Hello. After letting it sit approximately four years, I have been slowly working on reviving my 2003 R53. One of the first things I did was replace the cabin air filter and vacuum the interior.

When I powered up the automatic climate control, bits of (rotted) foam shot out of the dash vents and all over the interior. It was quite a surprise to receive a face full of foam from the fan. Where is the foam coming from? It must be downstream of the cabin filter.

Anyway, I assume the foam is probably weatherstripping foam around the duct work inside the dash. I am wondering if anyone can clue me in as to whether this is right, where the foam is located, and how far in the foam is, as in how much do I have to take apart to get to it. I know from reading other HVAC posts that it can be quite laborious to work on the HVAC system, i.e. the cabin blower is really buried and takes hours of disassembly in order to get to it.

Thanks