Disassembling and assembling heating AC unit

Disassembling and assembling heating - A/C unit

19 18 8

13 1211 7 9 10

19 18 8

13 1211 7 9 10

*

Note When:

No.

Description

Qty.

Removing

Installing

1 X

Left footwel1

1

vent

2

Sheet-metal

17

screw

3

Cover

1

4

Control motor

2

5

Control motor

1

6

Linkage

1

7

Plastic

4

bearing

8

Plastic

4

bearing

9

Tab washer

1

10

Linkage

1

11

Retaining ring

2

12

Plastic ring

c

13

Shaft ring

2

14

Linkage

1

15

Plastic bearing

2

16

Linkage

1

No.

Description

Removing

Installing

17

Angle bracket

1

18

Angle bracket

1

M 3 x 7 with spring washer

4

20

De-icer

1

Do not damage capillary tube

Push in up to marking

21

Rubber grommet

1

Turn by 90°

M 4 x 8 with spring washer and collar

4

36 43 35

24 28 29 22 31

33 24 32 22

24 28 29 22 31

33 24 32 22

Note V

Ihen:

No.

Description

Qty.

Removing

Installing

23

Right footwell vent

1

24

Solenoid valves

2

25

Vacuum 1 ine

1

26

Vacuum line

1

27

Vacuum line

1

28

Vacuum 1 ine

2

29

Branch piece

1

30

Bracket

1

31

Plug housing

1

32

Sheet-metal screw, long

6

33

Cover

1

34

Bracket

i

M 4 x 10 with spring washer and collar

1

'l

36

Bracket

1

37

Seal

1

No.

Description

Qty.

Note Whi Removing

en

Installing

38

Mounting plate

1

39

Clip

2

40

Refrigerant tube

1

41

Refrigerant tube

1

42

Seal

2

43

Refrigerant 1 ine

1

44

Seal

1

Replace and moisten with refrigerator oil

45

Clamp

1

46

Expansion valve

1

47

Fuse

1

48

Spring

1

49 *

Angle bracket

64 71 56 57 32 52 53 59 54 77 55 58 51 60 52 50 8 61 7

No.

Description

Removing

ihen

Installing

50

Clamp

13

51

Clamp

1

52

Sheet-metal screw

5

53

Angle bracket

1

54

Sheet-metal screw

2

55

Vaporizer

1

Do not damage discs

Do not damage discs

56

Seal

1

Replace and moisten with refrigerator oil

57

Spacer

1

58

Water drain hose

1

59

Lower part of housing

1

60*

Sheet-metal screw

2

61

Left footwell flap

1

62

Right footwell flap

1

63

Linkage

1

64

Heat exchanger

1

65

Clamp

1

No.

Description

Installing

66

Clamp

1

67

Sheet-metal screw

68

Left upper housing half

1

69

Right upper housing half

1

70

Plate nut

1

71

Temperature-mixing flap

1

72

Baffle flap

1

73

Defrost flap

1

74

Air ducting

75

Mixing-chamber sensor

1

76

Rubber grommet

1

77

Foam sealing

1

Replace

78

Foam sealing

1

Replace

79

Foam sealing

1

Replace

80

Foam sealing

1

Replace

POSITIONING OF FLAPS, AIR FLOW

A - Cold air B - Warm air F - Fresh air U - Circulating air

1 - Fresh/circulating air flap 5 - Defrost flap

2 - Footwel1 flap 6 - Blower

3 - Temperature-mixing flap 7 - Vaporizer

4 - Baffle flap 8 - Heat exchanger

REMOVING AND INSTALLING HEATING - A/C UNIT

1.Drain air-conditioning system.

2.Drain refrigerant.

3.Remove fresh air blower (see repair group 85}.

4.Remove center console (see repair group 68).

5.Remove instrument panel (see repair group 68).

6.Unciip instrument-panel wiring harness. 12.Remove vacuum 1ines.

8.Disconnect plug at in-terior-sensor blower.

15.Unscrew fastening nuts on the in-

9.Pull out air ducts. side.

