Looking at your picture the corner of that footwell looks rusted along with the side wall. I would check above that area. There is black foam that insulates under the dash and catches majority of the water. Sometimes it leaks sometimes it didn't. You can pull the glovebox and access it easier. What I found was soaked foam in that corner of the cowl. The foam would get saturated and move towards the fan. It rusted the cowl from the side to just short of the air intake. The side seam was leaking in various areas. The picture shows some holes that appeared from scraping the area. They were pin holes but underneath was shot from saturated foam against it for long periods. It was severely rusted on the underside. Also the drain hole on the cowl outside could separate from the side/firewall. All the seam sealer was deteriorated. I ended up cutting out about a 2-3inch strip wide and about 8 inches long and patched it with new metal. I removed the heated windshield cables and patched that hole as well. Good Luck!

Also, don't discount resealing the sunroofs. I did mine this past summer and was missing sealant in a front corner. I did have a leak that would travel to the side passenger side and drip outside the headliner by the grab handle or A-pillar. Since the headliner is down I would seal the roof bars for good measure. She is dry now.

 

Thank you, I will try to check behind the glovebox towards the wall. It is like a puzzle to find something. I will do the sunroofs over summer too, much easier and more light. I did put some sealant just now to the roof bars, unscrew them put some sealant and re-screw them basically. Also I have sealed the air intake and the somehow loose hose of the sunroof. Just before photos as below, I have put sealant all around of the intake and may put some around the heated windscreen cable thingy too.

 

I built a shield over my HVAC intake to divert water from entering. It was one of the first things I needed to do to it, and did not take any photos. It was just a piece of scrap rigid plastic, nothing difficult or fancy.

 

I have covered the part with a lot of sealant now as well just poured especially on the top side of that in the photo.

Now I have noticed my drivers side(LHD) carpet is also wet unfortunately, I believe I will just pour sealant all over under the cowl, I have replaced my cowl bought a new one yesterday as well. But now I will remove it again to really pour sealant from one end to other I do not know what else can be done as I have checked under the car there is no cracks I can see, I have checked behind the glove box nothing I can see. Also I believe I need to seal a bit on the bolts and nuts that goes under the car for the seats those are rusted as hell I have scraped the rust with wire brush, need to clean it and bought some rust converter awaiting it to arrive before I put back the carpets in. Now on I am inclined to just seal all.
I tried to remove the screws of the door treads that plastic thingy that holds the edge of the carpets and the screw just snapped due to corrosion it was rusted and once I started unscrewing it did just let it go

 

It seems that you are missing the point that is being made here; this is NOT about faulty sealant, this is about a deficiency in the design of the HVAC intake. That intake is poorly designed, and when you combine it with an aging or damaged cowl cover it can become easy for water to enter the mouth of that intake. What has been done by many of us - and documented in several threads - is to add material to raise the top edge of the intake to prevent water infiltration. This is not about repairing failed sealant.

 

This write up is what you need to do in that area. This weatherstrip is great for the cowl and this area. I did the exact same thing with this material

Cowl Weatherstrip

 

Ok understood it now thank you H20nSnow in a much clear way especially with the comment from Windcity_rover I will take into consideration to buy one and also cover the Hvac intake or extend it in a sense.

What now I have noticed on the drivers side(LHD) is a bit more disturbing, I wanted to check that side too which is mostly dry but now not The screws of the trim piece that holds the carpet is gone, literally cracked all the heads. I will remove the carpet after the new year day, wife is already pissed at me Attaching some photos from under the carpet as well. It does rain substantially today so lets see on thursday or friday.

What I have noticed is that the underneath of the screws is completely empty, so once removed you can see the floor hence the water goes in is my theory. But need to investigate more as this is also disturbing that I do not find water from the roof, nothing drips from under the steering or around. It either comes from the corner as a second point and also from the trim piece that holds the carpet. This repair has gone very beyond and now I am so invested, I will go in deep I do not know where all the parts are and would definitely need new screws for everything

 

Kool, now there are definitely places where the sealant fails that must be repaired. The tops of the A-pillars, the rain gutters, the sunroofs, the roof rack rails, the antenna hole in the rear roof area. All of those need to be addressed. There is NO repairs/replacements/etc. that should be done until the water has been banned from the inside of your ride. Stop the water...everywhere, then repair the damage.

 

Thank you, yes I have sealed as of now the HVAC sides and will extend it via rubber, sealed a broken hose connection on the front sunroof, sealed the drip rail as per technical bulletin, removed the roof racks and sealed around the screw and refit it.
Next to seal I believe is the whole corners etc under the cowl, then will move to seal the top of the windscreen and the corner pieces that is shown in technical bulletin, then I may seal those holes under that carpet trim piece because whatever I do there will be water from there, and most probably will replace the A pillar trim with some after market thingy
After yesterdays rain there is no water dripping from the HVAC fan under the glovebox so that might be a win after sealant and new cowl but I don't want to come to conclusion with just one day of rain I will pour some water with the hose on the window and lets see then

 

One thing I learned by doing this type of repair is that the damage will be worse then what your looking at. Prepare yourself! I would remove that black sound proofing membrane on the floor. One area to inspect is under/around the brake booster. Start at the steering components coming out the firewall and across to the corner by the wiring harness. I had a hole that was around the steering. Couldn't see it inside because of the second plate in the footwell covered it up. Water flowed in behind that plate. I would also remove the plastic trim on the outside sill. The seam sealer behind the front 1/4 panel was gone. I resealed those as well. I ended up replacing the inner and outer sills/ footwell/ lower side and almost half the floor. I posted some pics because it can seem over whelming but it's achievable. Good Luck!!



Someone stole the seam sealer. It was leaking on the inside wall.

New seam sealer and paint

New floor!