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AfterSales Training

Climate Control Systems Diagnosis & Repair

P-80

Содержание P-80 2005

Страница 1: ...AfterSales Training Climate Control Systems Diagnosis Repair P 80...

Страница 2: ...Dr Ing h c F Porsche AG is the owner of numerous trademarks both registered and unregistered including without limitation the Porsche Crest Porsche Boxster Carrera Cayenne Tiptronic VarioCam PCM 911 4...

Страница 3: ...r Chapter Description Section Introduction i Air Conditioning Basics 1 911 Carrera 993 1995 98 2 Sports Cars 911 Carrera 996 997 Boxster 986 987 3 Cayenne 9PA 2003 0n 4 A C Refrigerant System Service...

Страница 4: ...Climate Control Systems Diagnosis Repair...

Страница 5: ...sold in North America have A C standard and all US models are equipped with automatic climate control systems With the push of a button today s customer expects rapid heating and cooling Only when th...

Страница 6: ...on Dioxide R 134a refrigerant is better but still has a GWP value of 1 300 The discovery of these problems caused the governments of the industrialized world to establish a time table for the reductio...

Страница 7: ...ge Air Conditioning Overview 1 3 Principles of Heat Transfer 1 3 The Refrigeration Cycle 1 7 Compressor 1 8 Pressure Relief Valve 1 10 Condenser 1 11 Receiver Dryer 1 11 Evaporator 1 12 Thermostatic E...

Страница 8: ...Page 1 2 Climate Control Systems Diagnosis Repair Air Conditioning Basics Notes...

Страница 9: ...he evaporator as it removes heat from the passenger compartment Then the refrigerant gas condenses back to liquid in the condenser giving off heat to ambient outside air This is a short description of...

Страница 10: ...tes it removes body heat In a similar way refrig erant vaporizing changing from liquid to gas inside the A C evaporator absorbs heat from the warmer air around the evaporator Practical Application In...

Страница 11: ...ature of a liquid or gas varies with its pressure The pressure of the refrigerant in the closed A C circuit will vary with changes in temperature and the temperature of the refrigerant varies with cha...

Страница 12: ...quid as heat is removed R 134a refrigerant is as a gas at atmospheric pressures and ambient temperatures In the closed refrigerant circuit some refrigerant is in liquid form because of the higher pres...

Страница 13: ...used up unless there is a mechanical problem or a leak The amount of heat moved from inside to outside the vehicle determines the heat load Both temperature and humidity affect the heat load The refr...

Страница 14: ...ve The system high side contains high pressure refrigerant and includes the compressor outlet condenser receiver dryer and expansion valve inlet The flow of refrigerant gas into and out of the compres...

Страница 15: ...iable displacement compressors are more efficient than fixed displacement compressors because they pump only enough refrigerant to achieve the desired cooling Energy is not wasted pumping more refrige...

Страница 16: ...d helps to seal moving parts This lubricant is carried by the flow of refrigerant throughout the system and it must be compatible with the refrigerant seals and components Porsche A C systems with R 1...

Страница 17: ...fan comes ON to improve airflow and heat transfer Receiver Dryer 911 Carrera 996 Receiver Dryer The receiver dryer is a reservoir for refrigerant on the system high pressure side It is located betwee...

Страница 18: ...efrigerant becomes a gas it absorbs both sensible heat and large amounts of latent heat from the cabin air passing through the evaporator fins The refrigerant warms and the cabin air passing over the...

Страница 19: ...and pressure in the evaporator Both evaporator inlet and outlet lines pass through the TEV Refrigerant temperature is sensed at the evaporator outlet Increases in evaporator outlet gas temperature due...

Страница 20: ...ns 911 Carrera 993 models have A C high and low side service connections located in the rear near the A C compressor 911 Carrera 996 997 and Boxster 986 987 model connec tions are located in the cowl...

Страница 21: ...he refrig erant used today It has similar heat transfer properties like R 12 but it does not contain Chlorine R 134a has 84 less global warming potential than R 12 and it does not destroy ozone For th...

