® AfterSales Training Climate Control Systems Diagnosis & Repairs P80 Porsche AfterSales Training Student Name: Training Center Location: Instructor Name: Date: _ Electrical Troubleshooting Logic - Do you understand how the electrical consumer is expected to operate? - Do you have the correct wiring diagram? - If the circuit contains a fuse, is the fuse okay & of the correct amperage? - Is there power provided to the circuit? Is the power source the correct voltage? - Is the ground(s) for the circuit connected? Is the connection tight & free of resistance? - Is the circuit being correctly activated by a switch, relay, sensor, microswitch, etc.? - Are all electrical plugs connected securely with no tension, corrosion, or loose wires? Important Notice: Some of the contents of this AfterSales Training brochure was originally written by Porsche AG for its restof-world English speaking market The electronic text and graphic files were then imported by Porsche Cars N.A, Inc and edited for content Some equipment and technical data listed in this publication may not be applicable for our market Specifications are subject to change without notice We have attempted to render the text within this publication to American English as best as we could We reserve the right to make changes without notice © 2010 Porsche Cars North America, Inc All Rights Reserved Reproduction or translation in whole or in part is not permitted without written authorization from publisher AfterSales Training Publications 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®, Cayman™, Panamera®, Tiptronic®, VarioCam®, PCM®, 911®, 4S®, FOUR, UNCOMPROMISED.SM and the model numbers and distinctive shapes of Porsche's automobiles such as, the federally registered 911 and Boxster automobiles The third party trademarks contained herein are the properties of their respective owners Specifications, performance standards, options, and other elements shown are subject to change without notice Some vehicles may be shown with non-U.S equipment Porsche recommends seat belt usage and observance of traffic laws at all times Printed in the USA Part Number - PNA P80 004 Edition - 8/10 Table of Contents Chapter Description Section Introduction i A/C Refrigerant System Service and Diagnosis Air Conditioning Basics System Descriptions – Boxster (986), Boxster/Cayman (987) & 911 (996/997) Cayenne (9PA) 2003 - 2010 (E1 1st & 2nd Generations) Cayenne (92A) 2011 (E2) Cayenne S Hybrid (92A) 2011 (E2) Panamera (970) 2010 - 0n Conversion Charts Climate Control Systems Diagnosis & Repair Climate Control Systems Diagnosis & Repair Introduction In the past, air conditioning in automobiles was considered an option and a luxury A/C was rarely found in high performance vehicles and the customer was willing to trade comfort for performance The rules have changed and today’s customer expects A/C to be an included feature High levels of performance and comfort are expected All current Porsche models sold in North America have A/C standard With the push of a button, today’s customer expects rapid heating and cooling Only when the system fails to function will the customer be consciously aware of it This is where you, the technician, come in In order to satisfy the Porsche customer’s high expectations, you will need to successfully diagnose, test and repair climate control systems in a timely manner After a climate control system repair, the first thing that the customer will is operate the system Success or failure is measured in degrees Climate Control Systems Diagnosis & Repair Page i Introduction Ozone Depletion and Global Warming The Ozone layer is in the stratosphere 16-48 kilometers (10-30 miles) above the Earth's surface This layer shields the earth from much of the sun's ultraviolet radiation Chlorine found in R-12 refrigerant released into the atmosphere can seriously damage the Ozone layer Energy from the sun drives the earth's weather and climate Sunlight heats the earth's surface, and some of the sunlight is reflected in the form of infrared radiation Much of this radiant energy dissipates into space, but some is reflected back into the atmosphere Atmospheric greenhouse gases (water vapor, Carbon Dioxide, and other gases) trap some of the outgoing energy, retaining heat (like the glass panels of a greenhouse) The trapping of too much radiant heat energy is suspected to cause Global Warming There is strong evidence that the quantity of Carbon Dioxide in the atmosphere and the rising average world temperatures are related Carbon Dioxide, one of the gases emitted by internal combustion engines, has a significant greenhouse effect, but R-12 refrigerant in the upper atmosphere has a Global Warming Potential (GWP) 8,500 times greater than Carbon Dioxide R-134a refrigerant is better, but still has a GWP value of 1,300 Page ii The discovery of these problems caused the governments of the industrialized world to establish a time table for the reduction and eventual elimination of the production of chemicals that deplete the Ozone layer The Montreal Protocol was enacted in September 1987, and laws were enacted requiring the automotive service industry to modify the servicing of A/C refrigerant systems All refrigerants used in automotive air conditioners must now be recovered and recycled whenever an A/C system is opened for service or repair Also, refrigerant R-12 (FREON) is no longer produced, and has been replaced with a less harmful refrigerant, R-134a (SUVA) R-134a is the only alternative refrigerant for R-12 that is approved for use in new automobiles by all auto manufacturers Porsche phased-in the use of R-134a in 1993 Refer to page I-21 for more refrigerant information Any person servicing motor vehicle air conditioning systems MUST by law be properly trained, certified and use approved refrigerant recycling equipment Technicians must successfully complete an EPA approved recycling course and be tested Certification is available from the National Institute for Automotive Service Excellence (ASE) and the Mobile Air Conditioning Society (MACS) State and local jurisdictions may have their own certification requirements that supersede federal requirements Climate Control Systems Diagnosis & Repair A/C Refrigerant System Service & Diagnosis Subject Page A/C Refrigerant System Service 1.3 Environmental Impact 1.3 A/C Service Equipment 1.3 Equipment Maintenance 1.3 A/C Refrigerant System Service Procedures 1.5 A/C System Performance Testing 1.7 Warnings and Cautions 1.10 Service Equipment Safety 1.11 First Aid 1.12 Climate Control Systems Diagnosis & Repair Page 1.1 A/C Refrigerant System Service & Diagnosis Notes: Page 1.2 Climate Control Systems Diagnosis & Repair A/C Refrigerant