General safety regulations for refrigerants
| CAUTION | Extreme heating of air-conditioning system e. g. from sunlight shining into the vehicle or as a result of welding and soldering work. Danger of fire due to excessive heating of air conditioning. Danger of environmental pollution due to emerging refrigerant. |
> 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! This also applies for smaller quantities.
> No welding, soldering or hot-air heating may take place on parts of the filled air-conditioning system or in its immediate vicinity.
> While drying after painting work, the temperature burden on the vehicle must not exceed two hours at a maximum temperature of 80°C.
> Whether or not the system is filled with refrigerant, the heating causes a very strong overpressure which can cause damage to the system or even lead to an explosion.
> R134a is completely non-toxic at normal temperatures, but it decomposes upon contact with a flame or at high temperatures.
> 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.
> Risk of injury! High temperatures from open flames or hot solids causes chemical breakdown of refrigerant gas. Inhalation of the resulting breakdown products leads to coughing and nausea.
| WARNING | Contact with liquid or gaseous refrigerant. The refrigerant attacks the skin and damages the skin's surface. |
> Wear rubber gloves to protect your hands.
> Treat affected skin in the same way as in the case of freezing. Rinse immediately and then consult a physician.
> Wear safety goggles to protect your eyes.
> If refrigerant still gets in your eyes, consult a physician immediately.
| WARNING | The intensive effect of refrigerant on unprotected body parts can cause freezing. |
> Keep an eye-rinse bottle with clear water at hand.
> If liquid refrigerant gets into your eyes, rinse them thoroughly with water for about 15 minutes.
> Then consult a doctor immediately.
> The physician must be informed which refrigerant has caused the freezing.
Note. The following safety measures should be followed for refrigerant R134a (additional regulations may apply in certain countries).
If repair work necessitates opening the refrigerant circuit, the refrigerant circuit is first to be emptied. Avoid all contact with liquid or gaseous refrigerants. If refrigerant should escape despite all safety measures having been taken, the resulting refrigerant/air mixture should not be breathed in. Therefore, switch on extraction systems, protect hands with rubber gloves and protect eyes with protective goggles.
If refrigerant gets onto any other body parts despite all safety measures having been taken, these should also be rinsed immediately and thoroughly with water for at least 15 minutes.
Although refrigerant R134a is non-flammable, smoking, welding, soldering and hard-soldering is prohibited in a room containing refrigerant.
Emptying the refrigerant circuit
Note. Refrigerant R134a contributes to the greenhouse effect as soon as it is released into the Earth's atmosphere. Refrigerant should not be released into the environment but is to be extracted from the refrigerant circuit using an extraction or service station. The extracted refrigerant is then prepared again on-site or returned to the manufacturer for environmentally-friendly disposal (varying or additional regulations may apply in certain countries).
Working on the refrigerant circuit
| CAUTION | Emerging refrigerant in poorly ventilated rooms and erection pits. Danger of suffocation from odorless refrigerant. |
> The leaking refrigerant is not only colorless and odorless, but is also heavier than air and therefore displaces oxygen. In poorly ventilated rooms and erection pits there is therefore an undetectable risk of suffocation.
> The gas/air mixture formed when refrigerant escapes should not be breathed in but rather extracted via suitable extraction systems (workshop extraction system).
> There should be no erection pits, shafts or cellar stairs within a radius of 5 meters.
Painting work on vehicles with air-conditioning
| WARNING | Painting work on vehicles with air-conditioning Material damage due to the air-conditioning system bursting. |
> When carrying out repairs involving painting work, object temperatures in the drying oven or its preheating zone should not exceed 80 °C.
Notes on general repairs
The refrigerant circuit of the air-conditioning is only to be emptied and opened if this is necessary due to safety measures or if components of the refrigerant circuit have to be replaced.
The air-conditioning refrigerant circuit also remains closed during all other standard vehicle repair work.
Contact corrosion!
For this reason, the manufacturer only fits connecting elements with a special surface coating.
Contact corrosion can occur if unsuitable connecting elements (screws, nuts, washers, rivets, plugs, adhesives, etc.) are used.
Only use original Porsche parts!
Safety regulations for extraction and filling systems
| WARNING | Improper handling of the filling system for the air conditioning. Unnecessary damage to the environment due to emerging refrigerant. |
> Before connecting the filling system to the air-conditioning, make sure that the manual shut-off valves are closed.
> Before disconnecting the filling system from the air-conditioning, make sure that the process is complete so that no refrigerant can escape into the atmosphere.
> After the purified refrigerant has been filled into an external compressed gas bottle from the filling system, the manual shut-off valves on the bottle and on the filling system should be closed.
> Do not expose the filling system to moisture or use in a damp environment.
> Shut off the power supply at the filling system before carrying out maintenance work.
> An extension cable with cross-sectional area of at least 2.5 mm 2 should be used only when absolutely necessary.
> In the case of fire, the external bottle should be removed.
> Fill the oil extracted from the air-conditioning system into a suitable closable container (the refrigerant oil contains small quantities of refrigerant).
> The filling system must be secured to prevent rolling.
Technical data for air-conditioning system
| Air conditioning | Refrigerant quantity | Filling capacity of refrigerant oil |
|---|---|---|
| Climatronic | 900g R134a | 195 +/- 15 cm 3 ND 8 |
| General pressures | Bar |
|---|---|
| High-pressure cut-off | 32 |
| Low-pressure cut-off at ambient temperature > 5 °C | 1.4 (1.0) |
| High-pressure cut-off at ambient temperature < 5 °C | 0,5 |
| Pressure relief valve purge pressure | 40 |
| Refrigerant distribution in circuit | Approx. cm 3 |
|---|---|
| Compressor | 50 |
| Condenser (2 x 20 cm 3 ) | 40 |
| Evaporator | 30 |
| Fluids with containers | 30 |
| Circulating oil quantity in the refrigerant circuit | 60 |
Instructions for repairing air-conditioning systems and storing spare parts
Note. Close all openings immediately upon starting work on the refrigerant circuit. Store all spare parts in a dry and sealed-off area. Blast air-conditioning components with nitrogen before refitting. When fitting parts, do not remove plugs until shortly before installation. Do not remove the protective foil from the dryer until shortly before installation. The dryer absorbs moisture from the air and is then useless. Do not carry out repairs in the open in damp weather. Replace the dryer after each occasion of working on the refrigerant circuit. Moisture in the refrigerant circuit not only leads to poor cooling. Supersaturation can also cause the dryer to disintegrate and contaminate the air-conditioning from inside. This may lead to expensive and complicated repairs. Replace the dryer every 3-4 years. Evacuate the refrigerant circuit according to regulations. Use a pressure reducer when working with nitrogen.
Tools
Designation Type Number Explanation PIWIS Tester special tool P 9718
Scheme 118
Preliminary work for removing and installing air-conditioning system regulator
1. Remove left and right cover for the center console. --> 68 14 19 REMOVING AND INSTALLING CENTRE CONSOLE COVER - AS OF MY 2005 (ALL MODELS) .
