GRRRRRR.... RTV'd the bottom of the Evap box back on, and the water leak is still there (only with the AC on). WTF. If I jam my hand up behind the box I can actually feel the water coming down the back of the box. Could it be the seal where the A/C lines come into the box? I really didn't feel like removing the whole dash.... but I guess I'm going to have to.
You do realize that AC systems remove moisture from the air, and that moisture collects on the evaporator, drips down, and must be drained somewhere. If it doesn't drain, the car will soon smell very funky on the inside, and always have condensation on the windows in the morning.
The drain for the evaporator is located between where the 2 heater hoses enter the cabin, and is pointed straight down. Take a flashlight with you when you get under there, and you'll clearly see a 1/8" round hole there.
Plug that hole, and you'll have a swampy car.
For your sake, please identify if you're leaking clear water or engine coolant. Clear water is ok, engine coolant is not. If you can't figure it out, then put a piece of cardboard under the car where it's leaking. Let it get good and wet from the drip. Then dry it in the sunlight. If it dries with a white residue on it- then it's coolant. If not, then it's water from condensation.
If you don't believe me, this is a mechanical action- all cars drip clear water when sitting with the AC running. The amount of water depends on the humidity. You can commonly see this in parking lots- especially under those vehicles where someone is sitting there waiting for someone to come out of the store.
