2004 S2000. Significant water (not fluid) leak into passenger side foot-well. From rain or from AC? Has any body had this problem? How to fix it?

 

remove the passenger seat, get in the car and have somebody spray the car with water and look around for the source. if you don't see any water then let the car sit and run the ac full blast and look for the leak.

all cars have a drain for the evaporator, if the line is kink'd or damaged it could be overflowing back into the car, that may be your problem if its from the ac.

 

it is from the ac. i saw a service bulletin on it. It only said 00-01 though so who knows.

WATER DRIPS ON THE PASSENGER'S CARPET TECHNICAL SERVICE BULLETIN

SYMPTOM: In humid conditions, with the A/C on and the fan running at maximum speed, water drips on the passenger's carpet.

PROBABLE CAUSE: When the fan is running at maximum speed, water condensed on the evaporator core can blow into the heater unit. The heater unit does not have a drain to remove collected water. Water collects on the bottom of the heater unit and leaks from the lower seam in the housing.

CORRECTIVE ACTION: Seal the heater unit.


REPAIR PROCEDURE
1. Remove the blower/evaporator unit to access the heater unit opening
2. Use a utility knife to carefully shave off the lower lip of the heater unit opening where
the blower/evaporator unit.
3. Remove the front screw from the bottom of the heater unit.
4. While gently pulling the heater unit halves apart, fill the lower seam from inside the
weatherstrip adhesive.
5. Reinstall the screw, and let the adhesive cure for 20 minutes.
6. Spread a generous amount of silicone paste on the foam seal of the blower/evaporator opening.
7. Carefully reinstall the blower/evaporator unit, making sure to get a tight seal with the the foam seal.
8. Evacuate and recharge the A/C system
9. Start the engine, and run the A/C to make sure it works properly.

I would take it into the dealer just to make sure that is the issue. are you still under warranty?

 

Make sure the drain tube is not crimped. I had a similar problem after hauling some stuff and it turned out the drain tube was crimped and keeping water in the evaporator box.