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The foam is there to make up the difference in space between the housing and the filter. And before you ask why isn't the filter the entire height, the reason is that in some corners of the earth, Saab sells 9-5s WITHOUT air conditioning. The metal refrigerant lines pass over the top of the filter to get to the evaporator.
Hence, the foam strip for AC cars have two holes in them to go around the lines, and the foam strip for cars without AC has no holes, and is glued to the top of the filter.
As for the location, it's all in the packaging. The cabin filter needs to be inline so all the air passes through it, and where it is is pretty good, actually. The 9-5 has a very short and relatively straight path from the blower through the heater. Twists and curves make the airflow less efficient, and could create more noise, or require a more powerful blower.
Did you blow the drains clear? If they're clogged, that's probably why the foam was so disgusting...
_______________________________________
Current:
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2000 9-5 SE sedan, Imola Red
1990 900S Rose Quartz, Auto
Past:
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1990 900 5-speed
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1980 99 GLi
1986 900 turbo
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