Страница 22: ...Page 1 16 Climate Control Systems Diagnosis Repair Air Conditioning Basics Notes...

Страница 23: ...Repair Page 2 1 Subject Page A C System Description Refrigerant System Description 2 3 Air Distribution System 2 3 Heating A C Control Unit Operation 2 5 Sensors Actuators 2 6 Service and Diagnosis In...

Страница 24: ...Page 2 2 Climate Control Systems Diagnosis Repair 911 Carrera 993 Model System Notes...

Страница 25: ...left front wheel housing Evaporator The A C evaporator is located in the air distribution housing Evaporator removal requires removal and disas sembly of the air distribution housing Thermostatic Expa...

Страница 26: ...s drawn in through the engine air inlet grille by the engine cooling fan Some of this air is pumped to the exhaust heat exchangers by the auxiliary heater blower The auxiliary blower supplies hot air...

Страница 27: ...e recirculation switch on the Heater A C Regulator selects the recirculation mode The recirculation mode prevents outside air intake and increases the cooling efficiency of the A C It also prevents un...

Страница 28: ...Page 2 6 Climate Control Systems Diagnosis Repair 911 Carrera 993 Model System 911 Carrera 993 Sensors and Actuators...

Страница 29: ...re air through the condenser and to reduce high side refrigerant pressure The 3 way pressure switch is installed in the system high side Evaporator Temperature Sensor The evaporator temperature sensor...

Страница 30: ...nsors L R Fresh air flap position sensor Defrost flap position sensor Footwell flap position sensor Notes Actuators Compressor Clutch An electromagnetic clutch engages and drives the compressor The cl...

Страница 31: ...he auxiliary blower under these conditions Ambient temperature 14 C 11 F and the mixing flaps are allowing max heat Max heat is requested in cold ambient temperatures When no heat is requested in summ...

Страница 32: ...al passenger s controls Passengers can select the desired temperature blower speed and air distribution conditions The system will maintain the set temperature as conditions change The Heating A C Con...

Страница 33: ...onditions Vehicle speed 0 mph Temperature in one or both mixing chambers 80 C 176 F Auxiliary blower temperature 95 C 203 F Oil temperature 105 C 221 F The System Tester is required for troubleshootin...

Страница 34: ...Page 2 12 Climate Control Systems Diagnosis Repair 911 Carrera 993 Model System Notes...

Страница 35: ...ibution System 3 5 Regulating Air Temperature 3 6 Control Panel Function 911 Carrera 996 Boxster 986 3 8 Manual Air Conditioning Boxster S 987 3 9 Automatic Climate Control 911 Carrera S 997 Optional...

Страница 36: ...Page 3 2 Climate Control Systems Diagnosis Repair Sports Cars System Notes...

Страница 37: ...the selected passenger compartment tempera ture The system is capable of maintaining temperatures between 18 29 C 64 84 F with 22 C 72 F recommended In automatic operation the system deter mines and c...

Страница 38: ...at load The compressor displace ment is 160 cm3 9 8 in 3 at 100 output Output can be as low as approx 5 Condensers Two A C condensers are used on the 911 Carrera 996 997 and Boxster 986 987 models The...

Страница 39: ...t ment The system can add or remove heat from the cabin air and provide ventilation heating cooling and defrost functions On 911 Carrera 996 997 and Boxster 986 987 models the water cooled engine allo...

Страница 40: ...by the back pressure which arises in the area of the fresh air inlet according to the vehicle speed In order to compensate for this depen dency the distributor flap for fresh air recirculated air back...

Страница 41: ...outside fresh air and inside recirculation air When the fresh air mode is selected outside air is drawn into the vehicle from the intake air duct located in the plenum in front of the windshield All o...

Страница 42: ...a 996 Boxster 986 Automatic climate control was standard equipment on 911 Carrera 996 and Boxster 986 models sold in the United States The system automatically maintains temperatures between 18 29 C 6...

