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Assembly Work Involving The Refrigerant System

WARNING: This page is about a different car, the 2010 Porsche Cayenne, 2009 Porsche Cayenne, and 2008 Porsche Cayenne. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Refrigerant
  • Danger of freezing

→ Avoid contact with refrigerant.

→ Wear personal protective gear.

→ Observe the safety regulations for working on air-conditioned vehicles and dealing with refrigerant.

→ Observe the safety regulations for extraction and filling systems.

→ Observe the instructions for repairing air conditioning systems and storing spare parts.

Information 

Information 

  1. Remove the cover of the engine compartment lining.
    Fig 1: Removing Engine Compartment Lining Cover
    G09414471Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  2. Unscrew the two cover nuts -arrow 1-  and -arrow 2-  .
    1. High pressure
    2. Low pressure
      Fig 2: Unscrewing Cover Nuts
      G09414472Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    • Before connecting the high-pressure -3- and low-pressure lines -4- to the vehicle, remove any refrigerant remaining in the lines by suction  .
      Fig 3: Locating High-Pressure And Low-Pressure Lines Connection
      G09414473Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  3. Connect the high-pressure and low-pressure lines of the air-conditioning recycling system  .
    1. 3.1. 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.
    2. 3.2. Open the valves of the high-pressure and low-pressure lines.

    Information 

    In the case of service units with 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.

  4. Remove refrigerant by suction.
    1. 4.1. 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.

      Information 

      In the case of service units with 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.

    2. 4.2. Drain the extracted refrigerant oil into a measuring cup on the servicing equipment and determine the volume.

    Information 

    • The vehicle air-conditioning system is now completely empty. Necessary repairs, such as removing and fitting the dryer, can now be carried out. 
    • The open air-conditioning system should not be left open unnecessarily, but must be closed again as quickly as possible after being opened. 
    • If the air-conditioning system has been open for a long time, a new dryer must be fitted. →  875519 REMOVING AND INSTALLING DRYER  
  5. Carry out repairs.

    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. 5.1. Before closing off the refrigerant circuit, check whether the desiccator needs to be replaced.
    2. 5.2. If necessary, re-connect high-pressure and low-pressure lines.
  6. Evacuate the system and check it for leaks.
    1. 6.1. Using the service unit, evacuate the system for 5-10 minutes.
    2. 6.2. 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 

    • Do not allow any air to be taken in, otherwise point 6 must be repeated. 
  7. Add refrigerant oil.
    1. 7.1. For units without oil filling system:
    2. 7.2. 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. 7.3. For units with an integrated oil filling system:
    4. 7.4. Add the measured quantity of refrigerant oil and wait for it to be taken in.

    Information 

    • 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. 
    • If the air-conditioning system has been open for a long time, evacuation can be carried out for up to 120 minutes. 
  8. Evacuate the system.
    1. 8.1. For units with an integrated oil filling system, add refrigerant oil now.
    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.

    Information 

    • As refrigerant usually flows instead of being pumped, it may not be possible - especially if the vehicle is warm and the service unit cold - to add the entire quantity. If this is the case, switch the engine and the 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. 
  9. Fill the air-conditioning system.

    Information 

    • 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. 
  10. Add refrigerant from both connection hoses to the air-conditioning system in the vehicle.
    1. 10.1. Close the valve on the high-pressure line and disconnect it from the vehicle.
    2. 10.2. 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 above the valves and check the valves for signs of any leaks.

  11. If there are no leaks in the high-pressure and low-pressure connection valves, fit the caps.
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