Heating — Porsche Cayenne S I (2002-2007)

General warning notes

WARNING

Danger of material damage and damage to health when handling extraction and filling systems!

> 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 a 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.

Preliminary work

Remove glove compartment. Refer to 68 15 19 Removing and installing glove compartment - as of MY 2003 (All Models) .

Removing servomotor

Note. The heater servo motor - right temperature - is located on the right air conditioning unit. Switch ignition off and remove ignition key before starting work.

Scheme 368

Scheme 368: Removing servomotor

1. Unscrew the fastening screw of the right heat exchanger cover and unclip the cover.

Scheme 369

2. Disconnect plug connection of temperature sensor.

3. Unscrew both fastening screws -1- from the retainer plate. (Scheme 369)

4. Press in plug -2- -a- and pull apart plug connection. (Scheme 369)

5. Pull out retainer plate downwards.

Scheme 370

6. Unscrew fastening screws -Arrow A- and remove servo motor. (Scheme 370)

Installing servomotor

1. Place the servo motor on the retainer plate and screw down using the fastening screws -Arrow B-. --> Tightening torque: 1.0 ftlb. see scheme 4

Scheme 371

2. Move the servo motors with the Porsche System Tester to the service position. The drives must be parallel to the guides -Z-. (Scheme 371)

Note. Switch on ignition and carry out the service position menu, Drive links menu with the Porsche System Tester in the Climatronic. As an alternative, the servo motors can also be powered with 12 volts until they have reached the correct position. Always use the circuit diagram for this.

3. Connect the electrical plug connections to the servo motors.

4. Switch off ignition and remove ignition key.

5. Press in plug again and pull apart plug connection.

Scheme 372

Note. Make sure that the driver of the servo motor is pushed into the mount.

6. Insert the retainer plate from below into the guides.

Scheme 373

7. Connect the electrical plug, pressing on until it audibly clicks into place -2-. (Scheme 373)

8. Tighten the two fastening screws. --> Tightening torque: 1.0 ftlb.

Scheme 374

9. Clip in right cover and screw down with the fastening screw. --> tightening torque: 1.0 ftlb.

Subsequent work

Install glove compartment. Refer to 68 15 19 Removing and installing glove compartment - as of MY 2003 (All Models) .

1. Drain engine coolant. Refer to 19 38 17 Draining and filling in coolant (includes bleeding) - as of MY 2003 (All Models) .

2. Unclip cover for instrument panel into place on left and right. Refer to 70 16 19 Removing and installing dashboard cover on the passenger's side - as of MY 2003 (All Models) .

3. Remove front footwell vent on left and right. Refer to 85 34 19 Removing and installing air guide - as of MY 2003 (All Models) .

4. Remove Kessy control unit. Refer to 96 66 19 Removing and installing Kessy/immobilizer control unit - as of MY 2003 (All Models) .

5. Remove vehicle electrical system control unit. Refer to 97 10 19 Removing and installing vehicle electrical system control unit - as of MY 2003 (All Models) .

6. Remove relay carrier. Refer to 97 90 19 Removing and installing relay carrier, plenum chamber E-box - as of MY 2003 (All Models) .

Removing heat exchanger

Installation Location

Scheme 375

Scheme 375: Removing heat exchanger

Scheme 376

1. Unclip wiring harness on the left heat exchanger cover.

2. Unscrew both fastening screws on the left heat exchanger cover and unclip the cover.

Scheme 377

3. Pull the retaining clips -Arrows A- of the coolant supply line and return line downward. (Scheme 377)

Scheme 378

Note. Line the driver's footwell with very absorbent material.

4. Pull the interior carpet away from the coolant lines and put in a suitable collecting container.

5. Slowly pull out the lines from the heat exchanger -Arrows B- and drain the coolant into the collecting container. (Scheme 378)

Scheme 379

6. Unscrew the fastening screw of the right heat exchanger cover and unclip the cover.

7. Unscrew the fastening screw of the heat exchanger holding tray on the left and right side.

Scheme 380

Note. There is a retaining pin on the left side above the heat exchanger which joins the lower holding tray (where the heat exchanger is located) to the air conditioning unit. As soon as the retaining pin has been pulled out, the heat exchanger with the holding tray can be folded down.

8. Turn retaining pin out of the latch -Arrow 1- and pull out -Arrow 2-. (Scheme 380)

9. Fold down holding tray with heat exchanger.

Scheme 381

10. Pull out heat exchanger carefully to the left.

Scheme 382

Scheme 382: Installing heat exchanger

1. Insert heat exchanger carefully into the holding tray. Make sure not to damage the heat exchanger plates on the retaining stays in the holding tray.

Scheme 383

2. Lift up the holding tray, slide the retaining pin through the guide -Arrow 2- and lock the retaining pin into the holding tray -Arrow 1-. (Scheme 383)