16.Unscrew bracket for instrument

10.Pull out drainage hose. panel.

17.Run out heating-A/C unit.

11.Unscrew A/C lines.

Note

During installation, make sure that water drainage pipe is reinserted.

87 - 52 Removing and Instal1ing Heating - Printed in Germany

A/C Unit

REMOVING AND INSTALLING COMPRESSOR

1.Drain air-conditioning system.

2.Loosen both lock nuts on clamp clip.

3.Loosen V-belt.

4.Loosen clamp clip fastening and remove V-belt.

5.Disconnect plug.

6.Loosen hose connections.

Note

The fastening screws are microencapsulated. Use new screws during installation.

In order to facilitate installation, remove the generator ventilation hose.

7.Unscrew compressor fastening screws.

Adjusting Poly-Rib Belt

1.Prepare special tool 9201 for testing.

2.Turn tensioner until the set value of 9.5 scale units is reached. From this position, turn tensioner another 2 turns (increase tension, see also p. 13-1).

REMOVING AND INSTALLING CONDENSOR

1.Drain air-conditioning system.

2.Unscrew underbody protection.

3.Unscrew air duct.

4.Loosen hose connections.

5.Unscrew fastening screws (2 pes.).

6.Pull condensor out of rubber holders from below.

REMOVING AND INSTALLING REFRIGERANT TANK

1.Drain air-conditioning system.

2.Loosen hose connections.

S.Loosen clamp.

4.Pull tank out from above.

Note

During installation, make sure that the connection nipple marked "IN"

points forward.

Thé tank must be replaced in case of system malfunction and after every opening of the refrigerant system.

REMOVING AND INSTALLING INTERIOR SENSOR BLOWER

1.Remove glove compartment,

2.Pull hose from interior sensor.

3.Loosen fastening nuts.

4.Disconnect plug. Note

Make cable connection before installation.

REMOVING AND INSTALLING THE DE-ICER 1.Remove left footwell vent.

2.Loosen but do not entirely unscrew fastening screws.

3.Carefully pull capillary tube out of vaporizer.

Note

When installing, push capillary tube into marking.

4.Pull off cable

Printed in Germany-VII, 1986 Removing and Installing Interior 87 - 55

Sensor Blower

REMOVING AND INSTALLING EXPANSION VALVE

Note

The expansion valve can only be removed and installed when the heating - A/C unit is removed.

l.Pull off cold-insulating band on expansion valve.

2.Press off bracket for capillary tube.

3.Unscrew union nuts and remove expansion valve.

OIL DISTRIBUTION IN REFRIGERATION CYCLE

Compressor

Vaporizer

Condensors

Refrigerant tank/lines

These proportions should be maintained.

When a component is replaced, the oil in the system must be added to by the amount in the component replaced.

The proper quantity can be directly filled into the new component.

If the compressor is-replaced, 60 % = approx. 50 cm oil must be released from the new compressor, since this contains the oil for the entire system.

REMOVING AND INSTALLING EXPANSION VALVE

Note

The expansion valve can only be removed and installed when the heating - A/C unit is removed.

l.Pull off cold-insulating band on expansion valve.

2.Press off bracket for capillary tube.

3.Unscrew union nuts and remove expansion valve.

OIL DISTRIBUTION IN REFRIGERATION CYCLE

Compressor

Vaporizer

Condensors

Refrigerant tank/lines

These proportions should be maintained.

When a component is replaced, the oil in the system must be added to by the amount in the component replaced.

The proper quantity can be directly filled into the new component.

If the compressor is-replaced, 60 % = approx. 50 cm oil must be released from the new compressor, since this contains the oil for the entire system.

REMOVING AND INSTALLING CONTROL MOTOR FOR DEFROST FLAP

l.Unclip linkage.

2.Remove plug housing.

3.Unscrew the three fastening screws.

Adusting Defrost Flap l.Set control motor to final "closed" position. To do this, connect pin 4 with + and pin 5 with - of a 12 voltage source.

