Preliminary work for heating/fresh air unit
1. Drain refrigerant. Refer to 87 03 17 Draining and filling in refrigerant - as of MY 2005 (All Models) .
2. Drain engine coolant. Refer to 19 38 17 Draining and filling in coolant - as of MY 2005 (All Models) .
3. Remove dashboard. Refer to 70 18 19 Removing and installing instrument panel - as of MY 2005 (All Models) .
4. Remove tunnel support.
5. Remove passenger's airbag unit. Refer to 69 59 19 Removing and installing passenger's airbag unit - as of MY 2005 (All Models) .
6. Remove battery. Refer to 27 06 19 Removing and installing battery - as of MY 2005 (All Models) .
7. Remove right plenum panel cover. > 852219 Removing and installing cover - chapter on "Removing"
8. Remove heat exchanger. Refer to 80 23 19 Removing and installing heat exchanger - as of MY 2005 (All Models) .
Removing heating/fresh air unit
Note. Make sure not to damage the insulation of the main wiring harness.
Installation Location
Scheme 2
1. Immediately seal the openings of air-conditioning lines with suitable plugs.
Scheme 3
2. Unscrew fastening screw -1- for refrigerant line -C- and open the pressure line. (Scheme 3), (Scheme 2).
Scheme 4
3. Unscrew fastening screws -2- and remove expansion valve. Refer to 87 70 19 Removing and installing expansion valve - as of MY 2005 (All Models). (Scheme 4)
Scheme 5
4. Unscrew the fastening nuts -6- for the heater/air-conditioning unit in the area of the plenum panel/firewall. (Scheme 5)
Scheme 6
5. Unscrew fastening screw -3- for securing holder of the heater/air-conditioning unit to right side of dashboard bracket (next to A-pillar). (Scheme 6)
Scheme 7
6. Unscrew fastening screw -4- for securing heater/air-conditioning unit to right side of dashboard bracket (passenger's side). (Scheme 7)
Scheme 8
7. Unscrew the two fastening screws -5- for dashboard bracket to right side of body. (Scheme 8)
Scheme 9
8. Unclip holder for electric harness with a screwdriver from right side of dashboard bracket.
Scheme 10
9. Now pull dashboard bracket a few centimeters forward on the right side.
Scheme 11
10. Pull out cotter pin -A- for holder of the heater/air-conditioning unit. (Scheme 11)
Scheme 12
11. Turn holder -B- for heater/air-conditioning unit by 90° and pull up and out. (Scheme 12)
Scheme 13
12. Lay down the air conditioner, release clamp for water drain hose -C- and pull off the water drain hose from the heater/air-conditioning unit. (Scheme 13)
Scheme 14
13. Carefully lift heater/air-conditioning unit forward with a screwdriver under the right side of the dashboard bracket.
Scheme 15
14. Release lower plug connection on heater/air-conditioning unit -a- and unplug. (Scheme 15)
Scheme 16
15. Release upper plug connection on heater/air-conditioning unit -a- and unplug. (Scheme 16)
Scheme 17
16. Cut tie-wraps of electric line (vehicle wire harness to heater/air-conditioning unit wire harness) with side cutters. Remove vehicle wire harness.
Scheme 18
17. Pull air conditioner forward on the right side, unscrew fastening screw -7- for B+ line holder and remove holder for heater/air-conditioning unit. (Scheme 18)
Scheme 19
18. Pull/push heater/air-conditioning unit as far as possible in direction of passenger's seat.
Scheme 20
19. Remove heater/air-conditioning unit from passenger compartment via passenger's door.
Installing heating/fresh air unit
Note. Do not remove the plugs until just before installing the expansion valve. Check the condition of foam parts for damage; if in doubt replace.
