorrow).
Sop that i can have a car to get about in I put a oval floor bucket in under the drip spot in the footwell I poured another 1/2 gallon on the corner after covering the gap and it seems better but still leaks ;<

I too will make a intake umbrella . A shallow rubbermaid pan flipped upside down with some knotched spacers glued to the inside. the knotch will rest on the front and back cowl lips and keep the intake airflow open.

Perhaps a deep a deeper rubber maid pan, flip it over and cut it shallow - except for the 4 corners to keep it up and off the cowl to allow air and water to pass thru. Like a table standing over the cowl

Thanks for the great idea.
here's a picture of the foil seal - around the cowl and the aft section inside which one youtube post said he had water getting between the upper lip and the inside rear lip of the intake flange.

[jtmccue]

after receiving the gussets for the lower windshield corners, i installed them. mine were pretty brittle and shot.
I also added more of the weatherproof tape to the inside front and sides of the intake cowl.
reinstalled the sub tray and then the top tray with the concave fitting to the windshield.

poured a 1/2 gallon of water over the lower corner. nothing dripping on the inside.
poured water 2/3s the way up the side of the windshiels to see if maybe the side windshield may be the leak source.
no leak.

then poured a 1/2 gallong on the p/s corner of the sunroof. no inside leak. :> So i thought i had resolved it.

So I left the car out when a shower came bye. went out to check if i had a leak ( I had put an oval bucket under the forward glove box lip. Crap- it leaked again. maybe i hadnt poured enough water when i tested it earlier.

I then found "volvolugnut's" diagram ( the "invisible car") of the drain hoses for the car. I couldnt see them when I removed the A column pillar cover as assumed they must be fully inside the column rather than running down externally. from the picure it looks like it exhausts somewhere in the area of the lower windshield corner. Perhaps thats where it leaks. I will need to get out my cylinder video camera probe to try see in under the gusset area or possibly pull out the wheel well liner to see if its on that side.,

I still am concerned that maybe the windshield seal is the issue. Im pretty sure no water is getting down the intake cowl. but this next redo im gonna put a paper towel in it to retest and see if it gets wet.
stay tuned. .