Air Conditioner Porsche Boxster S 986 рестайлинг

Safety regulations when handling refrigerant R 134a

The refrigerant R 134a which is used is known as a safety refrigerant. This means that this refrigerant is non-flammable, non-explosive, non-toxic, non-irritating, odorless and tasteless. Despite this, you should still follow the points below.

1. Avoid all contact with liquid or gaseous refrigerants. Treat affected skin in the same way as in the case of freezing. Rinse immediately with cold water and then consult a physician. Wear safety goggles to protect your eyes. If refrigerant still gets in your eyes, consult a physician immediately. Wear rubber gloves to protect your hands.
2. When carrying out repairs on the air-conditioning system, the system must be emptied by suction and the refrigerant must be purified. Chlorine-free refrigerants must also not be allowed to escape into the atmosphere and must be disposed of correctly. Due to their chemical composition, different refrigerants must not be mixed with each other (not even in small quantities).
3. Never perform welding work on parts of the closed air-conditioning system or in its immediate vicinity. Whether or not the system is filed with refrigerant, the heating causes a very strong overpressure which can cause damage to the system or even lead to an explosion. R 134a is completely non-toxic at normal temperatures, but it decomposes upon contact with a flame or at high temperatures.
4. Refrigerant bottles must not be thrown and must not be subjected to direct sunlight or other heat sources for an extended period when full. The maximum permissible temperature of a filled refrigerant bottle must not exceed 45°C.

Assembly work on the air-conditioning system

Service unit SECU 134

Scheme 24

1. Low-pressure pressure gauge
2. High-pressure pressure gauge
3. Torr meter)
4. Low-pressure shut-off valve (blue)
5. High-pressure shut-off valve (red)
6. Torr meter shut-off valve (black)
7. Vacuum pump shut-off valve (yellow)
8. Low-pressure flange
9. High-pressure flange
10. Refrigerant inlet shut-off valve
11. Refrigerant outlet shut-off valve
12. Refrigerant oil inlet shut-off valve
13. Refrigerant oil vent valve
14. Moisture indicator
15. Oil tank vacuum flange
16. Hourmeter
17. Pilot light SUCTION END
18. Pressure switch SUCTION/CLEANING
19. Main switch ON/OFF
20. Pressure switch HEATING
21. Pilot light FAULT
22. Pressure switch VACUUM PUMP
23. Filling cylinder with weight scale
24. Filling cylinder shut-off valve
25. Filling cylinder high-pressure gauge
26. Refrigerant oil suction nozzle
27. Refrigerant oil reservoir inspection glass

Note. The manufacturer's operating and repair instructions must be observed when carrying out all work on the service unit.

Assembly work involving the refrigerant system

During all work on the air-conditioning system which necessitates opening the refrigerant system, the system contents must first be disposed of correctly. When doing so, follow the safety regulations.

Dirt and moisture must be kept out of the air-conditioning system's pipe system. Thorough cleanliness must therefore be ensured during all work. System components must never be cleaned on the inside with hot steam. Use only nitrogen for cleaning purposes.

When replacing a component, all openings must be closed off with suitable plugs.

General assembly sequence

1. Remove refrigerant by suction.
2. Remove faulty part.
3. Evacuate.
4. Check the system for leaks.
5. Rinse with refrigerant.
6. Empty the system by suction again.
7. Evacuate.
8. Fill.

Note. Pay attention to sealing rings when disconnecting or connecting the hose connections.

1. A - High-pressure; B - Low pressure
2. The charging valves are located in the area of the front right spring strut.

Scheme 25

Scheme 26

1. close
2. open

Note. Close all valves before carrying out each work step.

REFRIGERANT REMOVAL

*Pressure too high/filling cylinder full. Drain off refrigerant from the filling cylinder into a refrigerant bottle (approx. 50 %).

Scheme 27

1. close
2. open

CLEANING REFRIGERANT

*Pressure too high/filling cylinder full.

**One revolution OPEN. After approx. 15 minutes CLOSED.

Scheme 28

1. close
2. open

1-ON/OFF

Instructions

*1 open to *2 OFF, then *1 CLOSED and *3 OPEN.

Scheme 29

1. close
2. open

1-ON/OFF

2-VACUUM PUMP

Evaluation time at least 15 minutes.

Scheme 30

1. close
2. open

1. 1-ON/OFF

Scheme 31

1. close
2. open

1. ON/OFF
2. HEATING

* Pressure 8... 10 bar.