2.Close defrost flap and clip on 1inkage.

REMOVING AND INSTALLING CONTROL MOTOR FOR TEMPERATURE-MIXING FLAP AND BAFFLE FLAP

l.Unclip temperature-mixing flap 1inkage.

2.In order to disconnect the linkage of the baffle flap, remove retaining ring, plastic washer, and shaft ring.

3.Unscrew fastening screw.

Adust ing the Temperature - Mixture Flap and Baffle Flap l.Set the control motors to the final "cool" position. To do this, connect pin 4 with + and pin 5 with -of a voltage source of 12 V.

2.Press temperature-mixing flap lever upward until the flap is at the stop. Clip on the linkage in this position.

S.Loosen nut M 5 on baffle flap 1inkage.

4.Press together the two linkage halves and tighten nut M5.

REMOVING AND INSTALLING CONTROL MOTOR FOR FOOTWELL FLAPS

1.Remove plug housing.

2.Unscrew cover.

Adjusting the Foot well Flaps l.Set control motor to final "closed" position. To do this, connect pin 4 with + and pin 5 with - of a 12 voltage source.

2.Close footwell flaps and connect linkage.

3.Unciip linkage.

4.Unscrew fastening screws.

AIR-CONDITIONING SYSTEM TROUBLESHOOTING

General Requirements

Heating is off. Polyrib belt correctly tensioned.

At an engine spped of 2000 1/min, an ambient temperature of approx. 20° C, and with the compressor running, the following pressures must be attained:

High pressure: approx. 10 - 20 bar

Temperature at center nozzle: approx. 2 - 4° C.

Complete Cooling Failure l.When bursting seal on refrigerant tank has been destroyed.

No refrigerant in system. Look for leakage. Fill air-conditioning system.

3.Turn on air-conditioner and read off pressures.

Low pressure: too high High pressure: too low

Compressor is defectiive.

Low pressure: too low High presssure: too high

Expansion valve is defective.

Insufficient Cool i n g

1.Low pressure: normal High pressure: high

System is too full. Drain and refill system.

2.Low pressure: too low High pressure: too low

The system was overheated. Check direction of rotation of cooler and condensor blowers. If the blowers do not run, check fuses, relays.

2.Connect service unit and read off pressure values.

Low pressure: too low High pressure: too low

Insufficient refrigerant in system. Look for leakage. Refill system.

3.Low pressure: too high High pressure: normal

Expansion valve is defective.

Inadequate Cooling Heater heats con-After Short Period tinuously and of Operation cannolongerbe regulated

Cooling is OK at first, but then decreases in effectiveness during Interruption in sensor series. Check operation. outside sensor, interior sensor, and mixing chamber sensor.

Vaporizer is iced up. De-icing switch does not turn off compressor. Check capillary tube for damage and correct seating.

Remove control switch and pull plug A.

Outer sensor: Connect ohmmeter with term.9 and ground or

Expansion valve iced up. Warm expansion valve. The cooling effect of the air-conditioner should start back up.

Cause: Moisture in refrigerant. Replace refrigerant tank. Refill system.

Reading: at 0°C - 34 kohm + 10% at 10°C - 20 kohm + 10% at 25°C - 10 kohm + 10%

Interior sensor:Connect ohmmeter with term.2 and ground

Reading: As for outside sensor

Mixing chamber sensor: Connect with term.l and ground

Reading: As for outside sensor

Heating not Control 1 a b 1 e l.The heating regulates in the direction of maximum cooling and heats only starting from a temperature-switch position of approx. 27c

There is a short circuit in the sensor series.

To check the 3 temperature sensors, see "heater heats continuously and can no longer be regulated".

2.Defrost flap not controllable. Pull plug on control motor, switch on ignition and set defrost slide switch to "closed" position.

Voltmeter at term. 1 and term. 2

Reading: approx. 6 V

Voltmeter at term. 2 and term. 3

Reading: approx. 0.1 V

Defrost slide switch in "open" position.

