Heating, air conditioner

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety precautions when working on air conditioning systems
  1
• 1.2 Safety measures when working on vehicles with a start/stop system
  1
• 1.3 Safety precautions when using test and measuring instruments during a road test
  2
• 1.4 Safety precautions when working on the cooling system
  2
• 1.5 Safety precautions when handling refrigerants
  2
• 1.6 Safety precautions for working on vehicles with auxiliary/supplementary heater
  3
• 2 Identification
  5
• 2.1 Identification of heater and air conditioning unit
  5
• 3 General information
  7
• 3.1 Type plates
  7
• 3.2 Notes concerning odours in air conditioned vehicles
  7
• 3.3 Notes for vehicles with start-stop system
  8
• 3.4 Notes on dust and pollen filter
  9
• 4 Repair notes
  10
• 4.1 Rules for cleanliness
  10
• 4.2 Nuts and bolts
  10
• 4.3 Pipe/wire routing and attachment
  11
• 4.4 Fitting radiators and condensers
  11
• 4.5 Checking heater output
  11
• 4.6 Checking cooling output
  14
• 4.7 Working on refrigerant circuit
  16
• 4.8 Paint work on vehicles with air conditioning system
  16
• 4.9 Refrigerant circuit seals
  17
• 5 Technical data
  18
• 5.1 Refrigerant capacity
  18
• 5.2 Refrigerant oil capacities
  18
• 5.3 Oil distribution
  18
• Heating
  20
• 1 Overview of fitting locations - heating
  20
• 1.1 Overview of fitting locations - components not located in passenger compartment
  20
• 2 Heater
  24
• 2.1 Assembly overview – heater unit
  24
• 2.2 Removing and installing flexible shafts
  26
• 3 Control motors
  30
• 3.1 Removing and installing fresh air and air recirculation flap control motor V154
  30
• 4 Air duct
  31
• 5 Operating and display unit
  32
• 5.1 Overview of operating and display unit
  32
• 5.2 Removing and installing operating and display unit
  34
• 6 Other controlling and regulating components
  38
• Air conditioning system
  39
• 1 Overview of fitting locations - air conditioning system
  39
• 1.1 Overview of fitting locations - components not located in passenger compartment
  39
• 2 Refrigerant circuit
  48
• 2.1 System overview - refrigerant circuit
  48
• 2.2 Assembly overview – condenser
  50
• 2.3 Removing and installing high-pressure sender G65
  52
• 2.4 Removing and installing expansion valve
  53
• 2.5 Removing and installing condenser
  57
• 2.6 Removing and installing desiccant bag or cartridge
  60
• 3 Air conditioner compressor
  74
• 3.1 Assembly overview – drive unit of air conditioner compressor
  74
• 3.2 Assembly overview - pulley
  76
• 3.3 Removing air conditioning compressor from and installing on bracket
  78
• 3.4 Removing and installing air conditioner compressor
  79
• 3.5 Checking high-pressure safety valve on air conditioner compressor
  83
• 3.6 Removing and installing pulley
  84
• 4 Control motors
  88
• 4.1 Overview of fitting locations – control motors at front
  88
• 4.2 Removing and installing centre flap control motor V70
  90
• 4.3 Removing and installing defroster flap control motor V107
  91
• 4.4 Removing and installing air recirculation flap control motor V113
  93
• 4.5 Removing and installing left temperature flap control motor V158
  97
• 4.6 Removing and installing right temperature flap control motor V159
  99
• 4.7 Removing and installing fresh air/air recirculation, air flow flap control motor V425
  101
• 4.8 Removing and installing fresh air/air recirculation, air flow flap actuator
  103
• 5 Front heater and air conditioning unit
  105
• 5.2 Assembly overview – heater and air conditioning unit
  110
• 5.3 Assembly overview – evaporator housing
  114
• 5.4 Removing and installing evaporator
  115
• 5.5 Checking auxiliary air heater element Z35
  117
• 5.6 Removing and installing auxiliary air heater element Z35
  120
• 5.7 Removing and installing heater and air conditioning unit
  122
• 5.8 Dismantling and assembling heater and air conditioning unit
  128
• 5.9 Removing and installing air distribution housing
  130
• 5.10 Removing and installing dust and pollen filter
  132
• 5.11 Removing and installing fresh air blower V2
  133
• 5.12 Removing and installing fresh air blower control unit J126
  134
• 5.13 Removing and installing heat exchanger
  135
• 5.14 Removing and installing coolant pipes on heat exchanger
  147
• 5.15 Removing and installing evaporator temperature sensor G308
  149
• 5.16 Removing and installing condensation drain
  149
• 5.17 Checking condensation drain
  150
• 5.18 Removing and installing fresh air blower series resistor with overheating fuse N24
  151
• 5.19 Removing and installing glove box cooling
  151
• 6 Air duct
  153
• 6.1 Assembly overview – air duct and air distribution in passenger compartment
  153
• 6.2 Air intake and air outlet openings
  156
• 6.3 Removing and installing driver side footwell vents
  157
• 6.4 Removing and installing front passenger side footwell vents
  158
• 6.5 Removing and installing rear footwell vent
  159
• 6.6 Installing plug in air duct to centre vent
  160
• 6.7 Removing and installing air ducts
  161
• 6.8 Removing and installing forced ventilation for passenger compartment
  163
• 6.9 Checking forced ventilation for passenger compartment
  164
• 6.10 Removing and installing fresh air intake
  164
• 6.11 Removing and installing air duct for defroster vent
  166
• 6.12 Removing and installing air duct for centre dash panel vent
  166
• 7 Operating and display unit
  168
• 7.1 Overview of fitting locations – operating and display unit
  168
• 7.2 Removing and installing operating and display unit
  172
• 8 Other controlling and regulating components
  175
• 8.1 Removing and installing sunlight penetration photosensor G107
  175
• 8.2 Working principles of air quality sensor G238
  176
• 8.3 Removing and installing air quality sensor G238
  177
• 8.4 Removing and installing ambient temperature sensor G17
  178
• 8.5 Removing and installing left vent temperature sender G150
  179
• 8.6 Removing and installing left footwell vent temperature sender G261
  179
• 8.7 Removing and installing right footwell vent temperature sender G262
  180