This isn't exactly related, but Art's comment about the debris in there makes me wonder about the blend door problem. After having read some of the blend door posts, I get the impression that one cause for its failure is debris falling down there blocking the door itself.I've been mulling this over, and it occurs to me that a way to avoid this is to cement a fine screen or mesh onto the back side of the cowl vent covers. That would prevent 99% of the crap from getting in, but you'd probably have to be more diligent in keeping them clear. It'd be worth it to me though. I haven't looked at the covers closely, but what are everyone's thoughts on doing this?
As for the leak, I wouldn't necessarily rule out the windshield itself. There's a TSB about it. Here's the text:
Windshield - Water Leaks
Article No. 99-2-3
ISSUE
The customer may report a water leak from the windshield. This may be caused by a skip or a void in the production sealer somewhere around the periphery of the windshield.
ACTION
Apply a bead of Liquid Butyl Sealer (F8AZ-19554-CA) under the weatherstrip around the periphery of the windshield. Refer to the appropriate Service or Workshop Manual for weatherstrip removal where necessary.
NOTE DUE TO DIFFICULTY IN DETERMINING THE EXACT LOCATION OF A WATER LEAK, IT MAY BE IDEAL TO SEAL THE ENTIRE WINDSHIELD PERIPHERY (SIDES, TOP AND BOTTOM) TO ENSURE REPAIR OF THE LEAK.
Mark
'98 LSC
Black on Black