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