General Assembly Sequence

Fig 1: Removing Protection Caps On Charging Valves

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Before connecting the high-pressure and low-pressure lines to the vehicle, remove any refrigerant remaining in the lines by suction.

Fig 2: Connecting High-Pressure And Low-Pressure Lines To Vehicle

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information 

In the case of servicing equipment with a transparent oil separator, read and take note of the oil level before removing the refrigerant.

Do not carry out this step on empty air-conditioning systems (pressure gauge approx. 0 bar) because if you do, air will get into the refrigerant bottle.

If the vehicle is cold, it may be necessary to repeat the suction procedure until all refrigerant has been removed from the air-conditioning system. This step is carried out automatically with some units.

1. 2.1.
2. 2.2. Let the engine run for a short while with the air-conditioning on, then connect the high-pressure and low-pressure lines of the air-conditioning unit.
3. 2.3. Open the valves of the high-pressure and low-pressure lines.

1. 3.1. If the vehicle is cold, it may be necessary to repeat the suction procedure until all refrigerant has been removed from the air-conditioning system. This step is carried out automatically with some units.
2. 3.2. Wait for approx. 2 minutes after the servicing equipment has switched itself off. If the pressure gauge reading rises above 0 bar, repeat the suction process.
3. 3.3. The vehicle air-conditioning system is now completely empty. Necessary repairs, such as removing and installing the desiccator, can now be carried out.
4. 3.4. The open air-conditioning system should not be left open unnecessarily, but must be closed off using suitable stoppers immediately after being opened.
5. 3.5. Drain the extracted refrigerant oil into a measuring cup on the service unit and determine the volume.

Information 

The desiccator must be replaced in the following situations: 

Refrigerant circuit is open for > 20 minutes  .

Amount of refrigerant extracted is < 30% of the required quantity  .

Refrigerant circuit has been open for an indefinite period of time (gradual leak, stone damage to condenser)  .

Air-conditioning compressor has become blocked  .

Dryer cartridge is damaged  .

After opening the packaging and line connections (on a new desiccator), the desiccator must be installed within 20 minutes at the latest and the refrigerant circuit must be closed, evacuated and filled  .

The desiccator must not be replaced in the following situations: 

• If the components are closed off using stoppers immediately after opening the refrigerant circuit and the refrigerant circuit is closed and evacuated within 20 minutes at the latest  .

1. 4.1. Before closing off the refrigerant circuit, check whether the desiccator needs to be replaced.
2. 4.2. If necessary, re-connect high-pressure and low-pressure lines.

1. 5.1. If the air-conditioning system has been opened, evacuation should last at least 20 minutes so that the moisture can evaporate and be removed by suction.
2. 5.2. If the air-conditioning system has been open for a long time, evacuation can be carried out for up to 120 minutes.
3. 5.3. Observe the pressure gauge for approx. 2 minutes. If the pressure rises, air is entering the vehicle's air-conditioning system. The leak must be located and repaired. If the pressure remains constant, add refrigerant oil.

Information 

Only ND8 refrigerant oil must be used.

1. 6.1. For units without oil filling system:
2. 6.2. Start the vacuum pump. At the start of this vacuum phase, add the measured quantity of refrigerant oil using an oil injector or a hose disconnected from the servicing equipment. Re-connect the hose to the servicing equipment immediately after adding the oil.
3. 6.3. For units with oil filling system: Add the measured quantity of refrigerant oil and wait for it to be taken in.
4. 6.4. Do not allow any air to be taken in, otherwise Step  5 must be repeated.

1. 7.1. If the air-condi@tioning system has been opened, evacuation should last at least 20 minutes so that the moisture can evaporate and be removed by suction.
2. 7.2. If the air-conditioning system has been open for a long time, evacuation can be carried out for up to 120 minutes.
3. 7.3. For units with an integrated oil filling system, add refrigerant oil now.

1. 8.1. Using the service unit, add the refrigerant quantity stated in the manual into the air-conditioning lines. → Technical data for air-conditioning system 
2. 8.2. As refrigerant usually flows instead of being pumped, it may not be possible - especially if the vehicle is warm and the servicing equipment is cold - to add the entire quantity. If this is the case, switch the engine and air conditioning on. Wait for the suction pressure to fall below 2 bar. Now open the low-pressure valve on the unit slowly and carefully until the remaining quantity has been added.
   NOTE: Excessively high pressure in refrigerant circuit

   • Risk of damage to air-conditioning compressor

   → Do not allow the low-pressure gauge to exceed → Nominal value: 3 bar  at any time.

3. 8.3.

1. 9.1. The refrigerant in the high-pressure and low-pressure lines is part of the filling capacity of the refrigerant in the air-conditioning system in the vehicle.
2. 9.2. Close the valve on the high-pressure line and disconnect it from the vehicle.
3. 9.3. Start the engine and air-conditioning system. When the pressure on both pressure gauges falls below 2 bar, close the valve on the low-pressure line and disconnect it from the vehicle.

Information 

After filling the air-conditioning system, the valve on the high-pressure and low-pressure connection must be checked using a leak detector.

The protection caps must not be fitted.

Position the leak detector at a specified distance (see operating instructions for each leak detector) above the valves and check the valves for signs of any leaks.