Страница 43: ...ith integrated control unit in the center console The appearance of the control panel for the manual air conditioning system is based on that of the control panel for the automatic climate control sys...

Страница 44: ...re explained in the section on Automatic climate control Air Conditioning Automatic Climate Control Standard on the 911 Carrera S 997 and optional on the Boxster S 987 Functions This air conditioning...

Страница 45: ...individually for the left button A and right button G side Apart from OFF level two heating levels can be selected When the appro priate button is pressed the air conditioning control unit control pan...

Страница 46: ...ith the window heating to directly control the heating elements for the defrost function of the door mirrors The maximum heating time for the rear window and door mirrors is 15 minutes I Automatic Mod...

Страница 47: ...Sports Cars System Climate Control Systems Diagnosis Repair Page 3 13 Sensors and Actuators 911 Carrera 996 Boxster 986 Through M Y 2000...

Страница 48: ...r Sports Cars System Sensors and Actuators Sports Cars M Y 2001 on Except Boxster S 987 w Manual A C For 2005 the A C pressure switch was changed by connecting directly to the A C controller line inpu...

Страница 49: ...si The medium pressure switch is in the DME circuit to control the condenser fan The DME control unit runs the condenser fan at second speed when the switch contacts close This high fan speed moves mo...

Страница 50: ...to the A C Control Unit for interior temperature Interior temperature is sensed and compared with the target temperature requested by the passengers and also ambient tempera tures This comparison infl...

Страница 51: ...er Air Control Flap Position Sensors Automatic Climate Control system air control flap motors have feedback position sensors built in The position sensor is a potentiometer which provides an analog si...

Страница 52: ...t second high speed when engine coolant temperature exceeds 102 C 216 F Cooling Fans Sports Cars M Y 2005 on The engine coolant radiator and condenser fan speed is controlled by the DME and fan speed...

Страница 53: ...ator out of the airstream or with the vehicle fresh air inlet blocked During a cold start the voltage to the fresh air blower is reduced by 50 to prevent the unpleasant discharge of cold air At ambien...

Страница 54: ...From M Y 2001 the control unit communicates via low speed comfort CAN to the cluster which then communicates via high speed CAN to the DME The A C Control Unit outputs a pulse width modulated PWM sig...

Страница 55: ...n speeds can indicate drain blockage Evaporator fin temperatures cannot be allowed to drop below the freezing point of water If this happens the evaporator can become blocked with ice and airflow can...

Страница 56: ...ters are monitored and will set fault codes if defects are found Interface with the instrument cluster Outside temperature sensor Interior temperature sensor Blower outlet sensor Supply Voltage termin...

Страница 57: ...ignition off from instrument cluster Steering angle sensor If control module detects lots of steering angle changes it drops the temperature a little without changing the driver s selection for comfo...

Страница 58: ...Page 3 24 Climate Control Systems Diagnosis Repair Sports Cars System Notes...

Страница 59: ...tem 4 7 Air Distribution Components 4 8 Rear Heating and Cooling Unit 4 8 Auxiliary Park Heater 4 9 Manual A C Operation 4 10 Climate Control Operation 2 Zone 4 11 Climate Control Operation 4 Zone 4 1...

Страница 60: ...Page 4 2 Climate Control Systems Diagnosis Repair Cayenne Model System Notes...

Страница 61: ...ressor relay the compressor always runs if the engine is running 1 Plug connector electronic control valve 2 Pressure relief valve 3 Connector opening low pressure side 4 Electronic control valve Comp...

Страница 62: ...ssure side just in front of compressor near left wheel arch Refrigeration Circuit 2 Zone Climate Control The cold air circulation in the Cayenne is set up so that the compressor and the expansion valv...

Страница 63: ...Climate Control Systems Diagnosis Repair Page 4 5 Additional Refrigeration Circuit 4 Zone Climate Control 1 Refrigerant lines for the rear evaporator 2 Line for the heating circulation for the rear h...