2. Move gear-shift lever to rear position.
Removing air-conditioning system regulator
Installation Location
Scheme 119
Scheme 120
1. Insert a screwdriver behind the air-conditioning system regulator and press out.
2. Pull air-conditioning system regulator out of the installation slot.
Scheme 121
3. Release and pull off electric plugs -a-. (Scheme 120)
Scheme 122
1. Insert electric plugs into the air-conditioning system regulator until they are felt to engage.
Scheme 123
2. Slide the air-conditioning system regulator into the installation slot until it clicks into place.
Subsequent work for the air-conditioning system regulator
1. Install left and right side cover for center console. --> 68 14 19 REMOVING AND INSTALLING CENTRE CONSOLE COVER - AS OF MY 2005 (ALL MODELS) .
Coding the air-conditioning control
Note. If the control unit for the air-conditioning control is replaced, it must be programmed using the PIWIS Tester P 9718 . This is to adapt the control unit to the vehicle and equipment. During coding, it is essential to guarantee the power supply for the PIWIS Tester P 9718 . It is essential to connect a battery charger with a current rating of at least 40 A to the vehicle battery. The PIWIS Tester P 9718 instructions take precedence and in the event of a discrepancy these are the instructions that must be followed. Deviations may occur with later software versions. The procedure described here has been structured in general terms; different text or additions may appear in the Porsche System Tester.
1. Connect the PIWIS Tester P 9718 to the vehicle and start the System Tester. Switch on ignition. >> continue.
2. Select vehicle type using the cursor keys. >> continue.
3. Select air conditioner with the cursor keys and press the >> key.
4. Select Control unit replacement with the cursor keys and press the >> key.
5. Select Read out values (codings) with the cursor keys and press the >> key.
6. The message Codes successfully read out appears on the screen of the Porsche System Tester. Press >>.
7. Switch off ignition, replace air conditioning control.
8. Switch to the Special functions menu and perform the vehicle handover using the F8 key.
9. In the Special functions menu, erase All fault memories by pressing >>.
10. Carry out automatic search of control units.
11. In the menu Write in data >>, the data read-out is installed.
12. System Tester displays Codes successfully written in . Press >>.
13. Select System test with the cursor keys and press the >> key.
14. The Tester starts the system test , follow the instructions on the Tester.
15. Quit menu, carry out a test drive, and check operation of the air conditioning control. Read out fault memory.
| Designation | Type | Number | Explanation | |
|---|---|---|---|---|
| Air-conditioning recycling unit | Commercially available tool |
Warning notes for handling refrigerant
| CAUTION | Danger of injury when working on air-conditioned vehicles! |
> Observe safety regulations for working on air-conditioned vehicles and dealing with refrigerant R134a. --> 87 AW Safety regulations for working on air-conditioned vehicles and dealing with refrigerant R134a - as of MY 2005 (All Models) .
> Observe safety regulations for working with extraction and filling systems. --> 87 AW Safety regulations for extraction and filling systems - as of MY 2005 (All Models) .
> Observe instructions for repairing air-conditioning systems and storing spare parts. --> 87 01 IN Instructions for repairing air-conditioning systems and storing spare parts - as of MY 2005 (All Models) .
Servicing equipment
Air-conditioning recycling unit , --> " Gr. 2.5; Handbuch Werkstatteinrichtung"
Installing sun sensor
1. Press sensor into the holder until the sensor lugs engage.
Scheme 124
2. Connect the electric plug connection.
Scheme 125
3. Position cover and clip into dashboard.
Preliminary work - servo motor for temperature mixing valve
1. Remove left and right covers of console. Refer to 68 14 19 Removing and installing center console cover - as of MY 2005 (All Models) .
2. Remove front footwell outlet vent. Refer to 80 55 19 Removing and installing front footwell outlet vent - as of MY 2005 (All Models) .
Removing servo motor for temperature mixing flap
Installation Location
Scheme 126
1. Switch off ignition and remove ignition key.
Scheme 127
2. First unscrew the two accessible fastening screws -1-, then shift the servo motor and unscrew the third fastening screw -1-. (Scheme 126)
Scheme 128
3. Release and unplug electric connector -a-. (Scheme 127)
Scheme 129
4. Turn the servo motor out until the actuating lever -A- can be disengaged. (Scheme 128)
5. Remove servo motor.
Scheme 130
1. Position servo motor and engage actuating lever -A- on the servo motor. (Scheme 129)
Scheme 131
2. Connect electric connector to servo motor until the connector is felt to engage.
Scheme 132
3. Position servo motor on heater/air-conditioning unit and tighten with the three fastening screws -1-. --> Tightening torque: 1.2 (1.0 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm. (Scheme 131)
3.1. First screw in one fastening screw.
3.2. Turn the servo motor and screw in the remaining two fastening screws.
4. Switch on ignition and check function of servo motor by adjusting the air conditioning control.
Subsequent work - servo motor for temperature mixing valve
1. Install front footwell outlet vent. Refer to 80 55 19 Removing and installing front footwell outlet vent - as of MY 2005 (All Models) .
2. Install left and right covers of console. Refer to 68 14 19 Removing and installing center console cover - as of MY 2005 (All Models) .
Preliminary work - servo motor for central distributor flap
1. Remove left and right covers of console. Refer to 68 14 19 Removing and installing center console cover - as of MY 2005 (All Models) .
2. Remove front footwell outlet vent. Refer to 80 55 19 Removing and installing front footwell outlet vent - as of MY 2005 (All Models) .
Removing servo motor for central distributor flap
Installation Location
Scheme 133
1. Switch off ignition and remove ignition key.
Scheme 134
2. First unscrew the two accessible fastening screws -1-, then shift the servo motor and unscrew the third fastening screw -1-. (Scheme 133)
Scheme 135
3. Release and unplug electric connector -a-. (Scheme 134)
Scheme 136
4. Turn the servo motor out until the actuating lever -A- can be disengaged. (Scheme 135)
5. Remove servo motor.
Scheme 137
1. Position servo motor and engage actuating lever -A- on the servo motor. (Scheme 136)
Scheme 138
2. Connect electric connector to servo motor until the connector is felt to engage.
Scheme 139
3. Position servo motor on heater/air-conditioning unit and tighten with the three fastening screws -1-. --> Tightening torque: 1.2 (1.0 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm. (Scheme 138)
3.1. First screw in one fastening screw.
3.2. Turn the servo motor and screw in the remaining two fastening screws.
4. Switch on ignition and check function of servo motor by adjusting the air conditioning control.
Subsequent work - servo motor for central distributor flap
1. Install front footwell outlet vent. Refer to 80 55 19 Removing and installing front footwell outlet vent - as of MY 2005 (All Models) .
2. Install left and right covers of console. Refer to 68 14 19 Removing and installing center console cover - as of MY 2005 (All Models) .
Preliminary work for footwell/defrost servo motor
1. Remove dashboard trim panel. Refer to 70 19 19 Removing and installing trim under dashboard - as of MY 2005 (All Models) .
2. Remove left console cover. Refer to 68 14 19 Removing and installing center console cover - as of MY 2005 (All Models) .
