Replacing the heater core on a Porsche 968 can be a complex task that requires a good understanding of automotive systems, as well as mechanical skills. click here for more details on the download manual…..
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Below, I’ll provide a detailed guide on the components involved and the step-by-step procedure to replace the heater core.
### Components and Tools Needed:
1. **Replacement Heater Core**: make sure you have the correct part for the Porsche 968.
2. **Basic Hand Tools**:
– Socket set (including extensions)
– Wrenches (metric)
– Screwdrivers (flat and Phillips)
– Pliers
– Torque wrench
– Trim removal tools
3. **Specialty Tools**:
– Radiator hose clamp pliers (optional)
4. **Fluids**:
– Engine coolant (antifreeze)
5. **Shop Supplies**:
– Shop towels/rags
– Bucket or drain pan (to catch coolant)
– Safety glasses and gloves
### Procedure:
#### Step 1: Preparation
1. **Safety First**: Ensure the vehicle is parked on a level surface. Disconnect the battery to prevent any electrical issues.
2. **Drain the Coolant**:
– Place a drain pan under the radiator.
– Open the drain valve located at the bottom of the radiator and allow the coolant to drain completely.
#### Step 2: Remove Dashboard Components
1. **Remove the Glove Box**:
– Open the glove box and remove any contents.
– Unscrew the screws securing the glove box and gently pull it out.
2. **Remove Center Console**:
– Depending on the design, you may need to remove screws or clips securing the center console.
– Gently lift the center console out of the way.
3. **Remove Dashboard Trim**:
– Use trim removal tools to carefully detach any trim pieces around the dashboard area that may obstruct access to the heater core.
#### Step 3: Access the Heater Core
1. **Remove HVAC Control Unit**:
– Unscrew the HVAC control unit from the dashboard.
– Disconnect any electrical connectors carefully.
2. **Remove Ducting**:
– Locate the air ducts connected to the heater core and remove any screws or clips holding them in place.
– Carefully disconnect the ducting to gain access to the heater core.
3. **Access the Heater Core**:
– Locate the heater core housing, which is typically bolted in place. Remove the screws or bolts securing the housing.
– Gently pry the housing away to expose the heater core.
#### Step 4: Remove the Old Heater Core
1. **Disconnect Heater Core Hoses**:
– Locate the two hoses connected to the heater core (inlet and outlet).
– Use pliers to loosen the hose clamps and slide them back along the hoses.
– Carefully pull the hoses off the heater core. Be prepared for residual coolant to spill.
2. **Remove Heater Core**:
– Once the hoses are disconnected, carefully pull the heater core out of its housing. Take note of how it is positioned for reinstallation.
#### Step 5: Install the New Heater Core
1. **Insert the New Heater Core**:
– Place the new heater core into the housing, ensuring it is oriented the same way as the old one.
2. **Reconnect Heater Core Hoses**:
– Slide the hoses onto the new heater core and secure them with the hose clamps.
3. **Reassemble the Heater Core Housing**:
– Reattach the heater core housing and secure it with screws/bolts.
– Reconnect any air ducts removed earlier.
#### Step 6: Reinstall Dashboard Components
1. **Reinstall HVAC Control Unit**:
– Reconnect any electrical connectors
and secure the HVAC control unit back into the dashboard.
2. **Reattach Dashboard Trim and Console**:
– Reinstall any trim pieces and the center console, ensuring all screws and clips are secure.
3. **Reinstall Glove Box**:
– Reattach the glove box in reverse order of removal.
#### Step 7: Refill Coolant and Test
1. **Refill Coolant**:
– Close the radiator drain valve.
– Refill the cooling system with the appropriate coolant mixture.
– Start the engine and allow it to reach operating temperature, checking for leaks around the heater core hoses.
2. **Test Heater Functionality**:
– Turn on the heater and check for warm air coming from the vents. This indicates that the heater core is functioning correctly.
3. **Reconnect Battery**:
– Reconnect the battery and ensure all electrical components are working.
### Conclusion
Replacing the heater core in a Porsche 968 is a labor-intensive process that requires attention to detail. Ensure you follow each step carefully and take your time to avoid damaging any components. If you’re unsure about any part of the process, consider consulting a professional mechanic or referring to the vehicle’s service manual for specific instructions.
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