Scheme 21
1. Insert heater/air-conditioning unit in the vehicle over the passenger's side.
Scheme 22
2. Lift heater/air-conditioning unit over the center console and position under dashboard bracket.
Scheme 23
3. Position holder for the B+ line on the heater/air-conditioning unit and tighten with the fastening screw -7-. --> Tightening torque: 1.7 (1.5 ftlb.) Nm. (Scheme 23)
Scheme 24
4. Lay electric line from vehicle wire harness to heater/air-conditioning unit wire harness and fix with a tie-wrap.
Scheme 25
5. Connect upper electric plug connection at heater/air-conditioning unit until it is felt to engage.
Scheme 26
6. Connect upper electric plug connection at heater/air-conditioning unit until it is felt to engage.
Scheme 27
7. Check water drain hose for damage; if drain hose shows no sign of damage, connect hose to the drain on heater/air-conditioning unit and fix with the clamp -C-. (Scheme 27)
Scheme 28
8. Push heater/air-conditioning unit into position under right side of dashboard bracket in the direction of firewall.
Scheme 29
9. Guide holder -B- for the heater/air-conditioning unit over the dashboard bracket, push through the mounting of the heater/air-conditioning unit and turn through 90°. (Scheme 29)
Scheme 30
10. Fix holder for heater/air-conditioning unit with cotter pin -A-. (Scheme 30)
Scheme 31
11. Push dashboard bracket forwards while lifting the heater/air-conditioning unit and taking care that no electric lines get trapped.
Scheme 32
12. Screw down dashboard bracket with the two fastening screws -5-. --> Tightening torque: 23 (17 ftlb.) Nm. (Scheme 32)
Scheme 33
13. Clip in the plastic holders for the electric main wire harness to the dashboard bracket.
Scheme 34
14. Secure dashboard bracket with the fastening screw -4-. --> Tightening torque: 9.7 (7.0 ftlb.) Nm. (Scheme 34)
Scheme 35
15. Screw down holder of heater/air-conditioning unit with the fastening screw -3-. --> Tightening torque: 3.5 (2.5 ftlb.) Nm. (Scheme 35)
Scheme 36
16. Slide the fastening bolts of the heater/air-conditioning unit through the firewall lid and tighten with the three fastening nuts -6-. --> Tightening torque: 9.7 (7.0 ftlb.) Nm. (Scheme 36)
Note. Do not remove the plugs until just before installing the expansion valve. Check the condition of foam parts for damage; if in doubt replace.
Scheme 37
17. Install expansion valve and tighten with the two fastening screws -2-, replace sealing rings for refrigerant lines and wet them with refrigerant. Refer to 87 70 19 Removing and installing expansion valve - as of MY 2005 (All Models). --> Tightening torque: 9 (6.5 ftlb.) Nm. (Scheme 37)
Scheme 38
18. Replace sealing rings for refrigerant lines and wet with refrigerant. Position refrigerant line and tighten with fastening screw -1-. --> M8: 14 (10.5 ftlb.) Nm. (Scheme 38)
Subsequent work for heater/air-conditioning unit
1. Install heat exchanger Refer to 80 23 19 Removing and installing heat exchanger - as of MY 2005 (All Models) .
2. Install passenger's airbag unit. Refer to 69 59 19 Removing and installing passenger's airbag unit - as of MY 2005 (All Models) .
3. Install tunnel support.
4. Install dashboard. Refer to 70 18 19 Removing and installing instrument panel - as of MY 2005 (All Models) .
5. Install and connect the battery. Refer to 27 06 19 Removing and installing battery - as of MY 2005 (All Models) . --> 27 06 IN WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY - AS OF MY 2005 (ALL MODELS) .
