Found a new leak today. Looks like the windshield isn't sealed properly in a small spot. Water intruding into the a pillar. I pulled the interior trim and found where it's coming in. Blew air from the outside after removing the exterior trim and confirmed it's seeping in. I used some black silicon for now to seal it up, but will likely have a new windshield install done at some point.

 

Is that the original windshield? I dont see heating elements, but there are a few out there that never had em.

 

I don't think it's original but it definitely has heating elements running through it.

 

Well I fixed the leak that I found. I drove it about 3 hours today in the rain and water is still getting in somewhere up in the headliner/passenger a-pillar. I verified the windshield leak I found is fixed, but can't find the new/second leak. I think I'll have to drop the headliner a bit in the front to see if it's still coming from the windshield, or from somewhere else. I poured water over the tip of the a-pillar trim and it was channeling it properly nad not making it in. This water is getting in and wetting the airbag in the pillar, so I think it's coming either from the top right of the windshield, or somewhere else up there.

 

The pillar trim itself can actually cause leaks. I have attached a TSB for that. You can DIY the fit by removing the trim pins and covering the holes.

Also your sunroof drains may be clogged, once they fill up they can overflow. And I know of one instance where someone has the metal tubes rot and leak. So even if the drains are now flowing, you may have that issue - but its not at all common.

 

I just performed the TSB a few days ago, so I'm relatively sure it's not coming from there. I feel like it's higher up. When I douse the exterior a pillar I'm water I'm not getting intrusion now. The sun roof tubes are newer and appear in good shape behind the interior a pillar. When I tested them a few weeks ago they flowed well. I'll test again after dropping some of the headliner I think. I need to see what's going on behind there.

 

I think I (sort of) located the leak. It definitely has to do with the passenger side sun roof drain. But it's infiltrating not in the passenger footwell, but somewhere up in the headliner and working its way down the a-pillar. When I poured water into the sunroof channel water came through the top of the a-pillar. Looks like I'll have to drop the headliner a bit and see what is going on. Perhaps someone ran all new sunroof drains and didn't fully connect the passenger side properly.

 

Alright, chalk the most recent one up to human error. The foam piece that goes in the intake vent, which the passenger drain plug can be seen in, had slipped down and was blocking the outlet. I found the drain tube really hard to blow through, even after forcing air through it. I pulled the vent to try blowing it out from the other side and the foam piece was soaked. As soon as I pulled it out I could blow through the tube with ease.

 

Well at least it was something simple!