System Service & Diagnosis A/C Refrigerant System Service A/C Service Equipment Before 1992, automotive air conditioning services could be performed by anyone with a manifold gauge set, cans of refrigerant and a can tap Refrigerant was inexpensive and considered harmless Do-it-your-selfers routinely topoff leaking systems rather than paying for expensive repairs By law, all automotive repair facilities performing A/C system services must have approved equipment to recover and recycle refrigerant R-134a If the shop also services vehicles with R-12 or any other refrigerant, it must have separate equipment for those refrigerants as well In repair shops, refrigerant was routinely vented to the atmosphere whenever an A/C system needed to be opened This was accepted practice At the time, the environmental effects were unknown and methods to recover refrigerant were not available R-12 was so inexpensive that its complete loss and replacement was seen as insignificant All refrigerant recovery and recycling equipment must be certified to meet the Society of Automotive Engineers (SAE) standards for performance and refrigerant purity Equipment Maintenance Environmental Impact Things changed when it was discovered that R-12 released into the atmosphere has contributed to two serious effects: destruction of Ozone in the stratosphere, and global warming The Clean Air Act legislation of 1990 included these provisions: • • • • • A/C technician certification by Jan 1992 Use of EPA certified recovery and recycling equipment Recovery of both R-12 and R-134a refrigerants Prohibits mixing refrigerants Provides penalties including fines up to $27,500/day and yrs imprisonment Industry has responded 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 by OEMs • By law, technicians must be properly trained and certified to work on mobile A/C systems • All refrigerants used in mobile air conditioners must now be recovered and recycled whenever an A/C system is opened for service or repair A/C service equipment must be periodically maintained to reduce the possibility of refrigerant loss and inaccurate charge Follow the service and maintenance schedule and instructions for your service equipment Maintenance items vary but in general, periodic maintenance procedures are required for all service equipment Typical service procedures for refrigerant recovery/recycling/recharging stations include: • • • • Vacuum pump oil change Filter/dryer cartridge replacement Checking the station for leaks Refrigerant storage tank scale accuracy check Climate Control Systems Diagnosis & Repair Page 1.3 A/C Refrigerant System Service & Diagnosis Manifold Gauge Set Service Ports on the Vehicle The port under the low side gauge connects the low side service hose to the low side service connection on the system The low side service hose is always blue The red and blue service hoses mate with the A/C refrigerant service ports on the vehicle The high side and low side service port fitting quick connectors are different to prevent reversing the hose connections The port under the high side gauge similarly connects the high side service hose to the high side service connection on the system The high side service hose is always red The center port on the manifold can be connected to either the red high side or blue low side service hoses when the respective hand valve is opened The hand valves are opened ONLY when recovering, evacuating or recharging refrigerant from a system Otherwise, the hand valves must be closed Both high and low side gauges read system pressures with the hand valves on the manifold closed A/C service stations have similar gauges and hand valves They may appear different but in most cases they work the same way The service port fittings have spring loaded check valves to prevent the loss of refrigerant Dust caps keep the ports clean and are a secondary seal against refrigerant loss For service port locations on the different models, see the individual model sections (Cayenne service ports shown above) Notes: Service hoses for R-134a systems have quick connectors and check valves to minimize refrigerant loss when connecting and disconnecting the hoses Some hose connectors automatically depress the service port check valve pin Other hose connectors have a knob which must be screwed clockwise after the hose is connected to manually depress the service port check valve pin Page 1.4 Climate Control Systems Diagnosis & Repair Panamera Systems Operating and Air-Conditioning Unit (OAU, front) 4-Zone System The influence of the Carrera GT can be seen in the center console The idea to transfer almost all of the switches from the switch panel to the center console simplifies operation for the driver The most important functions are sorted into function groups for fast, uncomplicated and intuitive operation • The driver’s inputs are evaluated by these controls (buttons and sliders) in the operating and air-conditioning unit and forwarded to the relevant control units in the various function groups • The operating and air-conditioning unit also regulates and controls all the heating and air-conditioning system components required for cabin air conditioning Feedback is provided through the control panel (e.g LED button lights up/display at the front) Air-conditioning functions - A Safety functions - B Chassis functions - C Body functions - D • A distinction can be made between the following versions: a) OAU with automatic 2-zone adjustment Automatic adjustment (left/right) with different temperature, air flows and air distribution for driver and passengers b) OAU with automatic 4-zone adjustment This automatic adjustment also enables “single seat” air conditioning with independent temperature, air flow and air distribution control for all four seats A second OAU is used to operate these functions in the rear Both OAUs are connected via the LIN bus Notes: Page 7.8 Climate Control Systems Diagnosis & Repair Panamera Systems Operating and Air-Conditioning Unit (OAU, front) 4-Zone System Anti-Mist Control (“Auto Defrost”) An anti-mist control function is also available for the first time in the Panamera in automatic mode As part of this function, a sensor records the humidity in the vehicle The sensor for anti-mist control is located at the base of the rearview mirror With manual windshield defrosting (defroster), the air supply to the rear is cut off automatically in “defrost mode” to achieve maximum defrosting efficiency in the 4zone system OFF appears on the rear OAU display In the 2-zone system, the windshield is defrosted with maximum efficiency when the air vents in the rear are closed • When outside temperatures < 27° F (-3° C.) or the intake air temperature