Cowl firewall leak pics - Chevy Impala SS Forum
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post #1 of 13 (permalink) Old 06-22-2018, 07:09 AM Thread Starter
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Cowl firewall leak pics

Does anyone have pictures of where the cowl/firewall leaks on the passenger side? I just fixed my clogged ac drain hose and left the carpet pulled back and can see water coming in along the firewall. Insulation on floor and up under the heater box is soaked.

It seems I need to pull the wheel well off to access the box, but what else do I need to do to access where Iím assuming some seam sealer has failed? Iíve searched fo hours and not finding what I need.
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post #2 of 13 (permalink) Old 06-22-2018, 07:22 AM
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Did you check the bottom cover of your evaporator pan and also that the evap drain elbow is connected? I thought i had a cowl leak too. Blew it all out, cleaned everything, ensured the evap drain elbow was there. Still had a wet floor on the pass side. Pulled off the pan for the evap/heater core and re sealed it. No more water.


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post #3 of 13 (permalink) Old 06-22-2018, 11:08 AM Thread Starter
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Yeah the 16Ē hose I have on the drain elbow actually was clogged with mud 4 days ago and leaking. Cleaned it out and all was good. It rained hard yesterday and today and with the carpet out, I can see a slow stream of drips coming in.

Your leak was the bottom plastic cover that sits behind the glove box area? I donít see it leaking anywhere and Iím looking at it with the glove box removed, but it could be from the area against the firewall.
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post #4 of 13 (permalink) Old 06-22-2018, 04:49 PM
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Mine had a crack beside the outlet. I heat welded it, and was exceptionally careful when reinstalling it. I keep a couple of spares just in case I have to pull it again. It took me 4 years to figure it out.

The long hose is overkill, and will get clogged easily. You should shorten it, or keep the end above the frame rail.

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For a parts list, check https://www.impalassforum.com/vBulle...ion-parts.html
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post #5 of 13 (permalink) Old 06-22-2018, 05:37 PM
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There is a thread on this forum concerning rain leaks due to the factory seal sealer failure, in the cowl.

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post #6 of 13 (permalink) Old 06-22-2018, 08:16 PM Thread Starter
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Well I dropped the pan and not sure if it was leaking from there. Now I know this pan was overflowing on Monday due to a clogged drain hose and there is a 1Ē hairline crack towards the bottom left screw hole in the pic. It is along the rearmost part of the pan at its highest point and was not leaking today as I sat in the car watching water come from the drip elbow area of the firewall. It never leaked a drop onto the floor last summer with the ac on and the original seal that was re-used when I replaced the heater core a few years ago.as shown.


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post #7 of 13 (permalink) Old 06-22-2018, 08:19 PM Thread Starter
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Quote:
Originally Posted by Mikeceli View Post
There is a thread on this forum concerning rain leaks due to the factory seal sealer failure, in the cowl.
I found a few topics like that without pics but am looking for a visual before I get into a half day project. I know I will end up breaking some wheel well bolts as well due to corrosion and never having been removed.
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post #8 of 13 (permalink) Old 06-22-2018, 09:58 PM
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Mine had a crack at the white circle. You stated that yours has a hairline crack at the red circle.

I used silicone sealer to make a new gasket, and that may help.
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1991 OCC 461 (.030 over 454) BBC, 3.23 posi, flash to pass, drop spindles & springs, Impala rims, Hydroboost, Recaros, MOMO/wood SW w/QR, custom wood shift knob, Pioneer DEH P77DH
1992 OCC now with 5.7 tbi, DEH P77DH
For a parts list, check https://www.impalassforum.com/vBulle...ion-parts.html
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post #9 of 13 (permalink) Old 06-23-2018, 01:45 AM Thread Starter
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The crack is actually the opposite side from the red circle. So, towards the rear of the car when installed and the highest point of the pan. I just plastic welded it shut on both sides and will reseal with silicone in the morning, allow it to get tacky, and loosely install the screws to let a seal form in the channel. It definitely was not leaking from there yesterday or today when it was raining. While thatís drying, Iíll cut the hose back to right under the top of the frame rail and take the cowl panel off to clean it out. Sunday Iíll see if I still have a leak and if so, use seam sealer on the areas on the firewall that fail.
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post #10 of 13 (permalink) Old 06-24-2018, 02:39 PM Thread Starter
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Well the heater box is sealed and wasnít the issue. I removed the cowl and it was very clean underneath. I only wiped down with a wet rag before taking this pic. The seam sealer has cracks in it so Iím planning to skim over it with seam sealer rather than attempt to remove it all since itís pretty hard and in there really good. Would this likely be the cause of the leak?


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