1985 911 AC removal

[wjdunham]

I have an 85 Carrera from which the PO removed the major AC components, all that's left are all the plumbing and the blower in the smuggler's box. I am planning to finish the job, but don't want to cut any of the lines or do anything irreversible in case I ever want to put all back.

I undid the bolts holding the blower in the smugglers box, which loosened it up but it still has something holding it in place, which I assume is the line coming from the right side bottom of the car attaching to the underside of the blower somewhere. I have the bottom plate removed from the car so I can see up above the steering rack, but doesn't look like it's going to be easy to get up there with a wrench without access to a lift if indeed that's what is keeping it from coming out.

What's the secret for removing this, and for pulling the lines out of the car through the engine compartment without damaging anything?

Thanks for any help,

Bill

[scottrx7tt]

you will need to take the passenger side floor board off. There is a flange that you will have to remove. It sandwiches the firewall in between this piece, and the blower/evaporator assembly.

[darrin]

doesn't one also need to fabricate patches to cover all the holes left after the plumbing is removed?

Also, believe you can repurpose the blower to provide fresh air through the center vents if that's of interest to you.

[Luccia at Pelican Parts]

I know we have a few AC upgrades under the Exhaust, Heating, and Air Conditioning section in our articles here: Porsche 911 (1965-1989) Technical Articles - Pelican Parts. Maybe see if a few of them might give you an idea of what else you can do or see if they might help you with your current project. Good luck!

[DaveMcKenz]

Hi Bill,
I don't know where you live, but having good a/c is not easy with the stock system on your car. Given the state of your car, you may be a good candidate for the new electric a/c system being sold by JohnnyH. It starts about where you currently are, and replaces the a/c blower with there own unit.
A/C can be a valuable addition for extended season of use, and resale.
Good luck,
Dave

[vulcan300]

When I removed my AC I removed the condenser from the blower box, sealed up all the holes in the box, and retained it as a fan to circulate air in the cabin. It was convenient on days when it was too hot or humid and a little air flow was needed in the cabin.

[wjdunham]

Thanks for all the help so far. I doubt I will install an updated system of any sort, but may retain the blower for additional circulation when necessary. I live in San Jose CA, it can get quite warm here but I don't drive this car much so not a priority to have working AC.

I want to remove it in any case to clean the blower and smugglers box. I will remove the passenger floorboard this weekend and see how it goes removing the unit.

Any tips on pulling all the lines out? Seems like the one running down the drivers side of the car may be the trickiest?

Bill

[wayne robson]

You may think that you will never sell, but you will
one day, and for San Jose,and other CA areas,one of the
first items i would want is Air Con.

[DaveMcKenz]

To pull lines, cut them with pruning shears into manageable lengths, say two feet.
Good luck
Dave

[911 Rod]

The lines are a b#tch at the front. I think they put them in before the body panels.

You will be amazed at how much dirt and rubber is hiding in there.

[wjdunham]

Originally Posted by 911 Rod

The lines are a b#tch at the front. I think they put them in before the body panels.

You will be amazed at how much dirt and rubber is hiding in there.

Ya, I've already hit that area with Purple Power and a power washer. Even if I don't remove any more of the AC, I lost several lbs. of rocks and dirt. It just kept coming.

My plan for now is to see if I can get the blower unit out and clean everything up in the smugglers box. In parallel, do some research on the aftermarket products, after some consideration I may decide to keep it as the car is otherwise as it came from the factory with only some bolt-on modifications, and I have all the original parts.

Thanks again for the help.

Bill

[911 Rod]

I don't think I would be using a pressure washer. It will force dirt and water farther in. I just used air on a long wand.

[Lake Guy]

I pulled all of the gear out and made some patches. Also pulled the fuse and disconnected and removed the two control switches (blower and temp). I also had some trouble pulling the blower out of the smugglers box but can remember exactly what caused it. I tried to remove the lines without cutting them but it was impossible at the back so finally got the shears out like DaveyMac suggests. I even tried to sell some parts but nothing happened. I'm glad to have it gone.

[wjdunham]

I was able to get the blower out of the smugglers box. As was mentioned above, the inlet piece needed to be removed as it clamps the blower to the firewall. Very easy once the passenger side floorboard is out, disconnect an electrical connector and four phillips head screws and it pops right out. I'll post a photo when I have a chance in hopes it helps someone in the future.

Got most of the piping out in one piece, one more to go and it's done. Doesn't seem like it would be too difficult to reinstall this all at some point as long as the car is up on a lift.

Bill

[911 Rod]

Are the center vents not useless without the A/C blower?
I use it just to get circulation with the fan.

[Wout_RS]

Hi,

I was doing the same job this weekend on my '80 SC.
The blower is also stuck in the smugglers box. I followed everything like in the Bentley manual is mentioned. The big pipe that's connected to the fresh air blower i was able to remove, the support brackets and the pressure valve.
So if I remove the passenger floorboard an disconnect the electrical connector? for philips head screw it should pop right out?

Thnx

[PatrickS]

Originally Posted by 911 Rod

Are the center vents not useless without the A/C blower?
I use it just to get circulation with the fan.

^^
I'm curious about this also.

[wjdunham]

Originally Posted by Wout_RS

Hi,

I was doing the same job this weekend on my '80 SC.
The blower is also stuck in the smugglers box. I followed everything like in the Bentley manual is mentioned. The big pipe that's connected to the fresh air blower i was able to remove, the support brackets and the pressure valve.
So if I remove the passenger floorboard an disconnect the electrical connector? for philips head screw it should pop right out?

Thnx

Yes, the 4 phillips screws allow you to pull the plastic piece out of the firewall, it comes out in the direction of the passengers seat. Once you have that out the blower unit should come out with some coaxing. It's a tight fit in there for sure. A picture is worth a thousand words, but I've been swamped with other stuff and haven't had a chance to get back up in the attic and pull the blower down and snap a few shots. I've attached a picture from the PET, part #9 is the culprit, you can see where it inserts into the opening at the bottom of the blower enclosure, the lower passenger side footwell firewall is sandwiched in between.

And yes, the center vents do need the blower to provide airflow. As of right now, my plan is to disassemble the blower/evaporator and remove the (heavy) evaporator core. Then reinstall and hook up the electrical connections and have the fan there to move some air. I've seen other threads where folks have run a fresh air hose from the front of the car using the condenser blower cutouts as air inlets, but I'm not too keen on have a 3" hose running through the luggage compartment.

Let me know how it goes and if I can provide any more information.

Bill

[Wout_RS]

Thanks!

It worked. The piece you pull out in the passenger foot well is connected with the blower.
They should mention it in the Bentley otherwise, you can't pull out the blower.

I've attached a photo with the blower out, you can see now with the piece reattached in the foot well that it's sticking out.



How did you close the holes? Are there plastic pop ups avaible on the market?

[Flojo]

Rip it out, cut lines, don't worry. You'll never put it back.
And if yes, you'll take new lines as old ines are about rotten.
Is what I did.