Removing footwell/defrost servo motor
Installation Location
Scheme 140
1. Switch off ignition and remove ignition key.
Scheme 141
2. Unscrew the three fastening screws.
Scheme 142
3. Release and unplug electric connector -a-. (Scheme 141)
Scheme 143
4. Pull the servo motor out further until the actuating lever -A- can be disengaged. (Scheme 142)
5. Remove servo motor.
Scheme 144
1. Position servo motor and engage actuating lever on the servo motor.
Scheme 145
2. Connect electric connector to servo motor until the connector is felt to engage.
Scheme 146
3. Position servo motor on heater/air-conditioning unit and tighten with fastening screws -1-. --> Tightening torque: 1.2 (1.0 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm. (Scheme 145)
4. Switch on ignition and check function of servo motor by adjusting the air conditioning control.
Subsequent work for footwell/defrost servo motor
1. Install left console cover. Refer to 68 14 19 Removing and installing center console cover - as of MY 2005 (All Models) .
2. Install dashboard cover. Refer to 70 19 19 Removing and installing trim under dashboard - as of MY 2005 (All Models) .
Preliminary work for magnetic clutch
1. Move convertible top to service position Refer to 61 01 IN Diagram of convertible top - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
Scheme 147
2. Remove engine compartment lid Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
Scheme 148
3. Remove rear wall cover Refer to 55 59 19 Removing and installing rear wall cover - as of MY 2005 (All Models) .
4. Remove drive belt. --> 13 78 19 Removing and installing drive belt - as of MY 2005 (All Models) .
| WARNING | Danger of injury and damage to material through Pentosin Irritation and damage to skin Damage to hoses and wiring |
> Wear protective gloves and goggles
> If the eyes or skin come into contact with the fluid, wash immediately with water!
> Collect escaping Pentosin
> Use caps to protect the wiring against soiling and damage!
> Immediately clean hoses and wiring thoroughly
5. Remove Pentosin from the power-steering reservoir by suction and pour it into a suitable container.
Scheme 149
6. Release bayonet lock -arrow- on the power-steering reservoir and remove power-steering reservoir. (Scheme 148)
Removing the magnetic coupling
Installation Location
Scheme 150
A - Thrust plate
B - Spacer washer
C - Belt pulley
D - Solenoid coil
E - Seeger circlip ring for pulley
F - Seeger circlip ring for solenoid coil
Scheme 151
1. Use a commercially available strap wrench to securely hold the pressure plate -A- on the air-conditioning compressor, and undo the fastening screw -1-. (Scheme 150)
Scheme 152
2. Screw in an M8 screw -2- into the thread of the pressure plate until the pressure plate -A- can be removed by hand. (Scheme 151)
3. Take off spacers -B- behind the pressure plate. (Scheme 151)
Scheme 153
4. Use a Seeger circlip ring pliers to remove the Seeger circlip ring -E- on the pulley -C-. (Scheme 152)
5. Remove pulley -C- on the compressor. (Scheme 152)
6. Unscrew electric line of solenoid coil on the compressor
Scheme 154
6.1. Unscrew rear Torx screw for air-conditioning compressor (M8 x 120) -1- between the pipes of the intake system. (Scheme 153)
Scheme 155
6.2. Unscrew front Torx screws for air-conditioning compressor (M8 x 90) -1- and -2-. (Scheme 154)
6.3. Disconnect electric plug connection on the air-conditioning compressor's electrical line.
Scheme 156
7. Remove Seeger circlip ring -F- for the solenoid coil with the Seeger circlip ring pliers. Remove the magnetic coil from the compressor housing. (Scheme 155)
Installing the magnetic coupling
Note. If a new magnetic clutch is installed, the air gap between pressure plate and pulley must be checked with a depth gauge. > 872719 Removing and installing magnetic clutch - chapter on "Checking"
Scheme 157
1. Place the magnetic coil -D- on the compressor housing. The locking pin -G- must engage in the locking hole -H-. (Scheme 156)
Scheme 158
Note. When installing the Seeger circlip ring, the slanted surface of the Seeger circlip ring must point forward.
2. Position Seeger circlip ring -F- for solenoid coil -D- and install with Seeger circlip ring pliers. (Scheme 158)
Scheme 159
3. Position pulley -C- and install with the Seeger circlip ring -E-. (Scheme 159)
Scheme 160
4. Secure the electric line with the fastening screw -4- on the compressor. (Scheme 160)
5. Position compressor on engine again and screw down the fastening screws
5.1. Clip in connector for air-conditioning compressor supply line and clip connector housing into the holder provided.
5.2. Screw in front Torx screws for air-conditioning compressor (M8 x 90) -1- and -2-. see scheme 50
5.3. Screw in rear Torx screw for air-conditioning compressor (M8 x 120) -1- and tighten all three screws for air-conditioning compressor. --> Tightening torque: 23 (17 ftlb.) Nm. see scheme 51
6. Position the pressure plate -A- and tighten with the fastening screw -1-. --> Tightening torque: 14 (10.5 ftlb.) Nm. (Scheme 161)
Scheme 161
Subsequent work for magnetic clutch
1. Position power-steering reservoir. Lock bayonet lock -arrow- on power-steering reservoir. see scheme 53
2. Replace the quantity of Pentosin removed during removal with new Pentosin and pour this into the power-steering reservoir.
Scheme 162
3. Turn the tensioning roller clockwise using a ring wrench (a/f 24), position the drive belt and then tension it.
4. Check Pentosin level in power-steering reservoir Refer to 48 02 01 Checking the fluid level for the power-assisted steering - as of MY 2005 (All Models) .
5. Install rear underbody cover. Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models) .
6. Install rear wall cover Refer to 55 59 19 Removing and installing rear wall cover - as of MY 2005 (All Models) .
7. Install engine compartment lid Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
8. Assemble convertible top. Refer to 61 01 IN Diagram of convertible top - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
9. Start engine. Turn the steering wheel from stop to stop while the engine is running in order to bleed the steering system.
10. Check operation of air-conditioning compressor.
Check air gap of magnetic clutch
A - Thrust plate
B - Spacer washer
C - Pulley
D - Solenoid coil
E - Seeger circlip ring for pulley
F - Seeger circlip ring for solenoid coil
Scheme 163
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 least 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 -B-. see scheme 57
1. Remove engine compartment lid Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Cayman S, Cayman S RHD) .
2. Remove rear wall cover Refer to 55 59 19 Removing and installing rear wall cover - as of MY 2005 (All Models) .
3. Remove drive belt. --> 13 78 19 REMOVING AND INSTALLING DRIVE BELT - AS OF MY 2005 (ALL MODELS) .
| WARNING | Danger of injury and damage to material through Pentosin Irritation and damage to skin Damage to hoses and wiring |
> Wear protective gloves and goggles
> If the eyes or skin come into contact with the fluid, wash immediately with water!
> Collect escaping Pentosin
> Use caps to protect the wiring against soiling and damage!