**If pressure is less than 8 bar.

After using the SECU, perform internal suction removal; first close the hand valves on both suction lines.

Refilling the air-conditioning system

Note. In the event of insufficient refrigeration performance, remove the refrigerant by suction, top up with the stipulated quantity and check the system for leaks.

1. Remove the refrigerant by suction using the service unit.
2. Determine the refrigerant oil quantity after the refrigerant has been removed by suction.
3. Fill up with new refrigerant oil.
4. Evacuate.
5. Fill with the stipulated amount of refrigerant.
6. Check the system for leaks.

Distribution of the oil quantity in the refrigerant circuit

OIL QUANTITY

After suction removal from the system, the following quantities remain in the

DISTRIBUTION OF THE OIL QUANTITY IN THE REFRIGERANT

Note. In new vehicles, the amount of oil removed by suction is approx. 15 ... 40 cm 3 . Oil removed by suction must be returned to the system.

Refrigerant oil removed by suction from a previously run air-conditioning system must no longer be used (special-category waste).

After the refrigerant has been removed by suction and a component has been replaced, the oil quantity must be determined and topped up by the quantity remaining in the removed component.

Scheme 32

1. Remove the cover above the heating/air-conditioning system.
2. Remove refrigerant by suction using the service unit.
3. Pull off the cable plug on the pressure switch.
4. Undo and unscrew the pressure switch.

Installation

1. Replace the O-ring on the pressure switch and wet it with refrigerant oil. Tightening torque: 3 Nm
2. Refrigerant oil removed from a previously run air-conditioning system may no longer be used (special-category waste).

Scheme 33

1. Remove the cover above the heating/air-conditioning system and fluid tank.
2. Remove refrigerant by suction using the service unit.
3. Undo the hose clamp on the fluid tank. Undo both hexagon-head bolts on the fluid tank and remove the fluid tank upwards. Immediately close lines with plugs so that they are air-tight.

1. Do not remove the plug until shortly before installation. Replace the O-ring on the branch piece and on the refrigerant line, and wet the new O-rings with refrigerant oil.
2. Tighten both hexagon-head bolts on fluid tank with 6 Nm.
3. Determine the quantity of the refrigerant oil and fill up again with refrigerant oil (volume removed by suction + 30 cm 3 ).

Note. The fluid tank must be replaced if the system suffers from operational faults (e.g. accident damage or air-conditioning system depressurized). Refrigerant oil removed from a previously run air-conditioning system may no longer be used (special-category waste).

Scheme 34

Scheme 35

Scheme 36

Scheme 37

1. Remove the cover above the heating/air-conditioning system.
2. Remove refrigerant by suction using the service unit.
3. Remove the left seat. Disconnect the battery and cover the terminal or battery. Remove the lid for the engine compartment and rear wall flap behind the seats.
4. Relieve the drive belt on the tensioning pulley and remove the belt.
5. Detach the battery positive connector at the B+ connection on the engine. Undo the B+ connection (2 screws M6) on the engine and put it aside.
6. Remove the fluid of the power steering in the supply tank until below the connection. Remove the servo-tank (bayonet lock). Observe the marking (arrow) during installation. Seal off the connection against dirt.
7. Undo the compressor fastening screw between the intake pipes, cylinders 4 and 5.
8. Undo the refrigerant lines at the compressor. Immediately close the connections and lines with plugs so that they are air-tight.
9. Undo the front compressor fastening screws (2 ea.) and disconnect the electrical plug connection.
10. Carefully remove the compressor to the front.

Note. New compressors are under pressure and are filled with the required amount of oil for the refrigerant circuit. The remaining oil quantity in the individual components must therefore be taken into account.

Scheme 38

1. First, open the cap on the high-pressure side and relieve the pressure from the compressor (A).
2. Open the oil filler screw (B) on the compressor.
3. Empty approx. 80 cm 3 of refrigerant oil out of the compressor and into a measuring glass. The remaining quantity of oil (approx. 120 cm 3 ) remains in the compressor. NOTE: Refrigerant oil from the compressor or refrigerant oil removed by suction from a previously run air-conditioning system may no longer be used (special-category waste).
4. Tightening torque for the compressor fastening screws on the engine (screws M8): 28 Nm
5. Tightening torque for refrigerant line (screws M8 x 32): 23 Nm Use fastening screws from the new compressor. Replace O-rings and wet with refrigerant oil.
6. Do not remove the plugs for the lines and compressor connection until shortly before installation.
7. Tightening torque for oil filler screw (M10 x 1): 26-36 Nm Always replace the sealing ring.