Страница 64: ...front of the engine coolant radiator and fan Receiver Dryer The receiver dryer on Cayenne models is a replaceable cartridge that is integrated into the right side of the condenser The cartridge can re...

Страница 65: ...limate control system the temperature and air volume for the driver and front passenger can be separately adjusted Outlets are located in the instrument panel the rear console and floor vents under th...

Страница 66: ...e models have a charcoal particle filter integrated into the air distribution housing The filter is located in front of the evaporator and can be removed for service from the passenger side footwell R...

Страница 67: ...the heat source An electric circulation pump non return valve and 3 2 way valve can isolate the park heater from engine coolant The park heater is operated and set from the front control panel of the...

Страница 68: ...el The following individual settings can be displayed in the air conditioning display Air flow blower Air distribution Temperature adjustment Time synchronous to PCM or instrument cluster Suppression...

Страница 69: ...emperature right side S Air Volume Button right side 4 Zone Climate Control Optional Operation A Defrost Front Windshield B Defrost Rear Window C Auto Button automatic operation REST Button motor resi...

Страница 70: ...e Climate Control Unit is located in the dash and has the manual passenger s controls The standard Cayenne automatic climate control system provides 2 zone control while a 4 zone with front and rear c...

Страница 71: ...lectable In conjunction with the automatic front 2 zone A C system therefore the interior climate can be controlled for a total of 4 individual zones The settings for the 4 zones can be made on the fr...

Страница 72: ...Page 4 14 Climate Control Systems Diagnosis Repair Cayenne Model System 4 Zone Sensors Actuators Rear...

Страница 73: ...ses through the evaporator fins The evap orator temperature sensor is located right behind the evaporator The control unit monitors this sensor to prevent condensa tion on the evaporator fins from fre...

Страница 74: ...res are sensed by four outlet tempera ture sensors This permits the control unit to monitor outlet air temperatures on the left and right sides separately and to maintain different temperature setting...

Страница 75: ...limate Control system air control flap motors have feedback position sensors built in Each position sensor is a potentiometer which provides an analog signal to the Climate Control Unit for flap posit...

Страница 76: ...signal to the blower regulator to set the appropriate blower speed The blower regulator is located on the air distribution housing on the right side near the blower A heat sink on the back side of th...

Страница 77: ...ther the signal is within range If a sensor circuit fault is detected the system ignores the signal and substitutes a stored default value In this way emergency operation of the climate control system...

Страница 78: ...Page 4 20 Climate Control Systems Diagnosis Repair Cayenne Model System Notes...

Страница 79: ...ge 5 1 Subject Page A C Refrigerant System Service 5 3 Environmental Impact 5 3 A C Service Equipment 5 3 Equipment Maintenance 5 3 A C Refrigerant System Service Procedures 5 5 A C System Performance...

Страница 80: ...Page 5 2 Climate Control Systems Diagnosis Repair A C Refrigerant System Service Diagnosis Notes...

Страница 81: ...esponded with changes and improvements to A C systems and service procedures Refrigerant R 12 is no longer produced or installed by manufacturers and R 134a is the only approved refrigerant installed...

Страница 82: ...service stations have similar gauges and hand valves They may appear different but in most cases they work the same way Service hoses for R 134a systems have quick connectors and check valves to mini...

Страница 83: ...er service station instructions Most service stations will weigh the recovered refrigerant and indicate how much refrigerant was removed Note this value as it can help diagnosis later The recovery pro...

Страница 84: ...pened by an accident or has been left open It is unknown whether the system has been open Part of a leak check procedure Refrigerant Recycling A C service stations automatically recycle the recovered...

Страница 85: ...turning the A C system ON If this valve is left open the refrigerant storage tank will be exposed to high side pressures and can explode The A C system should be ON continuously for at least two minut...

Страница 86: ...y the complaint Checking for stored DTCs will identify suspect components or systems and whether the problem is likely to be electrical or mechanical Pressure gauge readings will help to verify the me...

Страница 87: ...nd low side pressure can help to diagnose poor A C performance Remember that the compressor s job is to increase pressure on the high side and reduce pressure on the low side Variable displacement com...

