Same problem solved
Hi, I recently bought a used 200 000 km 2004 Montana.
When doing my first good cleaning of this van, I found that the floor carpets were humid, and when I lifted them up I found quite a bit of water and rust! Was quite disappointed. The hunt for the leak began!
After a first attempt at drying the floor and a few search ont the web, I decided to attack the AC. I had no elbow on the firewall side, but, no evidence that water was leaking in. In fact, I saw that water was in fact flowing out of the car by the little tube. That is until I lifted the rubber/foam that starts where the carpet ends and goes up to meet the firewall. Did not see anything wet, as the foam quickly absorbs any moisture, but found traces of "dried" water running down on the foot panel. Need not look further. I went to the hardware store and bought a 1/2 inch copper elbow (thanks to I dont remember what forum), put some black silicone as glue and voila, I had a new working AC drain. Oh, I did check and it was not clogged at all.
Wanted to check if there was any other leak, so I washed the van. After washing, there was new water on the floor... Not much though. Seemed to get in where the wires are on the passenger side, near the door's hinge.
Removed the Wheel, inner fender splash guard, fender (that wasn't necessary but made my life easier) and poured some water on the windshield. Could not see where the water was getting in, but water kept flowing Inside. I put a flashlight on the inside of the van, pointing at the joint between the firewall and inner fender. I saw the light!!
There it was. I could see the metal sheets were not touching at some point.
Just to confirm, I put a drop of food coloring (red) just above this small opening, and poured water from the top. Water inside the car was red indeed.
Dried the whole thing up with a hair dryer, put some black silicon along the joint of the metal sheets and that's it. Reassemble everything before it gets too dark!
Hope this is going to help someone else!