Replace evaporator

[Fu Manchu]

All fixed now, with a brand new pedal plate. Zinc coated black spray over it first. Added extra insulation inside and omitted the external insulation panel in the engine bay.

 

[3_putt]

Awesome great work! I suffer from wet insulation under the brake pedal and in the corner next to the kick panel- it drips down from under the dash somewhere as the insulation isn’t wet further up. That was some serious rust for a relatively new car!

 

[3_putt]

You wouldn’t have come across the front drains at all?

 

[Fu Manchu]

There aren’t front drains.

The pedal plate is the only place it can be coming from if it’s as you describe.

Remove the kick panel, door sill panel, trim under the steering wheel and the lower trim in the foot well.

You’ll then be able to start looking in behind the carpet. Get your hand in behind the insulation and lift up. See if the accelerator pedal moves. You’ll need a light in there to see.

It’s rusted like that due to a design fault. The welds were too heavy and gone through the mild steel.

 

[Fu Manchu]

There is also a number of boots and seals that can easily be dislodged. Steering column seal, wiring loom seal, there is a seal where the bonnet cable goes through. There’s a blank seal there too. There is also a seal on the booster.

 

[3_putt]

I’ve pulled the major trim pieces out to gain a better view and from what I can tell there aren’t leaks from the pedal plate area. I did discover that the insulation up the top of the dash was wet at the edge and was dripping down to the insulation in the kick panel area.

Did you say you didn’t re install the insulation behind the pedals?

 

[Fu Manchu]

Did reinstall insulation inside, and extra. Didn’t replace insulation in the engine bay.

The only other place it could come from is the windscreen, which is held on with adhesive sealant.