> Immediately clean hoses and wiring thoroughly
4. Remove Pentosin from the power-steering reservoir by suction and pour it into a suitable container.
5. Release bayonet lock -arrow- on the power-steering reservoir and remove power-steering reservoir. see scheme 61
Installation Location
A - Thrust plate
B - Spacer washer
C - Belt pulley
D - Solenoid coil
E - Seeger circlip ring for pulley
F - Seeger circlip ring for solenoid coil
1. Use a commercially available strap wrench to securely hold the pressure plate -A- on the air-conditioning compressor, and undo the fastening screw -1-. see scheme 63
2. Screw in an M8 screw -2- into the thread of the pressure plate until the pressure plate -A- can be removed by hand. see scheme 64
3. Take off spacers -B- behind the pressure plate. see scheme 64
4. Use a Seeger circlip ring pliers to remove the Seeger circlip ring -E- on the pulley -C-. see scheme 65
5. Remove pulley -C- on the compressor. see scheme 65
6. Unscrew electric line of solenoid coil on the compressor
6.1. Unscrew rear Torx screw for air-conditioning compressor (M8 x 120) -1- between the pipes of the intake system. see scheme 66
6.2. Unscrew front Torx screws for air-conditioning compressor (M8 x 90) -1- and -2-. see scheme 67
6.3. Disconnect electric plug connection on the air-conditioning compressor's electrical line.
7. Remove Seeger circlip ring -F- for the solenoid coil with the Seeger circlip ring pliers. Remove the magnetic coil from the compressor housing. see scheme 68
Note. If a new magnetic clutch is installed, the air gap between pressure plate and pulley must be checked with a depth gauge. > 872719 Removing and installing magnetic clutch - chapter on "Checking"
1. Place the magnetic coil -D- on the compressor housing. The locking pin -G- must engage in the locking hole -H-. see scheme 69
Note. When installing the Seeger circlip ring, the slanted surface of the Seeger circlip ring must point forward.
2. Position Seeger circlip ring -F- for solenoid coil -D- and install with Seeger circlip ring pliers. see scheme 71
3. Position pulley -C- and install with the Seeger circlip ring -E-. see scheme 72
4. Secure the electric line with the fastening screw -4- on the compressor. see scheme 73
5. Position compressor on engine again and screw down the fastening screws
5.1. Clip in connector for air-conditioning compressor supply line and clip connector housing into the holder provided.
5.2. Screw in front Torx screws for air-conditioning compressor (M8 x 90) -1- and -2-. see scheme 74
5.3. Screw in rear Torx screw for air-conditioning compressor (M8 x 120) -1- and tighten all three screws for air-conditioning compressor. --> Tightening torque: 23 (17 ftlb.) Nm. see scheme 75
6. Position the pressure plate -A- and tighten with the fastening screw -1-. --> Tightening torque: 14 (10.5 ftlb.) Nm. see scheme 76
1. Position power-steering reservoir. Lock bayonet lock -arrow- on power-steering reservoir. see scheme 77
2. Replace the quantity of Pentosin removed during removal with new Pentosin and pour this into the power-steering reservoir.
3. Turn the tensioning roller clockwise using a ring wrench (a/f 24), position the drive belt and then tension it.
4. Check Pentosin level in power-steering reservoir Refer to 48 02 01 Checking the fluid level for the power-assisted steering - as of MY 2005 (All Models) .
5. Install rear underbody cover. Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models) .
6. Install rear wall cover Refer to 55 59 19 Removing and installing rear wall cover - as of MY 2005 (All Models) .
7. Install engine compartment lid Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Cayman S, Cayman S RHD) .
8. Start engine. Turn the steering wheel from stop to stop while the engine is running in order to bleed the steering system.
9. Check operation of air-conditioning compressor.
A - Thrust plate
B - Spacer washer
C - Pulley
D - Solenoid coil
E - Seeger circlip ring for pulley
F - Seeger circlip ring for solenoid coil
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 least 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 -B-. see scheme 81
Preliminary work for compressor
1. Drain refrigerant for air-conditioning system with one air-conditioning unit. > 870317 Draining and filling in refrigerant - chapter on "Draining"
2. Move convertible top to service position Refer to 61 01 IN Diagram of convertible top - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
3. Remove engine compartment lid Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
4. Remove rear wall cover Refer to 55 59 19 Removing and installing rear wall cover - as of MY 2005 (All Models) .
5. Remove drive belt. --> 13 78 19 Removing and installing drive belt - as of MY 2005 (All Models) .
Removing compressor
| WARNING | Danger of injury and damage to material through Pentosin Irritation and damage to skin Damage to hoses and wiring |
> Wear protective gloves and goggles
> If the eyes or skin come into contact with the fluid, wash immediately with water!
> Collect escaping Pentosin
> Use caps to protect the wiring against soiling and damage!
> Immediately clean hoses and wiring thoroughly
1. Remove Pentosin from the power-steering reservoir by suction and pour it into a suitable container.
2. Release bayonet lock -arrow- on the power-steering reservoir and remove power-steering reservoir. see scheme 85
3. Unscrew rear Torx screw for air-conditioning compressor (M8 x 120) -1- between the pipes of the intake system. see scheme 86
4. Unscrew front Torx screws for air-conditioning compressor (M8 x 90) -1- and -2-. (Scheme 164)
5. Disconnect electric plug connection on the air-conditioning compressor's electrical line.
Scheme 164
6. Unclip refrigerant hoses -1- and -2- between body and intake-air distributor. (Scheme 165)
Scheme 165
Note. After removal, place the air-conditioning compressor on a suitable protective support (e. g. foam, neoprene, etc.).
7. Guide refrigerant compressor through the rear wall opening and place on a suitable surface on the center tunnel.
Scheme 166
8. Unscrew both fastening screws -1, 2-, pull out the refrigerant lines carefully and close them immediately with suitable plugs. (Scheme 167)
Installing compressor
| CAUTION | Risk of damaging the air-conditioning compressor. |
> The engine must not be started until the air-conditioning system has been filled.
Note. New compressors are pressurized 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! 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)!
1. If a new compressor is installed, first correct the refrigerant oil quantity in the air-conditioning compressor. > 873419 Removing and installing compressor - chapter on "Checking"
2. Replace O-rings for the refrigerant lines and wet the new rings with refrigerant oil.
3. Do not remove the plugs for the lines and compressor connection until shortly before installation.
Scheme 167
4. Connect the lines and secure with the fastening screws -1, 2-. --> Tightening torque: 20 (15 ftlb.) Nm --> Tightening torque: 20 (15 ftlb.) Nm. see scheme 91
5. Guide air-conditioning compressor through the rear wall opening and place in installation position.
6. Clip in refrigerant hoses -1- and -2- between body and intake-air distributor. see scheme 92
7. Clip in connector for air-conditioning compressor supply line and clip connector housing into the holder provided.
8. Screw in front Torx screws for air-conditioning compressor (M8 x 90) -1- and -2-. see scheme 93
9. Screw in rear Torx screw for air-conditioning compressor (M8 x 120) -1- and tighten all three screws for air-conditioning compressor. --> Tightening torque: 23 (17 ftlb.) Nm. see scheme 94
10. Position power-steering reservoir. Lock bayonet lock -arrow- on power-steering reservoir. see scheme 95
11. Replace the quantity of Pentosin removed during removal with new Pentosin and pour this into the power-steering reservoir.
12. Turn the tensioning roller clockwise using a ring wrench (a/f 24), position the drive belt and then tension it.
Subsequent work for compressor
1. Check Pentosin level in power-steering reservoir Refer to 48 02 01 Checking the fluid level for the power-assisted steering - as of MY 2005 (All Models) .
