Nicole

Some time this winter, my dash will have to come out, so I can replace the AC Evaporator in the heater box. Sounds like a lot of fun...

I know how to get the console out and remove the airbag steering wheel. But that's about where my experience ends.

I have no idea how to remove the glove box on these cars.
I have no idea what I'll have to remove from the pod, beyond its cover.
I am stil not clear on how the dash is attached to the body.
And I don't know what to expect in terms of heater box disassembly and reassembly.

I just did the Ed Scherer comb flap replacement technique, then sprayed some disinfectant spray on the evaporator to get that moldy smell out. Likely that's what dissolved the leak stop I had in the system... They were able to recharge it again with leak stop, but we don't expect it to last very long. At this time the target is to survive the Sharktoberfest trip...

What are your thoughts on new vs. previously loved evaporator?

hacker-pschorr

If you hit the front bumper just right with a baseball bat (wood is preferred, better for the paint) the airbangs come right out.

Nicole

Yeah, the airbags, but not the dash...

0utlier

I am very much interested in this as well. My 90 s4 will soon need a dash and pod recovering. A nice write up with pictures for a pod and dash removal for an air bag equipped 928 would be excellent.

Nicole

One thing very tricky about removing the console: There is a screw on the side of the console, near the air bag cover, that I have no idea how one would access it. Fortunately, someone must have taken my console out at some point and did not put that screw back in. Otherwise i would have gotten stuck at that point. I wonder how others remove that screw...

Ron_H

I think it is best to have a few beers before tackling some of these tasks. Since I gave up alcohol, I guess I'm out of luck.

Ed Scherer

Nicole, see the thread "Center Console Screw".

That thread also refers to an earlier thread, "Need help with center console removal on '90 S4", which details my experience in this area. (I finally got it, too!) IIRC, it actually wasn't that hard to get back in, either, once I had the right tools on hand.

Nicole

Thanks, Ed! Have you ever taken out the whole dash, or only the console? Do we know anybody who has removed and replaced an airbag dash - maybe someone I could at least speak with before I tackle this project later this or early nest year?

Ed Scherer

Nope, just the console (for me). That was enough. I seem to remember some threads or mail list postings on console removal from a long time ago, though, so you might try hunting around a little bit more.

ROG100

Hi Nicole,
I will be doing it on my GTS when I receive my new leather covered dash from Paul C.
I do not see it being much different from a non airbag dash.
The dash itself is held in place by 4 small screws IIRC.
I will take plenty of pics.
To replace the evaporator you do not have to remove the dash. You can access it by splitting the HVAC unit in half. It is held together by clips. The whole HVAC unit will come out without removing the dash.
How do you know your evaporator is leaking?. I would bet on the expansion valve.
Are you using a sniffer?
Best,
Roger

Nicole

Hi Roger:

The car was at an AC place that is very experienced in 928s... I had used s spray to eliminate odor, and that probably dissolved the leak stop that had it sealed for the past four years. Their detector whent nuts near the evaporator, and after recharging it with more lake stop, it seemed to have hardly any detection. The goal is to keep it working for the trip to Sharktoberfest, then we'll see...

In regards to the dash, I'm glad if it does not have to come out. When I had the console out I did not see how I could get to the avaporator. Yes, there is a lower part that seems to be held with clips, but it is my impression that the evaporator is higher up - no? Is removing the lower part enough to get it in and out? That would be awesome!!!

I wish I had a heater box to look at from all sides, so I could better understand how it's put together. Often things are not that difficult once you know the tricks...

I might bother you with a call when I get closer to tackling this project. Glad to know there is someone here who knows something about it...

Shane

Nicole, while you are at sharktoberfest, you will have a great opportunity to look at all the 928 parts your heart desires.

Including the difference between '85-86 cam covers and S4 and up.

0utlier

Please take pics and if you could do a little write up I will make it all into html if you do not know how. I've created a site where I'll be posting all my work, along with picture tutorials (www.928s4.info). An airbag dash/pod removal would be HUGE and greatly appreciated by all MY 90 and up people. Thank you for considering doing this.

Scott Goodwin

Nicole

I took a look at the service manuals and the pictures I took with the console out - I don't know how you would open up the heater box with the dash in place. I just can't see how you could remove more than the bottom part with the footwell flap. The metal pieces of the dash would prevent the heater box from opening towards the passenger compartment.

Thinking about this project makes me sick...

ROG100

Hi Nicole,
I am traveling in Scotland at the moment so do not have a lot of info with me.
I have a 1994 GTS HVAC box which I am going to install in my 93 GTS so that I can have the benefit of the pollen filter. When I get home I wll send you pictures of the assembly so we can see better what has to be done to remove the HVAC unit.
I have never seen a failed evaporator core, more than likly it is your expansion valve. It is worth a try to mix some dishsoap with water and apply it to the expansion valve. All 4 connection points and the ends. The end on the passenger side is a common leak point. The freon leaks at this point and is sucked into the evap. area by the blower and always seems to be the leak point.
Humour me and try the leak test on the expanasion valve. You will see bubbles if it is leaking.
Good luck.
Roger