| | This outlines the modifications I made to the currently available A/C thermostat switch to fit my 1987 911. This the first time (and hopefully only time) I have done this repair and cant comment on whether other model years require similar changes. Dont know if this is what Porsche had in mind for modifications to the switch but it worked for me. As noted on the Pelican site the original equipment switch is no longer available and the recommended replacement switch (#911-613-121-01) requires modification to fit. |
Figure 1 | This picture shows the original (defective) switch on the left and new switch on the right. The new switch is approximately 3 mm taller than the original and will not fit into the console as is, the options are to open up the opening in the console or reduce the size of the switch. The other issue is the shaft on the switch is centered on the body but the mounting hole on the console is offset upwards. This means that the 3mm of material must all be removed from one side of the switch and not some from both ends. |
Figure 2 | The end of the switch where the electrical connections are located is the end that needs to be trimmed back. I began by removing the end of the steel housing by lifting up on the tab; twist it a couple of times and off it comes. |
Figure 3 | To remove the metal and plastic I started with a metal file but quickly switched to a belt sander to expedite the job, after a few trips between the basement and the garage the switch fit into the console with just a little sanding required to the mount hole in the console to allow the shaft to fit through cleanly. |
Figure 4 | Use the material around the lower electrical connection (arrow) to gauge your progress, approximately 1 mm of material remained (do not cut it all away) when the switch fits the console. |
| | Another related tip is to cut off the capillary tube at the base of the old temp switch, do not pull it out of the firewall. Once the new switch is mounted into the console carefully unwind the capillary tube and lay it along-side the end of the old capillary tube. I overlapped the new tube approximately 4 inches to the old tube and then wrapped them with electrical tape. Working from the smugglers box, gently pull on the old capillary tube, the new capillary should be pulled through the firewall attached to the end of the old one. Insert approximately 4 inches of the capillary tube into the evaporator enclosure and you are done. Hope this helps, at least you now have an idea of what is required before you take on this task or decide to hand it off to a mechanic. Blair L |
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