Air Conditioner: Removal & Installation Porsche Boxster 986 рестайлинг

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 24

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 25

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Scheme 28

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 29

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.

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 30

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Scheme 37

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»(ref-199813-S04189071802005102000000) ).
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»(ref-199813-S04189071802005102000000) ).
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 38

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»(ref-199813-S04189071802005102000000) ).
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»(ref-199829-S41714753422005102100000) ).

Scheme 39

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 40

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.

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Scheme 42

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 43

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.

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 44

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 45

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.

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 46

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 47

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 48

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.

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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.)).