This is the DIY fix for eliminating the black foam that comes out of Porsche heater vents. It had been originally posted on the Rennlist Forum, and wanted to make a video that showed my process in the hopes that you may be able to benefit from my experience. This should apply to Porsche models 996, 986, 997, and 987.
Here’s the original link to the instructions on Rennlist:
https://rennlist.com/forums/996-forum/1183277-repairing-the-black-foam-coming-out-of-vent-issue.html
The two products I used to make the repair:
Duct Seal:
https://www.amazon.com/dp/B00689V41G/
Foam Tape:
https://www.amazon.com/dp/B07WTPVPKK/
I’m not an experienced mechanic, but enjoy learning about my cars and slowly trying to fix more things on my own. This was a beginning step in that direction, and I believe doing it myself probably saved me $1000 in repair costs.
Many thanks to Joe Tegtmeyer for creating the original post on Rennlist that was clear, accurate, succinct, and thorough.
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14:10 – Someone on the Forum created a 3D printed cap file to cover the blend door pivot point. Looks good! https://www.thingiverse.com/thing:5762502
Great video giving instructions on how to get the metal piece out! My car is currently having a heater core change DIY so I`m thinking of getting this foam issue addressed as well. I noticed there`s actually another upstream foam door there as well other than the downstream door shown here. Is there an easy way to get that out and patched up?
Thank you for this, this was a great help!
why did you have to make that cut, could you not just clean the panel and tape without removal?
Great video , thanks!
Just about to embark on this on my 1999 c2. Can I check did anyone swap out the heat exchanger (matrix) while doing it? Or are these generally in good condition even after a number of years?
Had a friend help me with project. We are ###### impressed with you doing this single handed and do the camera work. My hat is off to you. We had an issue that you did not have, we have a subwoofer on the right side of the console. It had two screws to hold it in. One was hidden under the carpet. Don't know how Porschhe put it together. Without your video we could not have done it. Thanks so much!
Problem solved … Regarding the removal of the lower anchor pin via the passenger footwell. I COULD NOT free it from below by pulling on it per Martine500 suggestion. But, from above, looking down into the area where the heater core would sit you can see the top of the lower anchor pin. With a long screwdriver I tapped the top of the pin lightly once and it popped out.
I can't free the lower pin that anchors the mixing door. Understand it has to come out and I did try pulling it straight down (Martine500 suggestion) after I screwed the screw back in half way. It seems to held up by some locking mechanism. Any suggestions welcome.
That Air Flap looks exactly like the one in a 2002 Jetta. similar mechanism also. in my case, foam was also blowing out of the vents. i just had to remove the radio and console and glove compartment then pull on the front plastic piece to access the flaps. used aluminum tape and that was it. works and seals 90%. if i had foam it probably would have sealed up 100%
Is possibile just to cover the holes with other metal stuff??
the person(s) who designed to use bio-degradable foam on this flap is totally the stupidest person in the world. I mean people still go replace with non-biodegradable materials afterwards. Why causing this trouble to the owner?
This definitely seems like a better way to deal with the issue than the more traumatic cutting of the air duct. I will be doing this soon.
Great video. Will be doing mine using your vid as a guide. Thanks!
Cap can also be attached with superglue by sprinkling baking soda on the glue
Great video, gonna be doing it on my 987s boxster soon.
It looks like it may be possible to get to the flaps then put foil duct tape over the holes without cutting anything..
Do you think that's possible?
Did the fix over the weekend. No more foam coming out and my heater works again. Once i had access to the heater core box, I couldn't get the metal flap out until i read a comment to pull the plug under the glove box down/outwith some plyers (reinstall the screw) . On the reinstall i needed a second person to hold down the flap to install the plug back in. Thanks for the video and great fix!
Thanks for posting this, I followed this to do my 987.1 Boxster on the weekend, when i removed the flap there was 0 foam left!