Страница 88: ...ngs and cautions before starting diagnosis or repair work Observe the following precautions Automotive air conditioning systems and service equipment are under pressure and refrigerant can spray unexp...

Страница 89: ...atures exceed a certain value See Workshop Manual for speci fications For safety most charging stations recharge A C systems by pumping the refrigerant into the system with the compressor not running...

Страница 90: ...immediately with large quantities of water and seek medical attention If refrigerant contacts the skin remove the wet clothing and rinse immediately with large quantities of water Seek medical attenti...

Страница 91: ...Page 6 1 Subject Page CAN Bus Networking 6 3 Network Architechure 6 4 Bus Logic 6 5 Cayenne Networking 6 6 CAN Drive CAN C 6 6 CAN Comfort Convenience CAN B 6 7 CAN Infotainment 6 8 CAN Internal 6 9 C...

Страница 92: ...Page 6 2 Climate Control Systems Diagnosis Repair BUS Communications Notes...

Страница 93: ...temperature sensor and related wiring With CAN only one control unit needs to receive temperature input It processes this information and shares it with all units on the bus CAN communication message...

Страница 94: ...ge on both wires both lines on the oscilloscope moves up or down together so the voltage difference between CAN High and CAN Low always remains approx 2 Volts This is sometimes called a differential s...

Страница 95: ...h CAN High and CAN Low values approx 2 5 Volts to dominant CAN High signal approx 2 Volts higher than CAN Low signal and back to recessive Up to 30 control units can be present on the High Speed CAN n...

Страница 96: ...Page 6 6 Climate Control Systems Diagnosis Repair BUS Communications Networking Cayenne Cayenne models use the following networking systems CAN Drive Bus CAN C CAN Convenience CAN B CAN Infotainment...

Страница 97: ...Air Conditioning System Regulator Control Unit 9 Park Assist Control Unit 10 RDK Control Unit tire pressure control system 11 Memory Seat Adjustment Control Unit Passenger 12 Memory Seat Adjustment C...

Страница 98: ...ainment Data transfer rate 100 K bits second 100 K baud Failure mode Data transmission remains possible with a short or open in one bus line 1 Gateway 2 PCM2 3 Wiper Motor with integrated control unit...

Страница 99: ...BUS Communications Climate Control Systems Diagnosis Repair Page 6 9 CAN Internal 1 Combination Sensor 2 PSM Control Unit...

Страница 100: ...Left Rear 17 Control Door Right Rear 18 Control Driver s Door 19 Control Front Passenger Door 20 Trailer Control Unit 21 Vehicle Electrical System Control Unit 22 Climate Control Element Front 23 Clim...

Страница 101: ...S St te ee er ri in ng g C Co ol lu um mn n C Co on nt tr ro ol l U Un ni it t K Ke es ss sy y C Co on nt tr ro ol l U Un ni it t BUS Communications Climate Control Systems Diagnosis Repair Page 6 11...

Страница 102: ...9 Driving authorization control unit PAS 10 Steering column switch control module 11 Sliding roof control unit 12 Rear control unit 13 Vehicle electrical system control unit 14 Tire pressure monitorin...

Страница 103: ...BUS Communications Climate Control Systems Diagnosis Repair Page 6 13...

Страница 104: ...Page 6 14 Climate Control Systems Diagnosis Repair BUS Communications...

Страница 105: ...ETER cc cc CUBIC CENTIMETER X 061 CUBIC INCH FOOTPOUND ft lb X 1 3558 NEWTON METER Nm Nm NEWTON METER X 7376 ft lb FOOT POUND HORSEPOWER SAE X 746 KILOWATT Kw HORSEPOWER DIN X 9861 HORSEPOWER SAE Kw K...

Страница 106: ...Page 7 2 Climate Control Systems Diagnosis Repair Conversion Charts Notes...

Страница 107: ......

Страница 108: ...Part Number PNA P80 001...

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