2. Install rear underbody cover. Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models) .
3. Install rear wall cover Refer to 55 59 19 Removing and installing rear wall cover - as of MY 2005 (All Models) .
4. Install engine compartment lid Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
5. Fill refrigerant on the air-conditioning system in accordance with regulations. > 870317 Draining and filling in refrigerant
6. Open air exhaust nozzles on the dashboard, and set fan to at least 75 %.
7. After allowing the system to stabilize at idle speed (approx. 5 sec.), switch on air conditioner and allow the engine to run uninterrupted for at least 2 minutes at 1500 rpm.
8. Switch off the air conditioner again. Do not drive until the air conditioner has been filled.
9. Start engine. Turn the steering wheel from stop to stop while the engine is running in order to bleed the steering system.
Correct the refrigerant oil level in the "new" air-conditioning compressor
| WARNING | A new air-conditioning compressor contains the oil quantity for the complete air-conditioning circuit. Risk of damaging the air-conditioning compressor by excessive refrigerant oil in the air-conditioning circuit. |
> If a new air-conditioning compressor or a component in the circuit is replaced, the oil quantity must be determined and adjusted.
> Insufficient refrigerant oil causes a lack of lubrication, resulting in the failure of the air-conditioning compressor.
> Too much refrigerant oil results in reduced refrigerant performance.
Note. All connection points must be completely dirt-free. The air-conditioning compressor must be dry (washing the vehicle) and the air-conditioning compressor and lines must be free of moisture. The connection points must be closed after they have been opened. Use the original transport caps. A clean measuring cylinder with a capacity of approx. 300 ml is required.
Determining oil quantity on the "old" air-conditioning compressor
Scheme 168
1. First, open the cap on the high-pressure side and relieve the pressure from the compressor -A-. see scheme 99
2. Open the oil filler screw -B- on the compressor. see scheme 99
3. Fill the refrigerant oil from the air-conditioning compressor into the measuring cylinder. Turn the pressure plate on the air-conditioning compressor (not the belt pulley) when emptying the refrigerant oil.
The amount of refrigerant oil is referred to as "V old " in the formula below.
4. Always replace the sealing ring for the oil filler plug.
5. Screw oil filler plug -B- into the compressor. --> Tightening torque: 30 (22 ftlb.) Nm. see scheme 99
Determining the oil quantity at the "new" oil filler screw of the air-conditioning compressor
1. To drain refrigerant oil
1.1. First, open the cap on the high-pressure side and relieve the pressure from the compressor -A-. see scheme 100
1.2. Open the oil filler screw -B- on the compressor. see scheme 99
1.3. Drain the refrigerant oil from the air-conditioning compressor.
The refrigerant oil must not be re-used, but must be disposed of properly.
2. To determine the refrigerant oil quantity
2.1. V total = "V removed " + "V old " + 20 cm 3
2.2. V total = Total volume for the new air-conditioning compressor
2.3. V removed = Volume of refrigerant oil removed by suction
2.4. V old = Volume of refrigerant oil in the old air-conditioning compressor
2.5. 20 cm 3 = Additional safety volume
3. To fill the air-conditioning compressor
3.1. Fill the determined refrigerant oil volume V total into the air-conditioning compressor.
3.2. Always replace the sealing ring for the oil filler plug.
3.3. Screw oil filler plug -B- onto the compressor. --> Tightening torque: 30 (22 ftlb.) Nm. see scheme 99
3.4. Install air-conditioning compressor. > 873419 Removing and installing compressor - Installing
Preliminary work for air-conditioning compressor
1. Drain refrigerant for air-conditioning system with a refrigerant pump.
2. Remove engine compartment lid Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Cayman S, Cayman S RHD) .
3. Remove rear wall cover Refer to 55 59 19 Removing and installing rear wall cover - as of MY 2005 (All Models) .
4. Remove drive belt. Refer to 13 78 19 Removing and installing drive belt - as of MY 2005 (All Models) .
General warning notes for air-conditioning compressor
| WARNING | Safety regulations should be strictly observed when working on air-conditioned vehicles and dealing with refrigerant. Danger of injury. |
> 87 AW Safety regulations for working on air-conditioned vehicles and dealing with refrigerant R134a - as of MY 2005 (All Models)
> 87 AW Safety regulations for extraction and filling systems - as of MY 2005 (All Models) .
> 87 01 IN Instructions for repairing air-conditioning systems and storing spare parts - as of MY 2005 (All Models) .
Tool for air-conditioning system
Air-conditioning service unit, refer to Special Tools, Commercially Available Tools, Chapter 2.4, No. 96-2)
Removing the air-conditioning compressor
| WARNING | Danger of injury and damage to material through Pentosin Irritation and damage to skin Damage to hoses and wiring |
> Wear protective gloves and goggles
> If the eyes or skin come into contact with the fluid, wash immediately with water!
> Collect escaping Pentosin
> Use caps to protect the wiring against soiling and damage!
> Immediately clean hoses and wiring thoroughly
1. Remove Pentosin from the power-steering reservoir by suction and pour it into a suitable container.
2. Release bayonet lock -Arrow- on the power-steering reservoir and remove power-steering reservoir. see scheme 101
3. Unscrew rear Torx screw for air-conditioning compressor (M8 x 120) -1- between the pipes of the intake system. see scheme 102
4. Unscrew front Torx screws for air-conditioning compressor (M8 x 90) -1- and -2-. see scheme 103
5. Disconnect electric plug connection on the air-conditioning compressor's electric line.
6. Unclip refrigerant hoses -1- and -2- between body and intake-air distributor. see scheme 104
Note. After removal, place the air-conditioning compressor on a suitable protective support (e. g. foam, neoprene, etc.).
7. Guide refrigerant compressor through the rear wall opening and place on a suitable surface on the center tunnel.
8. Unscrew both fastening screws -1, 2-, pull out the refrigerant lines carefully and close them immediately with suitable plugs. see scheme 106
| CAUTION | Risk of damaging the air-conditioning compressor. |
> The engine must not be started until the air-conditioning system has been filled.
Note. New compressors are pressurized 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! 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)!
1. If a new compressor is installed, first correct the refrigerant oil quantity in the air-conditioning compressor. > 873419 Removing and installing compressor - section on "Checking"
2. Replace O-rings for the refrigerant lines and wet the new rings with refrigerant oil.
3. Do not remove the plugs for the lines and compressor connection until shortly before installation.
4. Connect the lines and secure with the fastening screws -1, 2-. --> Tightening torque: 20 (15 ftlb.) Nm --> Tightening torque: 20 (15 ftlb.) Nm. see scheme 107
5. Guide air-conditioning compressor through the rear wall opening and place in installation position.
6. Clip in refrigerant hoses -1- and -2- between body and intake-air distributor. see scheme 108
7. Clip in connector for air-conditioning compressor supply line and clip connector housing into the holder provided.
8. Screw in front Torx screws for air-conditioning compressor (M8 x 90) -1- and -2-. see scheme 109
9. Screw in rear Torx screw for air-conditioning compressor (M8 x 120) -1- and tighten all three screws for air-conditioning compressor. --> Tightening torque: 23 (17 ftlb.) Nm. see scheme 110
10. Position power-steering reservoir. Lock bayonet lock -Arrow- on power-steering reservoir. see scheme 111
11. Replace the quantity of Pentosin removed during removal with new Pentosin and pour this into the power-steering reservoir.