Reading: approx. 6 V

Voltmeter at term.2 and term.4

Reading: approx. 0.1 V

Defrost slide switch in "closed" position

Reading: approx. 10 V

Voltmeter at term. 2 and term. 5

Reading: approx. 0.1 V

Defrost slide switch in "open" position

Reading: approx. 10 V

3.Temperature mixing flap and baffle flap not controllable.

Pull plug on control motor, switch on ignition and set temperature pre-selector to maximum cooling.

Voltmeter at term.l and term.2

Reading: approx. 6 volts

Voltmeter at term.l and term.3

Reading: approx. 2.5 volts

Voltmeter at term.l and term.4

Reading: approx. 10 volt

Set temperature pre-selector to maximum heating

Reading: approx. 0.1 volts

Voltmeter at term. 1 and term.5

Reading: approx. 10 volts

Set temperature pre-selector to maximum cooling.

Reading: approx. 0.1 volts.

4.Footwell flaps not adjustable.

Pull plug on control motor, switch on ignition, and set foot-well slide switch to "closed11 position.

Voltmeter at term. 1 and term. 2 Reading: approx. 6 V

Voltmeter at term. 2 and term. 3 Reading: approx. 0.1 V

Footwell slide switch in "open11 position

Reading: approx. 6 V

Voltmeter at term. 2 and term. 4 Reading: approx. 0.1 V

Footwell slide switch in "closed" position

Reading: approx. 10 V

Voltmeter at term. 2 and term. 5 Reading: approx. 0.1 V

Footwell slide switch in "open" position.

Reading: approx. 10 V

Sluggish Interior Temperature Re g u 1 a -t i o n

The system overheats and reacts only very sluggishly.

Interior sensor not functioning.

Pull plug on interior sensor blower and switch on ignition. .

Voltmeter at term. 1 and term. 3 Reading: battery voltage

If no voltage present, check fuse No. 17.

Magnetic Coupling switching

1.Check voltage at compressor plug.

Voltage present —►Replace magnet coil.

no voltage present -►Check low-pressure switch.

2.Check voltage at low-pressure switch.

Voltage only at one pin -►Check system fill quantity-

System correctly filled —►Replace low-pressure switch.

Na voltage present Check A/C relay.

3.Check A/C relay.

There must be voltage at term. 3, No voltage present Check de-icer.

Checking Vacuum System l.Pull off vacuum hose on vacuum reservoir.

2.Switch on vacuum hand pump.

There must be no ground potential at term. 2. Ground present -►Check water-temperature switch.

4.Check voltage at de-icer.

Voltage at only one pin Replace de-icer.

No voltage

-►Replace control switch.

3.Switch on ignition.

4.Press air-circulation button and set temperature pre-selector switch to maximum cooling.

5.Generate vacuum. The fresh/circulation air flaps should close, as well as the heating valve.

6.If the fresh/circulation air flaps and the heating valve do not close, although the vacuum system has no leakage, check voltage at solenoid valves

TOOIS

No.

Description

Special Tool

Remarks

1

Holding wrench

95047-10040

Suppliers: see Workshop Manual

2

Coupling plate puller

95047-10060

3

Key puller

95042-10160 .1

4

Friction washer puller

95042-10150

5

Axial face seal puller

95042-10130

6

Key inserter

95042-10190

7

Thrust member

95042-10250

Rem. and installing magnetic coupling, shaft sealing ring

Printed in Germany - XXII, 1990

Air-Cond;'t;orrirg Sys t3-*n

INSTALLING AND REMOVING MAGNFT7r COUPLING-

l.For loosening or tightening the fastening nut, use 'holding wrench to counter-hold.

Tightening torque: 16 Nm/12 ftib

4,Remove retaining ring and belt pulley.

ifiiii

5.Remove retaining riro and magnet coi 1.

2.Remove ccuo'Hro plate with pu"H e>\

3.Remove shims

- tif Moving *nc Installing Magnetlr^cupl;ng Printed in Germany

If required, adjust air gap with shims.

Install the two retaining rings so~ -

that the diagonal points upwards"! •

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