Running-in regulations for new compressor

Note. Fill the air-conditioning system (fluid) via the high-pressure side from the refrigerant circuit with the engine "OFF".

1. If possible, all air outlet nozzles "OPEN", circulating air "CLOSED"
2. Start the engine and allow idle speed to stabilize (approx. 5 seconds).
3. Set the fan to max. output.
4. Switch on the air-conditioning system (AC switch) and allow it to run uninterrupted for at least 2 minutes at 1500 rpm.
5. After 2 minutes uninterrupted compressor operation time, the oil distribution in the air-conditioning system is completed and the compressor can be run up to the max. engine speed.

Scheme 39

1. Remove the cover above the heating/air-conditioning system.
2. Remove refrigerant by suction with the service unit.
3. Undo the air-conditioning lines at the expansion valve. Close connections and lines immediately with plugs so that they are air-tight.
4. Undo the expansion valve and remove it. Immediately close the lines to the evaporator with plugs so that they are air-tight.

1. Do not remove plugs until shortly before installation. Replace O-rings and wet the new rings with refrigerant oil.
2. Refrigerant oil removed by suction from a previously run air-conditioning system may no longer be used (special-category waste). Tightening torques: TIGHTENING TORQUES Screw M5 6 Nm Screw M6 9 Nm

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

1. Remove the covers over the heating/air-conditioning system, battery and fluid tank. Disconnect and remove the battery.
2. Remove refrigerant by suction using the service unit.
3. Detach the air-conditioning lines at the expansion valve. Close the connections and lines with plugs immediately so that they are air-tight.
4. Remove the steering wheel and loosen the steering column panel. Observe the safety regulations for handling airbag units (see «SAFETY REGULATIONS FOR VEHICLES WITH AIRBAG AND BELT TENSIONER»(/porsche/boxster-s/986-2002-2004/remont/airbag/#passenger-protection__safety-regulations-for-vehicles-with-airbag) ).
5. Undo the central screw (clamp) on the steering column switch from below and pull it forwards slightly. Remove the cover at the top and disconnect the electrical plug connections. Remove the steering column switch.
6. Detach the instrument panel and unclip the right side upwards. Disconnect the electrical plug connections.
7. Remove the steering column cover (4 screws).
8. Remove the radio and heating/air-conditioning controller. Unclip the switch panel on the left and on the right. Disconnect the electrical plug connections. Undo the retaining frame in the center and remove it.
9. Remove the left side nozzle and disconnect the electrical plug connection. Unclip and remove the sun sensor cover and defrost panel.
10. Undo the interior monitoring system and disconnect the electrical plug connection.
11. Remove the air guide at the bottom right. Remove the passenger's airbag unit. Observe the safety regulations for handling airbag units (see «SAFETY REGULATIONS FOR VEHICLES WITH AIRBAG AND BELT TENSIONER»(/porsche/boxster-s/986-2002-2004/remont/airbag/#passenger-protection__safety-regulations-for-vehicles-with-airbag) ).
12. Remove the front cover of the center console. Undo the fuse holder and diagnosis plug in the left footwell.
13. Undo the control panel at the bottom, center, left and right. Carefully remove the control panel and detach the loudspeaker cable.
14. Undo the center tunnel support on the support frame at the top and on the tunnel holder at the bottom.
15. Remove the left air guide. Only loosen the defrost channel. Undo and remove the center air distributor casing.
16. Disconnect the central plug connections (2 ea.) from the heater/air-conditioning unit.
17. Disconnect the battery positive terminal on the current distributor and the current distributor on the cover front wall.
18. Disconnect both heating hoses upstream of the heat exchanger with the standard hose clamp. Disconnect the heating hoses on the heat exchanger and plug the connections.
19. Undo the heater/air-conditioning unit on the lid firewall (3 nuts). Pull off the water drainage hose from the heater/air-conditioning unit.
20. Undo the holder of the heater/air-conditioning unit from the passenger's side at the top right.
21. Carefully lower and remove the heater/air-conditioning unit downwards into the footwell. Do not damage the electrical plug connections or cables.

