Interior vent debris

[Meir]

OK.
i found the file, but it is to big to upload, so here is a link from my dropbox.

https://www.dropbox.com/s/hx9qr0t3jtkv6th/986%20Heater%20Flap%20Repair.pdf?dl=0

[grc0456]

Originally Posted by Meir

OK.
i found the file, but it is to big to upload, so here is a link from my dropbox.

https://www.dropbox.com/s/hx9qr0t3jtkv6th/986%20Heater%20Flap%20Repair.pdf?dl=0

Thanks, Meir. Yes, I saw that DIY write-up for 986: Heater Box Repair. That's the one I may try this weekend. I'm just a little hesitant as this - for me - is a big DIY. I want to know if there are any "top tips" (to quote Edd China from Wheeler Dealers) or "beware of this" warnings. I understand you removed the entire heater core, whereas I just want to procedure above.

I actually made a brief attempt to remove the cowl to investigate a few weeks ago and ended up not being to properly re-connect the windshield washer tubes to the nozzles. Not a big deal as the 12-year old nozzles were barely functioning and were going to be replaced anyway by my indy, but you get the picture. Thanks for your help!

Also, did I read you sold the '99? Replace it with anything fun?

[Meir]

Originally Posted by grc0456

Thanks, Meir. Yes, I saw that DIY write-up for 986: Heater Box Repair. That's the one I may try this weekend. I'm just a little hesitant as this - for me - is a big DIY. I want to know if there are any "top tips" (to quote Edd China from Wheeler Dealers) or "beware of this" warnings. I understand you removed the entire heater core, whereas I just want to procedure above.

I actually made a brief attempt to remove the cowl to investigate a few weeks ago and ended up not being to properly re-connect the windshield washer tubes to the nozzles. Not a big deal as the 12-year old nozzles were barely functioning and were going to be replaced anyway by my indy, but you get the picture. Thanks for your help!

Also, did I read you sold the '99? Replace it with anything fun?

Whatever you decide to do, take your time, and do not rush anything.
Come with confidence, but not over confidence. This is the key for any secsessfull project. I remember that when I started mine, I took in mind that I might fail, and will need the help of a professional. So worst case scenario, I assumed I will pay someone to fix the car. So it makes no difference if I try first, right?
During the past 5 years I owned 2 boxsters and compleated many projects, including 2 clutches,2 coolant tanks, 2 RMS , IMS bearing,axels rebuild and many more.
Spent only $260 on labor, to have the AC guy evacuate and recharge the system.
My 01S was my first car I ever worked on. I do not consider my self as a gifted mechanic or anything like it. I just spent a lot of time reading, and learning from others. Most important, I accepted the fact that if I mess up, I have no problem to pay for it.
Funny you mentioned.
I just saw today a nice 01 996 with 75k miles, that will probebly need all of the above.
So looks like I might have another project for this winter, if I get it for the right price.

[grc0456]

to perform the DIY. Took my quite a while to get to the point that the mixer door was out of the car, but I got there. Re-foamed and taped up the door. Putting it back in was very difficult for me. To get the little bushings under the door axis caps on both top and bottom was super tricky. After some cursing and blood, I thought I had every thing back together in order.

Alas, when I started the car up and brought it up to temp for the all-important test of my not too handiwork.......it blew cold air Not even luke warm like before. I could hear the servo motor moving (or trying to move?) the door when I changed the temp on the dash control unit. Any ideas before I admit final defeat and take her to the dealer?

I did take some pics that I hope can be of help to others.

[Meir]

do you have a picture of the re foamd flap back in place?

[grc0456]

I have heat! Now measures 124F when at running temp on HIGH.

The DIY would have worked if I was a little more patient or skilled. The bushing at the bottom of the mixer door axis was cracked, causing the door not to pivot when activated by the servo motor. Not sure if I damaged it during reassembly (it was very tricky to remount the door), or if it had been broken all along. The problem area is located under the circle accessed from the under dash in passenger footwell:



The indie was able to repair the bushing - hopefully - for a long term fix. They had never heard of this foam/mixer door problem, so they learned something. Maybe because it is not as common in colder climates. My car was born and raised in FL. Cost was 4 hours labor.

[Meir]

Glad to see you sort it out.
:dance:

[grc0456]

Originally Posted by Meir

Glad to see you sort it out.
:dance:

LOL, yes! The indie sorted it out for me for $400. Oh well, like you said - try it myself and if it fails then - I was going to pay anyway.

But seriously, I feel like I learned a lot about the car and, actually, the indie learned something new too. They had never seen this problem before as I guess the foam doesn't deteriorate over time up north like it does in the south.

Thanks for your help, Meir!