Air Conditioner: Other Porsche Boxster 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.

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 60

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.

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 61

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.

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 62

Drive motor for central valve

Scheme 63

Removing and installing outside temperature sensor

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

Scheme 64

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.

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.

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