12. Turn the tensioning roller clockwise using a ring wrench (a/f 24), position the drive belt and then tension it.
Subsequent work on compressor
1. Check Pentosin level in power-steering reservoir Refer to 48 02 01 Checking the fluid level for the power-assisted steering - as of MY 2005 (All Models) .
2. Install rear underbody cover. Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models) .
3. Install rear wall cover Refer to 55 59 19 Removing and installing rear wall cover - as of MY 2005 (All Models) .
4. Install engine compartment lid Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Cayman S, Cayman S RHD) .
5. Fill refrigerant on the air-conditioning system in accordance with regulations. > 870317 Draining and filling in refrigerant
6. Open air exhaust nozzles on the dashboard, and set fan to at least 75 %.
7. After allowing the system to stabilize at idle speed (approx. 5 sec.), switch on air conditioner and allow the engine to run uninterrupted for at least 2 minutes at 1500 rpm.
8. Switch off the air conditioner again. Do not drive until the air conditioner has been filled.
9. Start engine. Turn the steering wheel from stop to stop while the engine is running in order to bleed the steering system.
| WARNING | A new air-conditioning compressor contains the oil quantity for the complete air-conditioning circuit. Risk of damaging the air-conditioning compressor by excessive refrigerant oil in the air-conditioning circuit. |
> If a new air-conditioning compressor or a component in the circuit is replaced, the oil quantity must be determined and adjusted.
> Insufficient refrigerant oil causes a lack of lubrication, resulting in the failure of the air-conditioning compressor.
> Too much refrigerant oil results in reduced refrigerant performance.
Note. All connection points must be completely dirt-free. The air-conditioning compressor must be dry (washing the vehicle) and the air-conditioning compressor and lines must be free of moisture. The connection points must be closed after they have been opened. Use the original transport caps. A clean measuring cylinder with a capacity of approx. 300 ml is required.
Determining oil quantity on the "old" air-conditioning compressor
1. First, open the cap on the high-pressure side and relieve the pressure from the compressor -A-. see scheme 114
2. Open the oil filler screw -B- on the compressor. see scheme 114
3. Fill the refrigerant oil from the air-conditioning compressor into the measuring cylinder. Turn the pressure plate on the air-conditioning compressor (not the belt pulley) when emptying the refrigerant oil.
The amount of refrigerant oil is referred to as "V old " in the formula below.
4. Always replace the sealing ring for the oil filler plug.
5. Screw oil filler plug -B- into the compressor. --> Tightening torque: 30 (22 ftlb.) Nm. see scheme 114
Determining the oil quantity at the "new" oil filler screw of the air-conditioning compressor
1. To drain refrigerant oil
1.1. First, open the cap on the high-pressure side and relieve the pressure from the compressor -A-. (Scheme 169)
1.2. Open the oil filler screw -B- on the compressor. see scheme 114
1.3. Drain the refrigerant oil from the air-conditioning compressor.
The refrigerant oil must not be re-used, but must be disposed of properly.
2. To determine the refrigerant oil quantity
2.1. V total = "V removed " + "V old " + 20 cm 3
2.2. V total = Total volume for the new air-conditioning compressor
2.3. V removed = Volume of refrigerant oil removed by suction
2.4. V old = Volume of refrigerant oil in the old air-conditioning compressor
2.5. 20 cm 3 = Additional safety volume
3. To fill the air-conditioning compressor
3.1. Fill the determined refrigerant oil volume V total into the air-conditioning compressor.
3.2. Always replace the sealing ring for the oil filler plug.
3.3. Screw oil filler plug -B- onto the compressor. --> Tightening torque: 30 (22 ftlb.) Nm. see scheme 114
3.4. Install air-conditioning compressor. > 873419 Removing and installing compressor - Installing
Preliminary work for line condenser-condenser
Removing front apron. Refer to 63 15 19 Removing and installing front spoiler - as of MY 2005 (All Models) .
Draining refrigerant. > 870317 Draining and filling in refrigerant - chapter on "draining"
Removing the condenser-condenser line
Installation Location
Scheme 169
Scheme 170
1. Unscrew the two fastening screws -1- holding the air guide for the condenser. (Scheme 171)
2. Pull the air guide forward and disengage it at the condenser -A-. (Scheme 171)
Scheme 171
3. Unscrew the fastening nuts for both holders line, open the holder and take out the line.
Note. When loosening or tightening the M8 refrigerant lines on the condenser, always counter with a 21-mm open-ended wrench.
Note. Before re-installing the component, check the O-rings of the refrigerant lines for damage and replaced them if necessary. Wet the O-rings of the refrigerant lines with refrigerant oil. Do not open the plugs for the lines and connections until shortly before installation. Close off all lines and connections using suitable plugs during removal.
Scheme 172
4. Unscrew the fastening screws -1- of the line condenser-condenser and pull the line out of both condensers. (Scheme 173)
Installing the condenser-condenser line
Note. When loosening or tightening the M8 refrigerant lines on the condenser, always counter with a 21-mm open-ended wrench.
Note. Before re-installing the component, check the O-rings of the refrigerant lines for damage and replaced them if necessary. Wet the O-rings of the refrigerant lines with refrigerant oil. Do not open the plugs for the lines and connections until shortly before installation. Close off all lines and connections using suitable plugs during removal.
Scheme 173
1. Carefully push the lines into the condensers and screw tight with the fastening screws. --> Tightening torque: 14 (10.5 ftlb.) Nm
Scheme 174
2. Attach line to both holders, close holders and secure with fastening screws.
Scheme 175
3. Engage air guide on condenser -A- and screw down using the two fastening screws -1-. --> Tightening torque: 4 (3 ftlb.) Nm. (Scheme 176)
Subsequent work for line condenser-condenser
Filling in refrigerant. > 870317 Draining and filling in refrigerant
Install front apron. --> 63 10 19 REMOVING AND INSTALLING FRONT BUMPER - AS OF MY 2005 (ALL MODELS) .
Preliminary work for compressor/condenser line
Draining refrigerant. > 870317 Draining and filling in refrigerant - chapter on "draining"
Remove air-conditioning compressor from engine. > 873419 Removing and installing compressor - chapter on "Removing" [987310 987311 987320 987321] > 873419 Removing and installing compressor - chapter on "Removing" [987120 987121]
Removing compressor/condenser line
Note. Close off all lines and connections using suitable plugs during removal. Before re-installing the component, check the O-rings of the refrigerant lines for damage and replaced them if necessary.
Installation Location
Scheme 176
A - Compressor/condenser line
1. Unscrew fastening screw -1- on compressor, pull out line on compressor and remove it from support -7-. (Scheme 177)
Scheme 177
2. Unscrew fastening nut -5- on cable holder, open cable holder and pull line out of rubber mounting -6-. (Scheme 177)
3. Unscrew fastening screw -3- on connection point and pull out line. (Scheme 177)
4. Remove line downwards from the engine area.
Installing compressor/condenser line
Note. Before re-installing the component, check the O-rings of the refrigerant lines for damage and replaced them if necessary. Wet the O-rings of the refrigerant lines with refrigerant oil. Do not open the plugs for the lines and connections until shortly before installation.
