Schocki

The evaporator in my HVAC started to leak last fall and needed to be replaced. I installed a complete 94 unit from Roger in my 92. Box was opened completely everything cleaned (it was close to new). All diaphragms replaced (including recirc), new compressor, new dryer, new expansion valve and all deals and o-rings replaced.

Perfect leak charge and charge. It is blowing very cold air, great.

I have driven the car since my winter project a couple of times with AC on and so far no issues. Yesterday on my way to work after about 30 minutes my foot on the accelerator got wet. Very warm day with high humidity. Normally the vent setting on the controller is either on automatic (both arrows up and down) or on the rectangular box besides the recirc circle. Yesterday, I decided to drive with the upper vents selected only and I got wet feet.

This morning I checked the drain, just to be sure, although I cleaned everything before assembly. I was able to pull the drain hose that sits directly under the evaporator and boroscope it. Nothing in there I was able to see the mesh and evaporator with no problem. The second drain located under the footwell flap is clean to. The drain hose sits properly in the grommet. I checked it from below, it was easy, I have an x-pipe installed.

The only thing I remembered is, that I removed the foam that sits on the lower portion of the footwell openings. It was old, practically non existent and I did not bother to replace it. Below a Rennlist picture of the foam. Any ideas?

Bigfoot928

there is a rubber seal that when it goes it starts leaking. in the drivers feet. Unfortunately you have to pull the box back out to replace the seal.... or you can just put some duct tape on it.

Schocki

Hi Sterling and thank you for your quick reply. All the seals have been replaced and the two parts of the HVAC box were sealed with some sticky non-hardening sealant. Do you have a picture of the exact location of the leak? I prefer the duct tape option (if necessary)

928 GT R

Schocki,

Is it possible that when the output of the AC is focused only on the defrost system that a point of "Local Condensation" is created and that it is not coming from the box?
This can be tested by tracing the source of the condensation... Just a thought.

Enjoy!

Schocki

Might be, but the amount of water was not only a few drops. More water dripped on my right foot when turning (typical).