I bought a 986 last month on the cheap. It had a leaking heater core, which I have now replaced. I also did the "hack" repair for the missing blend door foam. I don't know if the a/c worked or not before I got it. I do know that when I first drove it here in Atlanta, I was getting cool air out of the dash...but it was 40 degrees so there's that. Now I'm only getting heat out of it no matter what. No matter how I change the temp, I get heat. I'm pretty sure it has something to do with the door actuator, which I think is under the dash, below the glovebox area. I've tried searching Google, but can't get what I'm looking for. Anyone help?
Try using the diagnostics from the HVAC unit. I haven't tried it for years, but it may help isolate the problem.
https://rennlist.com/forums/996-forum/534109-climate-control-diagnostics.html#post7057458
I have a complete under dash HVAC unit in my parts pile and can get a look at it this evening, post pics etc. and maybe get a diagram from the factory shop manual.
To be clear, I don't claim to be an 'expert', just a hack that plays with Boxsters. Here's a little help:
Thanks!! Mine is an '03, so this should work. The details I may need are accessing that drive motor. From what I can see in the photos, if I remove the cover in the footwell of the passenger compartment, I should be able to see it. I replaced the foam on the flap, but thinking maybe I didn't install it properly and now it's stuck??
I'm not sure which hack you used for the blend door. 'Meir' documented the method going in from the heater core side. I (forum name '78F350') later went in from behind the radio and cutting the duct, starting at post #37 of this thread: http://986forum.com/forums/performance-technical-chat/42802-interior-vent-debris.html
There's also a recent post with a YouTube link showing how to use pre-made plugs for the vent door. https://986forum.com/forums/diy-project-guides/81960-diy-repair-hvac-blend-doors-using-plastic-plugs-i-e-fix-foam-air-vents.html
Those threads and pictures may be helpful for sorting it out.
Thanks! I went in from the heater core side. I don't have the skills to remove the dash or the entire HVAC unit. I cut the top off of the cap in the area where the heater core sits. You can then reach in there and remove the door. I tried to put it back in, but now I get nothing but heat.
If you need more info or any parts, let me know. I have complete units I can pull parts from and it's normally stuff that gets scrapped with the car rather than sold.
SKJSS (formerly Klayfish) said:
Thanks! I went in from the heater core side. I don't have the skills to remove the dash or the entire HVAC unit. I cut the top off of the cap in the area where the heater core sits. You can then reach in there and remove the door. I tried to put it back in, but now I get nothing but heat.
I did the same repair the same way on a 996, with the same results. There's about 3 possible combinations of getting the blend door back in and actuator arm put back together that will fit, but won't work. Took some trial and error to figure it out.
If your electric fans are working with the AC on, it's probably fine and you just need to take another pass at that blend door.
I have the car completely reassembled. Grrr... Don't really want to take it all apart again.
SKJSS (formerly Klayfish) said:
I have the car completely reassembled. Grrr... Don't really want to take it all apart again.
On the 996, you can do all of it through the frunk. Don't know about the 986. The blend door actuator was also accessible without having to take apart the interior, as long as you have three wrists on your right arm and can work upside down and blind. ;)
In reply to Tyler H (Forum Supporter) :
The front of the 986 is the same. I expect that SKJSS will need to go back in the way he came (remove the heater core from the frunk) and get the blend door placed correctly. Before doing that, it's pretty easy to get a look at the actuator under the dash, just to the left of the glove box. See if the actuator is moving at all.
Unless I am replacing the heater core too, my preferred method of repairing the foam issue is to remove the radio console from the dash and access the doors by cutting a flap in the duct.
Helluva place for them to save weight - speed holes covered in biodegradeable foam.
