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Hello,Lilo The styrofoam pack MUST stay in place.When in operation the air tempature is so cold the unit will condensate(create water)if not insluated.Your unit would LEAK all over the place.The blower fan is a PLASTIC composit and should not rust.
If you remove the unit from it's housing by sliding out, you can run it while it is out. This will enable you to see exactly where the sound is coming from. Very often it is because the unit is slightly out of alignment with the outer housing. This can be fixed with a spacer.
Yes to the Styrofoam ,
If there is water running out the front of the system your drain is blocked and or the system needs to be removed to inspect the drain tray and clean out if required.(serviced).
As for it not turning on , check that the fuse isn't blown as the water may have shorted the controls wires and blown the fuse
You need to clean the unit outside(take it out of the window) with a water hose because it is dirty inside( you have to remove screws on cover and take cover off), be sure to cover the electronic control board with plastic so you don't get it wet.Clean fins on front and back with water hose and inside .
It should remain there it is the insulation seperating the condensing side from the evaporating side you may nve to reach in and move it around to prevent the destruction of the foam.
I've never seen styrofoam in a window A/C unit, but who knows.
Where is the styrofoam? Do you suspect the styrofoam is causing a problem?
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