Pelican Parts
Porsche Parts Catalog Accessories Catalog Porsche How To Articles Porsche Tech Forums
Call Pelican Parts at 888-280-7799
View Recent Cars  |Shopping Cart Cart | Project List | Order Status | Help
Bookmark and Share

Pelican Technical Article:

HVAC Suitcase Removal

Steve Vernon

Time:

15 hours15 hrs

Tab:

$0 to $2,500

Talent:

****

Tools:

Philips, Flathead screwdriver, 5mm Allen, 13mm, 10mm, 7mm socket, 19mm, 17mm, 8mm, wrenches, hose clamps, diagonals, 5mm Allen, T20 Torx

Applicable Models:

Porsche 993 Carrera (1995-98)
Porsche 993 Carrera 4 (1995-98)
Porsche 993 Carrera 4S (1996-98)
Porsche 993 Carrera S (1998)
Porsche 993 Targa (1996-98)
Porsche 993 Turbo (1996-97)

Parts Required:

Zip ties

Hot Tip:

Get a friend to help lift it out

Performance Gain:

Access to everything in the front of the car

Complementary Modification:

Check all of your fuel hoses

There are host of reasons for removing the HVAC "suitcase" from your 993 including replacing the evaporator or just getting it out of the way to work on other components. This can seem like a very intimidating job especially for a DIY'er, but if you take your time and follow these steps you can safely remove it. It is not a quick job and will involve getting under the dash to follow wires and work on vents. I would recommend that you not attempt this job the first time unless you give yourself a weekend to work through it.

Things are packed pretty tight in modern Porsches and that includes the 993. One of the important questions you will ask yourself when you start working on your Porsche is: how the heck do they expect me to get at that part without removing this part? The truth of the matter is that a lot of times you do need to move other parts, systems or components out of the way to change something and then re-install them. Lots of first time DIY'er get frustrated working in really tight spaces or end up damaging something they are not working on just to "save the time" of having to remove other components. If you are going to work on your 993 get in the habit of moving things out of the way and giving yourself all the room you can to work; in the end you will end up saving time and money.

Over the years Porsche has changed small things on the HVAC unit, but the procedure is the same. Just make sure to check that you have disconnected all of the wires and lines that you need to. Also over the years your car may have been serviced by multiple people including previous owners and this can lead to parts having been replaced with different size fasteners and hardware. The sizes of the nuts and bolts we give may be different from what you have, so be prepared with different size sockets and wrenches.

You are going to be working with the main electrical control board which houses the main fuse and relay panel.
Figure 1

You are going to be working with the main electrical control board which houses the main fuse and relay panel. Before you begin you must disconnect the ground strap from the post and the battery and place it where it cannot accidentally come in contact with the post while working (red arrow).

Next drain and remove the fuel tank which will include moving the main electrical board out of the way; please see our article on fuel tank removal for additional assistance.
Figure 2

Next drain and remove the fuel tank which will include moving the main electrical board out of the way; please see our article on fuel tank removal for additional assistance.

Firewall will come out next, so please see our article on firewall removal for further information.
Figure 3

Firewall will come out next, so please see our article on firewall removal for further information.

You are going to be opening the A/C lines (red arrow).
Figure 4

You are going to be opening the A/C lines (red arrow). It is very important that you have the refrigerant removed and stored or disposed of by a professional before you open the lines. Opening up charged A/C systems and venting the refrigerant to the atmosphere is illegal and dangerous, so please make sure to have your refrigerant professionally removed and re-installed if good or properly disposed of!

Figure 5

While not really necessary it is a good idea to remove the cabin air filter covers and filters (red arrows) to give you a good place to grab while removing the suitcase; if you choose to do this please see our article on cabin air filters replacement

Use a Philips head screwdriver and remove the four screws holding the grill and mesh in place (red arrows).
Figure 6

Use a Philips head screwdriver and remove the four screws holding the grill and mesh in place (red arrows). This is also a good time to repaint the grill and mesh

Use a 10mm wrench and remove the two bolts behind the grill (red arrows).
Figure 7

Use a 10mm wrench and remove the two bolts behind the grill (red arrows). These will have rubber isolators with them so do not lose them or forget to reinstall them

Disconnect the A/C sensor (red arrow) and then use a 10mm wrench and remove the single screw holding the bracket in place (yellow arrow).
Figure 8

Disconnect the A/C sensor (red arrow) and then use a 10mm wrench and remove the single screw holding the bracket in place (yellow arrow). Gently pry the mounting block or bracket away from the housing. Cover the lines once they are removed to keep any dirt out.