Scheme 178
1. Insert line from below into engine compartment.
2. Insert line into evaporator line and secure using the fastening screw -3-. --> Tightening torque: 14 (10.5 ftlb.) Nm. see scheme 126
3. Push line into the compressor, secure with the fastening screw -1- and clip line into the support. --> Tightening torque: 21 (16 ftlb.) Nm. (Scheme 179)
Scheme 179
4. Insert line in underbody area into rubber mount -6-, close support and secure with fastening nut -5-. (Scheme 180)
Subsequent work for compressor/condenser line
Install air-conditioning compressor on engine. > 873419 Removing and installing compressor - chapter on "Installing" [987310 987311 987320 987321] > 873419 Removing and installing compressor - chapter on "Installing" [987120 987121]
Fill in refrigerant. > 870317 Draining and filling in refrigerant - chapter on "Filling in"
Preliminary work on compressor-condenser line
Remove front right wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
Remove front right wheel housing liner. Refer to 50 56 19 Removing and installing front wheel housing liner - as of MY 2005 (All Models) .
Drain refrigerant. > 870317 Draining and filling in refrigerant - chapter on "draining"
Removing compressor-condenser line
Note. Before re-installing the component, check the O-rings of the refrigerant lines for damage and replaced them if necessary. Wet the O-rings of the refrigerant lines with refrigerant oil. Do not open the plugs for the lines and connections until shortly before installation. Close off all lines and connections using suitable plugs during removal.
Installation Location
Scheme 180
Note. When loosening or tightening the M8 refrigerant lines on the condenser, always counter with a 21-mm open-ended wrench.
Scheme 181
1. Unscrew the fastening screw -1- for the condenser line and pull the line out of the condenser. (Scheme 182)
Scheme 182
2. Unclip holder for line and remove the line.
3. Unscrew the fastening screw -2- for the line to the compressor and pull the line out of the compressor line. (Scheme 183)
4. Pull the line out of the line holder and take it out.
Installing compressor-condenser line
Note. When loosening or tightening the M8 refrigerant lines on the condenser, always counter with a 21-mm open-ended wrench.
Scheme 183
1. Clip line into the line holder at the top and engage it in the rubber mounting.
Note. Before re-installing the component, check the O-rings of the refrigerant lines for damage and replaced them if necessary. Wet the O-rings of the refrigerant lines with refrigerant oil. Do not open the plugs for the lines and connections until shortly before installation. Close off all lines and connections using suitable plugs during removal.
2. Insert compressor-condenser line into the line to the compressor and fasten with the fastening screw -2-. --> Tightening torque: 14 (10.5 ftlb.) Nm. (Scheme 184)
3. Close and engage holder for rubber mounting.
Scheme 184
4. Insert compressor-condensor line into the condenser and fasten it with the fastening screw -1-. --> Tightening torque: 14 (10.5 ftlb.) Nm. (Scheme 185)
Subsequent work on compressor-condenser line
Fill in refrigerant. > 870317 Draining and filling in refrigerant
Install front right wheel housing liner. Refer to 50 56 19 Removing and installing front wheel housing liner - as of MY 2005 (All Models) .
Install front right wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
Laying compressor/condenser line
Note. Close off all lines and connections using suitable plugs during removal. Before re-installing the component, check the O-rings of the refrigerant lines for damage and replaced them if necessary.
Installation Location
Scheme 185
A - Compressor/condenser line
Remove the compressor/condenser line and the compressor/evaporator line together.
Installation Location
Scheme 186
1 - Fastening nut for both holders
2 - Grommet for continuity to plenum panel
Preliminary work for compressor/evaporator line
Draining refrigerant. > 870317 Draining and filling in refrigerant - chapter on "draining"
Remove air-conditioning compressor from engine. > 873419 Removing and installing compressor - chapter on "Removing" [987310 987311 987320 987321] > 873419 Removing and installing compressor - chapter on "Removing" [987120 987121]
Removing compressor/evaporator line
Note. Close off all lines and connections using suitable plugs during removal. Before re-installing the component, check the O-rings of the refrigerant lines for damage and replaced them if necessary.
Installation Location
Scheme 187
B - Compressor/evaporator line
1. Unscrew fastening screw -2- on compressor, pull out line on compressor and remove it from support -7-. see scheme 137
2. Unscrew fastening nut -5- on cable holder, open cable holder and pull line out of rubber mounting -6-. see scheme 138
3. Unscrew fastening screw -4- on connection point and pull out line. see scheme 137
4. Remove line downwards from the engine area.
Installing compressor/evaporator line
Note. Before re-installing the component, check the O-rings of the refrigerant lines for damage and replaced them if necessary. Wet the O-rings of the refrigerant lines with refrigerant oil. Do not open the plugs for the lines and connections until shortly before installation.
1. Insert line from below into engine compartment.
2. Insert line into evaporator line and secure using the fastening screw -4-. --> Tightening torque: 14 (10.5 ftlb.) Nm. see scheme 139
3. Push line into the compressor, secure with the fastening screw -2- and clip line into the support -7-. --> Tightening torque: 21 (16 ftlb.) Nm. see scheme 140, (Scheme 188).
4. Insert line in underbody area into rubber mount -6-, close support and secure with fastening nut -5-. (Scheme 188)
Subsequent work for compressor/evaporator line
Install air-conditioning compressor on engine. > 873419 Removing and installing compressor - chapter on "Installing" [987310 987311 987320 987321] > 873419 Removing and installing compressor - chapter on "Installing" [987120 987121]
Fill in refrigerant. > 870317 Draining and filling in refrigerant - chapter on "Filling in"
Laying compressor/evaporator line
Note. Close off all lines and connections using suitable plugs during removal. Before re-installing the component, check the O-rings of the refrigerant lines for damage and replaced them if necessary.
Installation Location
Scheme 188
B - Compressor/evaporator line
Remove the compressor/evaporator line and the compressor/condenser line together.
Installation Location
1 - Fastening nut for both holders
2 - Grommet for continuity to plenum panel
Preliminary work for condenser
> 870317 Draining and filling in refrigerant
> 63 10 19 REMOVING AND INSTALLING FRONT BUMPER - AS OF MY 2005 (ALL MODELS) .
Removing the condenser
Installation Location
Scheme 189
1. Unscrew the two fastening screws -1- holding the air guide for the condenser. (Scheme 190)
2. Pull the air guide forward and disengage it at the condenser -A-. (Scheme 190)
Scheme 190
Note. When loosening or tightening the M8 refrigerant lines on the condenser, always counter with a 21-mm open-ended wrench.
3. Unscrew the two fastening screws -2- for the refrigerant lines. (Scheme 191)
4. Unscrew fastening screw -3-, lift the condenser and disengage from radiator bracket. (Scheme 191)
Scheme 191
Note. Before re-installing the component, check the O-rings of the refrigerant lines for damage and replaced them if necessary. Wet the O-rings of the refrigerant lines with refrigerant oil. Do not open the plugs for the lines and connections until shortly before installation. Close off all lines and connections using suitable plugs during removal.
5. Unclip the condenser from the four brackets -A- and lift it out of the retaining bracket -arrow-. (Scheme 192)
Scheme 192
1. Insert condenser into the retaining bracket and clip it into place -A-. (Scheme 193)
Scheme 193
2. Engage the condenser on the radiator bracket and secure with the fastening screw -3-. --> tightening torque: 4 (3) Nm (ftlb.). see scheme 161
Note. When loosening or tightening the M8 refrigerant lines on the condenser, always counter with a 21-mm open-ended wrench.
