A timely post...my first to this forum...g'day all from Melbourne Aus!!
I currently have my 92 Tdi in about a million pieces trying to track down a very similar leak. This is what I have found so far...
Water soaking through the sound proofing stuff under the carpet, but it doesn't seem to wet the carpet surprisingly.
I have removed the front carpet and cut the sound proofing so that the wet bits can be removed and then run water over the roof and down the windscreen. Water is entering from quite high up behind the dashboard and dripping down the wiring
I then removed the wipers and the plastic cowel that covers the big levers that operate the wipers and insider the 'vent' thing in the middle was quite wet. Somehow water is getting into this. From other post I've read elsewhere, it seems that water can get past the bottom part of the windscreen rubber and into this vent intake, thus running down the interior firewall. I also read a post from another guy who had made some sort of aluminium plate to put over this air vent, whilst still allowing it to work...am waiting for the info to be emailed to me.
My plan:
1. check out the cost of a new windscreen rubber
.. may be $$$$$
2. fit ?plate over this air vent (as per this other guys instructions.
3. liberal application of seam sealer over any parts/joins/cracks that MAY let water in.
4. remove surface rust on floor of both footwells and apply sealer as above
5. put interior back together as best as I can without losing too much or busting anything...then
watch for it to leak again!! If not
If you would kike some pics of the bits PM me off line...
Cheers and good luck. Let me know if you have found out further.
Mark
