For future reference just in case anyone has the same water ingress problem - this is an issue and fix and didn't see anywhere else when doing plenty of searching.
Symptoms: steaming up windows, damp carpet, water dripping around heater blower onto peddles etc (so not o-rings obviously). Suspected pollen filter covers etc and stirpped all that back and sealed things up - problem remained but not too bad. Then had lots of snow and ice for weeks, and after the thaw very big problem, lots of water in footwell, could catch water running out of pedal area. Then saw wet headlining above sun visor.
Investigation: suspected sunroof, so checked drain tubes (see other posts) and all seemed well. Removed inner screen pillar trim, sunvisor brackets and eased headlining down - soaking wet from leak and condensation. Poured water into sunroof channels and no issue. Poured it onto roof above screen and it literally ran out inside of the car and hit the steering wheel (as headlining moved down). Suspected windscreen sealing, so removed side then upper screen finisher and poured water on the screen/body join - no problem - couldn't recreate the waterfall? So then poured on roof again next to the front-back running strip for roof racks and waterfall. Removed that strip (it just pulls upwards against stong clip pressure), and found the culprit...
Problem: A hole in the original seam-sealer where two steel panels join beneath the roof-rail running strip. In my case it would have been just visible in front of the ruuning strip behind the screen finisher, but best to remove the rail to be sure. In my case i suspect the hole has been there from manufacture. Under the screen finsiher some sealer had been squirted in the the trim in place, and i suspect this had blocked the hole reasonably well but the cold and ice had dislodged it and allowed much more water in.
Fix: Blew some compressed air into the hole to clean and dry it up (came whistling into the cab...) - then sealed with a quick squirt of RTV sealant. Reassemble and then spend several days trying to dry waterlogged carpet etc...
trim removed:
the problem hole in the seam sealer:
hope it may help someone else with water problems
Symptoms: steaming up windows, damp carpet, water dripping around heater blower onto peddles etc (so not o-rings obviously). Suspected pollen filter covers etc and stirpped all that back and sealed things up - problem remained but not too bad. Then had lots of snow and ice for weeks, and after the thaw very big problem, lots of water in footwell, could catch water running out of pedal area. Then saw wet headlining above sun visor.
Investigation: suspected sunroof, so checked drain tubes (see other posts) and all seemed well. Removed inner screen pillar trim, sunvisor brackets and eased headlining down - soaking wet from leak and condensation. Poured water into sunroof channels and no issue. Poured it onto roof above screen and it literally ran out inside of the car and hit the steering wheel (as headlining moved down). Suspected windscreen sealing, so removed side then upper screen finisher and poured water on the screen/body join - no problem - couldn't recreate the waterfall? So then poured on roof again next to the front-back running strip for roof racks and waterfall. Removed that strip (it just pulls upwards against stong clip pressure), and found the culprit...
Problem: A hole in the original seam-sealer where two steel panels join beneath the roof-rail running strip. In my case it would have been just visible in front of the ruuning strip behind the screen finisher, but best to remove the rail to be sure. In my case i suspect the hole has been there from manufacture. Under the screen finsiher some sealer had been squirted in the the trim in place, and i suspect this had blocked the hole reasonably well but the cold and ice had dislodged it and allowed much more water in.
Fix: Blew some compressed air into the hole to clean and dry it up (came whistling into the cab...) - then sealed with a quick squirt of RTV sealant. Reassemble and then spend several days trying to dry waterlogged carpet etc...
trim removed:
the problem hole in the seam sealer:
hope it may help someone else with water problems