Removal/Installation of Heater/Air Conditioner

Removing and Installing Heater/Air Conditioning Unit

Removal
1. Take off battery ground cable.
2. Draw off refrigerant with service equipment.





3. Remove carpet liner from the trunk.





4. Remove fuel tank. Image above depicts fuel tank hose connections.













5. Remove fuse block and 5 firewall bolts. Images above depict removal of these items.





Note: Airbox components are shown in the image above.

6. Remove the pollen filter covers and the filters themselves. The covers are two thumb screws and the filters are keyed so that the tabs face upwards upon removal.

7. Remove the Air intake grill and retainer frame shown in the image above. Inside the grill, there are 2 bolts that hold the airbox intake that need to be removed.





8. Remove Climate Control Unit(CCU) (shown in the image above) using suitable wire or Porsche SST to release retaining tabs.





9. Disconnect 2 electrical connectors from CCU shown in the image above.

10. Remove Radio. Service and Repair

11. Remove Glovebox.








12. Disconnect Vacuum relay and remove the 3 nuts (shown in the image above) from where the radio and CCU used to be. These hold the lower portion of the airbox in place.





13. Disconnect A/C lines to the expansion valve (shown in the image above). Swing the 2 A/C lines out of the way.









14. Disconnect wiring harness and vacuum lines from airbox (shown in the images above.





15. Remove airbox ducts (shown in the image above). Each duct has 3 plastic snap connectors that must be depressed before the airbox can be removed.





16. Remove airbox assembly (shown in the image above)

Installation

1. Detach spring clamp of left and right heated A/C unit (new version).
2. When re-installing, fit right-hand air guide before heated A/C unit is brought into installation position (for better accessibility). The left-hand air guide can be pushed in place with the heated A/C unit fitted after the large instrument cluster has been removed.
3. Replace O-ring for refrigerant pipes at expansion valve and coat lightly with refrigerant oil.

Note:
Be sure to top up with refrigerant oil when replacing the heated A/C unit or the evaporator. Determine refrigerant oil volume and refill with refrigerant oil (volume drawn off + 30 cc).

4. Recharge A/C system refrigerant.

5. For airbox installation, reverse removal procedure.