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i had a 1990 964 with the same problem. i crawled under the dash on the passenger side to find some intelligant previous owner tried expanding foam as a cure, but you can guess that didn't do anything. i got all of that **** out and found the duct work/tubing was old and brittle, basically had a full time leak. i just cut out a short piece and spliced it back together with a hose clamp. problem solved for me. although the other guy had a pretty good reccomendation too with the two heater valves, im not familar with them but that sound quite possible too.
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