6. Fill in refrigerant. Refer to 87 03 17 Draining and filling in refrigerant - as of MY 2005 (All Models) .
7. Top up engine coolant. Refer to 19 38 17 Draining and filling in coolant - as of MY 2005 (All Models) .
8. Install right cover for plenum panel. > 852219 Removing and installing cover - chapter on "Installing"
Installing cover
Installation Location
Scheme 39
Scheme 40
1. Lift rubber lip of luggage compartment seal to one side, lift up the cover and disengage it from cowl panel cover.
2. Check condition of Velcro strip -1- on the body and on the cover; replace if necessary. (Scheme 40)
Scheme 41
1. Check condition of Velcro strip -1- on the body and on the cover; replace if necessary. (Scheme 41)
2. Engage cover in cowl panel cover, lift rubber lip of luggage compartment seal to one side and press the cover onto the Velcro strip -1-. (Scheme 41)
Preliminary work for the particle filter
1. Remove battery cover.
2. Remove cover on right for plenum chamber.
Removing particle filter
1. In conjunction with telephone preparation, loosen the antenna at the two top fastening screws and unscrew the two bottom fastening screws. Remove antenna part.
Scheme 42
2. Open the lock -1- on the filter housing. (Scheme 42)
Scheme 43
3. Remove the particle filter upwards and to the side -2- out of the housing guide. (Scheme 43)
Scheme 44
1. Insert a new particle filter into the housing guide -2-. (Scheme 44)
2. Ensure correct seating and installation position.
Scheme 45
3. Close the lock -1- on the filter housing. (Scheme 45)
4. For vehicles with telephone preparation, insert antenna part at the top. Secure the antenna with the four fastening screws.
Work subsequent to installing particle filter
1. Install cover on right for plenum chamber.
2. Install battery cover.
Preliminary work for heating and fresh air blower motor
1. Refer to 68 15 19 Removing and installing glove compartment - as of MY 2005 (All Models) .
Removing heater/fresh-air blower motor
Set blower to position 0 on climate control and remove ignition key.
Scheme 46
1. Unscrew the two fastening screws -1- of support strut and remove support strut. (Scheme 46)
Scheme 47
2. Squeeze the plug -a- on the blower motor and pull off. (Scheme 47)
Scheme 48
3. Unscrew the two fastening screws -2- holding the blower motor cover. (Scheme 48)
Scheme 49
4. Remove the cover -3- for the blower motor and pull out the blower motor downwards. (Scheme 49)
Scheme 50
1. Insert the heater/fresh-air blower motor from below into the heater/ A/C unit and position the cover -3-. (Scheme 50)
Scheme 51
2. Secure cover -3- with the two fastening screws. (Scheme 50)
Scheme 52
3. Insert the electrical plug connection until the plug can be felt to engage.
Scheme 53
4. Install support strut and tighten with the two fastening screws -1-. (Scheme 53)
5. Switch on ignition and the blower in stages on the heating and fresh-air control. Check the function of the blower.
Subsequent work for heater blower motor
Refer to 68 15 19 Removing and installing glove compartment - as of MY 2005 (All Models) .
Preliminary work for defrost air guide
Remove dashboard. Refer to 70 18 19 Removing and installing instrument panel - as of MY 2005 (All Models) .
Preliminary work for left air guide
Remove air vent for left door window. > 855919 Removing and installing air vent at door - section on "Removing"
Remove instrument panel trim. Refer to 70 19 19 Removing and installing trim under dashboard - as of MY 2005 (All Models) .
Preliminary work for right air guide
Remove glove compartment. Refer to 68 15 19 Removing and installing glove compartment - as of MY 2005 (All Models) .