Note. Before re-installing the component, check the O-rings of the refrigerant lines for damage and replaced them if necessary. Wet the O-rings of the refrigerant lines with refrigerant oil. Do not open the plugs for the lines and connections until shortly before installation. Close off all lines and connections using suitable plugs during removal.
3. Carefully insert refrigerant lines into the condenser and secure with the fastening screws -2-. --> tightening torque: 14 (10.5) Nm (ftlb.). see scheme 161
4. Engage air guide on condenser -A- and screw down using the two fastening screws -1-. --> tightening torque: 4 (3) Nm (ftlb.). see scheme 162
Rework on condenser
> 870317 Draining and filling in refrigerant
> 63 10 19 REMOVING AND INSTALLING FRONT BUMPER - AS OF MY 2005 (ALL MODELS) .
Preliminary work for dryer
1. Remove cover on left for plenum chamber. Refer to 85 22 19 Removing and installing cover - as of MY 2005 (All Models) .
2. Drain refrigerant for air-conditioning system with one air-conditioning unit. > 870317 Draining and filling in refrigerant - draining
General safety regulations for work on the air-conditioning systems.
| CAUTION | Danger of injury when working on air-conditioned vehicles! |
> Observe safety regulations for working on air-conditioned vehicles and dealing with refrigerant R134a. --> 87 AW Safety regulations for working on air-conditioned vehicles and dealing with refrigerant R134a - as of MY 2005 (All Models) .
> Observe safety regulations for working with extraction and filling systems. --> 87 AW Safety regulations for extraction and filling systems - as of MY 2005 (All Models) .
> Observe instructions for repairing air-conditioning systems and storing spare parts. --> 87 01 IN Instructions for repairing air-conditioning systems and storing spare parts - as of MY 2005 (All Models) .
Tools for air-conditioning compressor
Air-conditioning service unit, refer to Special Tools, Commercially Available Tools, Chapter 2.4, No. 96-2)
Subsequent work for the dryer
1. Fill in refrigerant correctly. > 870317 Draining and filling in refrigerant - filling in
2. Install cover on left for plenum chamber. Refer to 85 22 19 Removing and installing cover - as of MY 2005 (All Models) .
Removing temperature sensor
Installation Location
Scheme 194
1. Switch off ignition and remove ignition key.
Scheme 195
2. From the driver's side, reach around to the "driver's footwell" air vent to release and disconnect the electrical connector -a-. (Scheme 196)
Scheme 196
3. Turn temperature sensor through 90° and pull it out of the heating/air conditioner unit.
Installing temperature sensor
1. Switch off ignition and remove ignition key.
Scheme 197
2. From the driver's side, reach around the "driver's footwell" air vent to insert the temperature sensor into the heater/air-conditioning unit and turn it through 90°.
Scheme 198
3. Plug in the electric connector until it clicks into place.
Preliminary work for outside temperature sensor
Refer to 85 15 19 Removing and installing heating/fresh air unit - as of MY 2005 (All Models) .
Removing outside temperature sensor
Installation Location
Scheme 199
1. Switch off ignition and remove ignition key.
Scheme 200
2. Release electrical connector to the temperature sensor -a- and unplug it. (Scheme 201)
Scheme 201
3. Turn temperature sensor through 90° and pull it out of the heating/fresh-air unit.
Installing outside temperature sensor
1. Switch off ignition and remove ignition key.
Scheme 202
2. Insert temperature sensor into the heating/fresh air unit and turn through 90°.
Scheme 203
3. Push electrical connector into temperature sensor until it clicks into place.
Subsequent work for outside temperature sensor
Refer to 85 15 19 Removing and installing heating/fresh air unit - as of MY 2005 (All Models) .
Preliminary work for expansion valve
Refer to 85 22 19 Removing and installing cover - as of MY 2005 (All Models) .
> 870317 Draining and filling in refrigerant
Removing expansion valve
1. Unscrew fastening nuts -1-. (Scheme 204)
2. Remove the bracket for the two refrigerant lines and pull the refrigerant lines out of the expansion valve.
Scheme 204
3. Undo the two fastening screws on the expansion valve and remove expansion valve.
Installing expansion valve
Note. Before re-installing the component, check the O-rings of the refrigerant lines for damage and replaced them if necessary. Wet the O-rings of the refrigerant lines with refrigerant oil. Do not open the plugs for the lines and connections until shortly before installation. Close off all lines and connections using suitable plugs during removal.
1. Carefully push expansion valve onto refrigerant lines from evaporator - do not tilt.
2. Insert and tighten the two fastening screws. --> tightening torque: 9 (6.5) Nm (ftlb.)
3. Position refrigerant lines on expansion valve and press into place - do not tilt.
4. Position bracket for refrigerant lines and secure with the fastening nuts -1-. --> tightening torque: 6 (4.5) Nm (ftlb.). (Scheme 205)
Rework on expansion valve
> 870317 Draining and filling in refrigerant
Refer to 85 22 19 Removing and installing cover - as of MY 2005 (All Models) .
Preliminary work for blower regulator
Remove glove compartment. Refer to 68 15 19 Removing and installing glove compartment - as of MY 2005 (All Models) .
Remove air guide C . Refer to 85 34 19 Removing and installing air guide - as of MY 2005 (All Models) .
Removing blower regulator
Installation Location
Scheme 205
1. Switch off ignition and remove ignition key.
Scheme 206
2. Release electrical connector and unplug it from blower regulator.
Scheme 207
3. Undo fastening screw.
4. Lift blower regulator and detach at the top side.
Installing blower regulator
1. Switch off ignition and remove ignition key.
Scheme 208
2. Engage blower regulator and insert into the heating/air-conditioning unit.
3. Secure the blower regulator with the fastening screw. --> Tightening torque: 1.5 (1.0 ftlb.) Nm
Scheme 209
4. Insert electrical connector into blower regulator until it clicks into place.
Subsequent work for blower regulator
Install air guide C . Refer to 85 34 19 Removing and installing air guide - as of MY 2005 (All Models) .
Install glove compartment. Refer to 68 15 19 Removing and installing glove compartment - as of MY 2005 (All Models) .
Preliminary work for pressure switch
> 870317 Draining and filling in refrigerant - chapter on "draining"
Removing pressure switch
The pressure switch is located in the radiator tank, right side in the direction of travel, under the cowl panel cover.
Scheme 210
1. Press release on electrical connector and disconnect from pressure switch.
Scheme 211
2. Place one open-ended wrench on the hexagon of the pressure switch and a second open-ended wrench on the hexagon of the refrigerant line.
3. Unscrew pressure switch from refrigerant line and remove.
Installing pressure switch
Replace the O-ring on the pressure switch and wet it with refrigerant oil.
1. Screw pressure switch onto refrigerant line and tighten with an open-ended wrench. Counter with a second open-ended wrench. --> Tightening torque: 3.5 ftlb.
Scheme 212
2. Push electrical plug onto pressure switch until it clicks into place.
Subsequent work for pressure switch
> 870317 Draining and filling in refrigerant - chapter on "filling in"
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