Move inside the car and remove the climate control unit from the dash.
Figure 9

Move inside the car and remove the climate control unit from the dash. Porsche makes a special tool for releasing the unit from the dash (red arrows) but you can make your own using very strong metal wire and insert them into the four openings.

Pull the climate control unit out and remove the wiring connections from the rear.
Figure 10

Pull the climate control unit out and remove the wiring connections from the rear. The connections are a little different than most, press in the clip (red arrow) and then pivot the connection out from the unit. The two connections are opposite from each other in pivot directions

Working inside the climate control opening remove the two 10mm nut and bolt (red arrows).
Figure 11

Working inside the climate control opening remove the two 10mm nut and bolt (red arrows).

Remove your radio (red arrow).
Figure 12

Remove your radio (red arrow). Depending on what type of system you have will depend on how it is going to come out.

There is a single 10mm nut behind it the holds the suitcase in place that you will now remove (red arrow).
Figure 13

There is a single 10mm nut behind it the holds the suitcase in place that you will now remove (red arrow).

Remove the glove box door and liner (red arrow); please see our article on glove box removal for additional information.
Figure 14

Remove the glove box door and liner (red arrow); please see our article on glove box removal for additional information.

Use a Philips head screwdriver and remove the two screws (red arrows) and then the kick panel on the right side.
Figure 15

Use a Philips head screwdriver and remove the two screws (red arrows) and then the kick panel on the right side.

On the left side you will need to remove the two T20 Torx screws that hold the hood release cover in place to remove the kick panel (red arrows).
Figure 16

On the left side you will need to remove the two T20 Torx screws that hold the hood release cover in place to remove the kick panel (red arrows).

There is a duct on each side of the car that connects with the blower motors in the suitcase.
Figure 17

There is a duct on each side of the car that connects with the blower motors in the suitcase. Get under the dash and wiggle these ducts (red arrow) until the clips on the side release from the blower motor housings and then pull them down. Most people try and force these down from above and break them. This is one of those times where taking a few extra minutes to move some things will end up saving you time, frustration and money. Disconnect the wiring from the unit on the tube (yellow arrow)

The left side is the same; just take your time and remove the duct from the blower (red arrow) and then the wiring connection (yellow arrow).
Figure 18

The left side is the same; just take your time and remove the duct from the blower (red arrow) and then the wiring connection (yellow arrow).

From above you can see that the ducts are now out of the way so you can safely remove the suitcase (red arrow).
Figure 19

From above you can see that the ducts are now out of the way so you can safely remove the suitcase (red arrow).

When you start pulling the suitcase out you are going to bring the wiring harness with it.
Figure 20

When you start pulling the suitcase out you are going to bring the wiring harness with it. Take some time and follow the wiring from the harness and snip all of the zip ties from the climate control unit, blower tubes from both sides and any other wires that will be traveling with the suitcase. If the suitcase is fighting you when you are pulling it out, then you missed some zip ties.

Working back in the front disconnect the drain tubes (red arrows0.
Figure 21

Working back in the front disconnect the drain tubes (red arrows0.

Move the A/C lines out of the way and pull the suitcase forward making sure to compress the rubber bellows on top so it doesn't get hung up (red arrow).
Figure 22

Move the A/C lines out of the way and pull the suitcase forward making sure to compress the rubber bellows on top so it doesn't get hung up (red arrow).

Pass the wiring harness through the opening in the bulkhead (red arrow).
Figure 23

Pass the wiring harness through the opening in the bulkhead (red arrow). If the wiring harness does not come out easily you have missed disconnecting something or a zip tie. Stop and get back under the dash until you have removed everything attached to the harness.

You can now safely remove the entire suitcase and harness, congratulations.
Figure 24

You can now safely remove the entire suitcase and harness, congratulations.

With the HVAC unit out, it is much easier to service.
Figure 25

With the HVAC unit out, it is much easier to service. Installation is the reverse of removal and once everything is back together you can have your A/C system recharged.



Bookmark and Share

QUICK LINKS
About Us
Careers
Pelican Parts, Inc.
1600 240th Street
Harbor City, CA 90710
Order Online or Call:
888-280-7799
CONNECT WITH US
NEWSLETTER
Sign Up for Pelican Pit Stop News & Special Offers
Page last updated: Fri 3/24/2017 03:12:55 AM