Scheme 54
1. Pull defrost air guide -2- up out of the heater/air-conditioning unit. (Scheme 54)
Scheme 55
1. Disengage air guide -A- for air vent at left door window by pulling it upward at the mounting bracket, then pull to the left out of the air guide slot -B- to remove it in a downward direction. (Scheme 55)
If the air guide -B- is to be removed, first remove the dashboard. Refer to 70 18 19 Removing and installing instrument panel - as of MY 2005 (All Models). (Scheme 55)
Scheme 56
2. Pull the air guide -B- up out of the heater/air-conditioning unit. (Scheme 56)
Scheme 57
1. Disengage air guide -C- at the heater/air-conditioning unit and at the air guide -D-. (Scheme 57)
2. If the air guide -D- has to be removed, first remove the air vent at the right door window. > 855919 Removing and installing air vent at door - section on "Removing" (Scheme 57)
Scheme 58
3. Disengage air guide -D- by pulling it upward at the mounting bracket, and pull it out in a downward direction to remove it. (Scheme 58)
Scheme 59
1. Push defrost air guide -2- onto the connection on the heater/air-conditioning unit. Ensure it is seated properly. (Scheme 59)
Scheme 60
1. Insert the air guide -B- into the heating/air-conditioning unit and check that it is secure. (Scheme 60)
2. Install the dashboard if necessary. Refer to 70 18 19 Removing and installing instrument panel - as of MY 2005 (All Models) .
Scheme 61
3. Slide the air guide -A- into the air guide slot -B- and engage air guide -A- at the mounting bracket. (Scheme 61)
Scheme 62
1. Engage the air guide -D- at the mounting bracket. (Scheme 62)
Scheme 63
2. Connect air guide -C- at the heater/air-conditioning unit and at the air guide -D-. (Scheme 63)
3. Install air vent at door window if necessary. > 855919 Removing and installing air vent at door - section on "Installing"
Subsequent work for defrost air guide
Install dashboard. Refer to 70 16 19 Removing and installing dashboard cover - as of MY 2005 (All Models) .
Subsequent work for left air guide
Install air vent for left door window. > 855919 Removing and installing air vent at door - section on "Installing"
Install trim under instrument panel. Refer to 70 19 19 Removing and installing trim under dashboard - as of MY 2005 (All Models) .
Subsequent work for right air guide
Install glove compartment. Refer to 68 15 19 Removing and installing glove compartment - as of MY 2005 (All Models) .
Preliminary work for central air vent
Remove PCM/radio. Refer to 91 10 19 Removing and installing PCM display and control unit - as of MY 2005 (All Models) .; Refer to 91 24 19 Removing and installing car radio CD player - as of MY 2005 (All Models) .
Removing middle air vent
Installation Location
Scheme 64
Note. The air vent is installed in the dashboard using three locking tabs.
Scheme 65
The two bottom locking tabs can be raised using a small screwdriver.
Scheme 66
The top locking tab must be levered downwards using a thin screwdriver.
1. Using a size one screwdriver, raise the two bottom locking tabs, pulling out the air vent underneath at the same time.
Scheme 67
2. Hold the bottom air vent under tension and push a size one screwdriver through the ventilation slats and the slot for the top locking tab.
Scheme 68
3. Turn the screwdriver to the left through 90° so that the locking tab is pushed down.
Scheme 69
4. Hold the screwdriver and carefully lever out the top air vent from the dashboard using a plastic spatula.
Scheme 70
5. Disengage electric plug connection on device carrier and pull apart plug connection.
Installing middle air vent
1. Connect electric line for air vent with the harness and attach to device carrier.
2. Push air vent into dashboard and ensure that the air vent is pushed into the air guide on the heating/air-conditioning unit.
3. Push air vent into dashboard right up to the stop. Check adjustment options and illumination of air vent to ensure that everything is operating correctly.
Subsequent work for central air vent
Install PCM/radio. Refer to 91 10 19 Removing and installing PCM display and control unit - as of MY 2005 (All Models) .; Refer to 91 24 19 Removing and installing car radio CD player - as of MY 2005 (All Models) .
Removing air vent at door
Note. The air vent is installed in the dashboard using three locking tabs.
The two bottom locking tabs can be raised using a small screwdriver.
The top locking tab must be levered downwards using a thin screwdriver.
Installation Location
Scheme 71
1. Using a size one screwdriver, raise the two bottom locking tabs, pulling out the air vent underneath at the same time.
2. Hold the bottom air vent under tension and push a size one screwdriver through the ventilation slats and the slot for the top locking tab.
