AC repair/evaporator/foam

[Meirschwartz]

Hello Guys.
Recently I replaced the AC evaporator in my car.
It was leaking from the first day a bought it.
The PO was quoted 3500$ for the fix, and that was one of the reasons he wanted to sale the car.
“While I was in there”, as people here in the forum like to say, I cleaned the whole AC system from those
Annoying foam flakes, that use to come out of the air vents when the AC was on.
I also re-foamed the internal flaps of the air box, to make the flap seal the passages as they suppose to.

i have documented the whole process, and prepared some DIY's

As I mentioned in my original post (AC question - 986 Forum - for Porsche Boxster Owners and Others) I will be happy to receive any comments.

This is the full procedure:

Step 1 -Heater removal:
https://www.dropbox.com/s/hxb4w0y3incjrcc/step%201%20heater%20core%20removal.pdf
Step 2 - Dashboard cover removal
https://www.dropbox.com/s/bjsmzjkt7fz4jru/step%202%20Dashboard%20cover%20removal.pdf
Step 3 - Evaporator replacement:
https://www.dropbox.com/s/wjz9stc83j3wxpe/step%203%20Evaporator%20replacement.pdf

[tomk]

I just had a look at the first installment, and it looks like you've done a great job!

thanks for the hard work and very nice writeup

[anderk2]

Meirschwartz,
I very much appreciate your write-up on changing out the heater core. Very instructive --and timely. I am convinced my 2000 Boxster S has a leak, a very small one, I believe, in the heater core or in the connections to the core because I can smell anti-freeze when the blower is on. It is such a small leak that the coolant level has not changed in over a month of checking the level. Also, I can see no dripping from the drain tube that drains the air plenum. It is a very small leak --but I am afraid it will get bigger --and the smell is annoying. Is there any way I can view the core without disassembling all that stuff in front of the window?

[Meirschwartz]

Originally Posted by anderk2

Meirschwartz,
I very much appreciate your write-up on changing out the heater core. Very instructive --and timely. I am convinced my 2000 Boxster S has a leak, a very small one, I believe, in the heater core or in the connections to the core because I can smell anti-freeze when the blower is on. It is such a small leak that the coolant level has not changed in over a month of checking the level. Also, I can see no dripping from the drain tube that drains the air plenum. It is a very small leak --but I am afraid it will get bigger --and the smell is annoying. Is there any way I can view the core without disassembling all that stuff in front of the window?

Unfortunately not.
You will have to compleate step one in order to inspect the heater core.
It is not to hard to complete though.