Scheme 48

1. Ensure that the air distributor casing and air guides are correctly positioned. Engage the electrical plug connections and carefully lay the electrical cables (do not pinch).
2. Observe the safety regulations for handling airbag units (see «SAFETY REGULATIONS FOR VEHICLES WITH AIRBAG AND BELT TENSIONER»(/porsche/boxster-s/986-2002-2004/remont/airbag/#passenger-protection__safety-regulations-for-vehicles-with-airbag) ).
3. Set the steering column switch: Use a depth gauge to measure between the end of the steering axle and the metal cover of the steering column switch (see figure). Adjustment dimension: 55 +/- 0.5 mm
4. Replace the seal between the current distributor and firewall if necessary. After fitting the current distributor on the firewall (tightening torque 15 Nm), tighten the battery cable with a new M8 hexagon nut. Tightening torque: 15 Nm.
5. Replace the O-rings for the refrigerant lines at the expansion valve and wet the new O-rings with refrigerant oil. NOTE: If the heating/air-conditioning unit is replaced, the refrigerant oil in the evaporator must be topped up. Determine the quantity of the refrigerant oil and top up again with refrigerant oil (volume removed by suction + 20 cm 3 ). Refrigerant oil removed by suction from a previously run air-conditioning system may no longer be used (special-category waste).
6. The heat exchanger is connected to the engine-cooling system, and coolant flows through it when the engine is running. The cooling system must be bled after removal or installation of the heater/air-conditioning unit (see «DRAINING AND FILLING IN COOLANT (INCLUDES: BLEEDING»(/porsche/boxster-s/986-2002-2004/remont/cooling-system-mechanical/#engine) ).

Scheme 49

1. Remove the cover above the heating/air-conditioning system.
2. Remove the refrigerant by suction using the service unit.
3. Completely remove the front spoiler. Remove the air guide to the condenser and pull off the electrical plug connection on the temperature sensor.
4. Undo the refrigerant line on the condenser. Immediately close connections and lines with plugs so that they are air-tight.
5. Undo the fastening screws (2 screws) from the condenser and pull the condenser to the side out of the holder.

1. Do not remove the plugs for the lines and condenser connection until shortly before installation.
2. Replace O-rings and wet the new O-rings with refrigerant oil.
3. Tightening torques: TIGHTENING TORQUES Refrigerant lines M6 10 Nm Condenser 4,0 +/- 0,5 Nm When loosening or tightening the M8 refrigerant lines on the condenser, always counter with a 21-mm open-ended wrench.
4. Determine the quantity of the refrigerant oil and top up again with refrigerant oil (volume removed by suction + 20 cm 3 ). NOTE: Refrigerant oil removed by suction from a previously run air-conditioning system may no longer be used (special-category waste).

Scheme 50

1. Use a standard strap wrench to securely hold the pressure plate, and undo the fastening screw.
2. Screw a screw M8 into the thread of the pressure plate until the pressure plate can be removed manually. Remove the spacer washers.
3. Use standard Seeger circlip ring pliers to remove the Seeger circlip ring. Manually remove the belt pulley.
4. Unscrew the cable of the magnetic coil from the compressor housing. Remove the Seeger circlip ring. Remove the magnetic coil from the compressor housing.

Scheme 51

Scheme 52

1. Place the magnetic coil on the compressor housing. The locking pin must engage in the locking hole.
2. Install the Seeger circlip ring. The slanted surface (arrow) of the Seeger circlip ring faces upwards (to the fastening screw).
3. Tighten the pressure plate fastening screw. Tightening torque: 14 Nm.

Scheme 53

1. Check the air gap between the pressure plate and belt pulley with a depth gauge.
2. Place a rule on the outer edge of the belt pulley. Use a depth gauge to measure up to the pressure plate. Apply battery voltage to the magnetic coupling and measure the distance (air gap) to the attracted pressure plate. Always measure at atleast three points on the pressure plate in order to obtain a mean value. Distance: 0.5 mm +/- 0.15 mm
3. If the air gap is not in the tolerance range, it must be adjusted with the aid of the spacer washers.

Removing and installing drive motors of the heating/air-conditioning unit

Note. Removal and installation of drive motor for temperature valve, central valve and footwell/defrost valve. Removal or installation is performed with the heating/air-conditioning unit installed.

Drive motor for temperature valve

Scheme 54

Drive motor for central valve

Scheme 55

Removal

1. Remove footwell bulkhead and air guides. Unclip centre console cover at the front and remove the footwell vent (3 screws).
2. Press pivot pin on the adjusting lever together and disengage the deflection lever.
3. Unscrew drive motor of the heating/air-conditioning unit and disconnect the electrical plug connection.

Scheme 56

1. Unscrew drive motor with bracket from the heating/air-conditioning unit (2 screws).
2. Swivel drive motor to the side and disengage the deflection lever.
3. Disconnect electrical plug connection and detach bracket from the drive motor.