3. Turn the screwdriver to the left through 90° so that the locking tab is pushed down.
4. Carefully lever out the top air vent from the dashboard using a plastic spatula.
5. Unclip the side panel on the dashboard using a plastic spatula and disengage the electrical plug connection on the mounting bracket and pull apart the plug connection.
6. Pull out air vent.
Installing air vent at door
1. Connect electric line for air vent with the harness and attach to mounting bracket. Attach the side panel to the dashboard and clip it in.
2. Push air vent into dashboard and ensure that the air vent is pushed into the air guide on the heating/air-conditioning unit.
3. Push air vent into dashboard right up to the stop. Check adjustment options and illumination of air vent to ensure that everything is operating correctly.
Preliminary work for fresh/recirc. air servo motor
1. Remove heater/air-conditioning unit. > 851519 Removing and installing heating/fresh-air unit - chapter on "Removing"
Removing fresh/recirc. air servo motor
Installation Location
Scheme 72
1. Switch off ignition and remove ignition key.
Scheme 73
2. Unscrew fastening screw -1- from below -arrow-. (Scheme 73)
Scheme 74
3. Release and unplug electric connector -a-. (Scheme 74)
Scheme 75
4. Press the locking mechanism of the servo motor actuating lever and press it out from the deflector of the recirculation flap.
Scheme 76
5. Swing down the servo motor and remove from the heater/air-conditioning unit.
Scheme 77
1. Slide servo motor into heater/air-conditioning unit as far as it will go and then swing it upwards.
Scheme 78
2. Clip the servo motor actuating lever onto the deflection lever of the heater/air-conditioning unit.
Scheme 79
3. Lay electric line to the servo motor -A- and connect the electric connector to servo motor until it is felt to engage. (Scheme 78)
Scheme 80
4. Secure servo motor with the fastening screw -1-. --> Tightening torque: 1.2 (1.0 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm. (Scheme 80)
5. Switch on ignition and check function of servo motor by adjusting the air conditioning control.
Subsequent work for fresh/recirc. air servo motor
1. Install heating/air-conditioning unit. > 851519 Removing and installing heating/fresh-air unit - chapter on "Installing"
Remove rear apron. Refer to 63 55 19 Removing and installing rear spoiler - as of MY 2005 (Boxster S, Boxster S RHD) . Refer to 63 55 19 Disassembling and assembling rear apron - as of MY 2006 (Cayman S, Cayman S RHD) . Refer to 63 55 19 Removing and installing rear spoiler - as of MY 2005 (Boxster, Boxster RHD) .
Remove rear luggage compartment carpet.
The ventilation covers are located laterally, underneath, and in front of the tail lights on the left and right.
Installation Location
Scheme 81
Scheme 82
1. Pull the support for the electric line through the luggage compartment to the ventilation cover.
Scheme 83
Note. Removing the ventilation covers destroys the air boxes. The air boxes must be replaced.
2. Unclip the ventilation cover on the body from the inside (luggage compartment area) and take off toward the outside.
Scheme 84
3. Take off the air box from the body and remove any remaining adhesive with cleaning agents.
Note. Removing the ventilation covers destroys the air boxes. The air boxes must be replaced.
Scheme 85
1. Move and position the ventilation cover through the air box, and pull off the protective film of the air box for the butyl cord. The air boxes have a butyl cord attached in the sealing area.
Scheme 86
2. Position the ventilation cover together with the air box on the body and clip in the ventilation cover. Press on the air box in the sealing area to the body again.
3. Push on electric line to the ventilation cover.
Insert rear luggage compartment carpet.
Install rear apron. Refer to 63 55 19 Removing and installing rear spoiler - as of MY 2005 (Boxster S, Boxster S RHD) . Refer to 63 55 19 Disassembling and assembling rear apron - as of MY 2006 (Cayman S, Cayman S RHD) . Refer to 63 55 19 Removing and installing rear spoiler - as of MY 2005 (Boxster, Boxster RHD) .
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