1. Ensure that the deflection levers are seated correctly.
2. Tighten fastening screws carefully (plastic housing).
3. Engage electrical plug connections and route wire carefully.
4. Perform function test after installation of the drive motors.

Scheme 57

1. The recirculation button must be pressed before removal (fresh-air supply blocked). The drive motor can be removed from the installed heating/air-conditioning unit in this position (recirculation).
2. Remove footwell and right air guide. Disconnect electrical plug connection of the drive motor and undo fastening screw.
3. Disengage pivot pin on the adjusting lever with a screwdriver.
4. Swivel down the drive motor and remove it to the side.

1. The removal or installation position of the drive motor and fresh-air/recirculation valve cannot be changed.
2. Ensure that the deflection lever of the outside-air valve is seated correctly.
3. Tighten fastening screw carefully (plastic housing).
4. Engage electrical plug connection and route wire carefully.
5. Perform a function test after installation.

Removing and installing outside temperature sensor

Removing and installing outside temperature sensor on the installed heating/air-conditioning unit

Scheme 58

1. Remove footwell bulkhead and right-hand air guide. Remove drive motor for fresh-air/recirculation valve.
2. Pull off electrical plug connection on the outside temperature sensor. Turn temperature sensor by 90° and pull it out.

1. Place temperature sensor on the intake duct and turn by 90° (tighten).
2. Engage electrical plug connection and route the wire carefully.
3. Install drive motor for fresh-air/recirculation valve and perform a function test.

Scheme 59

1. Pull off cover for temperature sensor. Undo three Torx screws of the right side vent and carefully pull the side vent out of the dashboard. One Torx screw is located behind the cover.
2. Press locking tabs together slightly and remove temperature sensor from the dashboard.
3. Pull off electrical plug connection.

1. Engage electrical plug connection, ensuring that the temperature sensor is seated properly in the dashboard.
2. The cover simultaneously serves as the intake grille for the fan and must not be closed off.

Scheme 60

1. Remove footwell bulkhead. Unclip centre console cover at the front and remove the footwell vent (3 screws).
2. Turn blower outlet sensor by 90° and pull it out.
3. Pull electrical plug connection off blower outlet sensor.

1. Position temperature sensor on the heating/air-conditioning unit housing and turn by 90° (tighten).
2. Engage the electrical plug connection and route the wire carefully.

Scheme 61

1. Remove footwell bulkhead and right air guide. Unscrew fastening screw and detach the blower driver from the heating/air-conditioning unit housing from below.
2. Pull blower driver out of the upper bracket and remove in downward direction.
3. Pull off the electrical plug connection.

1. Engage the electrical plug connection and slide the blower driver into the upper bracket.
2. Tighten the fastening screw carefully (plastic housing). Install the air guide and footwell bulkhead.
3. Perform function test on heater/fresh-air blower motor.

Scheme 62

Scheme 63

Scheme 64

1. Remove front wheel, wheel housing liner and wing support.
2. Detach cooler bracket from the body (1 nut, 2 M8 screws). Unclip ventilation hose and ballast resistor. Undo retaining clips from the cooler and pull off the cooler bracket downwards.
3. Disconnect the electrical plug connection and undo retaining clips from the fan housing. Pull fan housing out of the holder, bending up the ventilation hose on the cooler at the same time.
4. Detach fan motor from the fan housing and remove.

1. After installation, check whether the fan can rotate freely.
2. Tighten front wheel to the specified torque (130 Nm (96 ftlb.)).

Removing and installing ballast resistor for fan motor

Note. The ballast resistor is available as a spare part and can be replaced by crimping it onto the old wires.

Scheme 65

1. Disconnect the battery and cover the terminal or battery.
2. Unclip ballast resistor from the holder from below.
3. Cut off wires approx. 30 mm behind the old ballast resistor.
4. Slide heat-shrink tubing over the wires to the plug connection (2x) and to the fan motor (1 x).
5. Shorten wires of the new ballast resistor to approx. 30 mm and strip approx. 5 mm of insulation off all wire ends.
6. Using a commercially available crimping tool, join the wires with crimp connectors.
7. After crimping, solder the crimp connectors. Slide heat-shrink tubing over the crimp connectors and then shrink the tubing with a hot-air gun.
8. Carefully route the wires and, if necessary, fix in place with plastic tape.

Poses Online

See also:
• SAFETY REGULATIONS FOR VEHICLES WITH AIRBAG AND BELT TENSIONER
• DRAINING AND FILLING IN COOLANT (INCLUDES: BLEEDING