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 precautions when handling refrigerants
  1
• 1.3 Safety measures when working on vehicles with a start/stop system
  2
• 1.4 Safety precautions when working on the cooling system
  2
• 2 General information
  3
• 2.1 Notes concerning odours in air conditioned vehicles
  3
• 2.2 Notes for vehicles with a start/stop system
  3
• 2.3 Type plates
  4
• 3 Repair instructions
  6
• 3.1 Working on refrigerant circuit
  6
• 3.2 General repair instructions
  6
• 3.3 Refrigerant circuit seals
  6
• 4 Technical data
  8
• 4.1 Refrigerant capacity
  8
• 4.2 Refrigerant oil capacities
  8
• 4.3 Oil distribution
  9
• Heating
  10
• 1 Overview of fitting locations - heating
  10
• 1.1 Overview of fitting locations - components not located in passenger compartment
  10
• 2 Heater
  15
• 2.1 Assembly overview – heater unit
  15
• 2.2 Removing and installing fresh air blower V2
  17
• 2.3 Removing and installing fresh air blower series resistor with overheating fuse N24
  17
• 2.4 Removing and installing dust and pollen filter
  17
• 2.5 Removing and installing heat exchanger
  17
• 2.6 Removing and installing heater unit
  17
• 2.7 Dismantling and assembling heater unit
  17
• 2.8 Checking auxiliary air heater element Z35
  19
• 2.9 Removing and installing auxiliary air heater element Z35
  19
• 2.10 Removing and installing flexible shafts
  19
• 3 Control motors
  20
• 3.1 Overview of fitting locations - front control motors
  20
• 3.2 Removing and installing air distribution flap actuator
  21
• 3.3 Removing and installing temperature flap actuator
  23
• 4 Air duct
  27
• 4.1 Assembly overview - air duct and air distribution in passenger compartment
  27
• 4.2 Removing and installing centre vent at front
  27
• 4.3 Removing and installing right or left vent
  27
• 4.4 Removing and installing driver side footwell vents
  27
• 4.5 Removing and installing front passenger side footwell vents
  27
• 4.6 Removing and installing rear air duct
  27
• 4.7 Checking forced ventilation for passenger compartment
  27
• 4.8 Removing and installing forced ventilation for passenger compartment
  28
• 4.9 Removing and installing fresh air intake
  28
• 4.10 Removing and installing air duct for defroster vent
  28
• 4.11 Removing and installing air duct for centre vent
  28
• 5 Operating and display unit
  29
• 5.1 Overview of fitting locations - operating and display unit
  29
• 5.2 Removing and installing operating and display unit
  29
• 6 Other controlling and regulating components
  31
• 6.1 Removing and installing ambient temperature sensor G17
  31
• Air conditioning system
  32
• 1 Overview of fitting locations - air conditioning system
  32
• 1.1 Overview of fitting locations - components not located in passenger compartment
  32
• 2 Refrigerant circuit
  45
• 2.1 System overview - refrigerant circuit
  45
• 2.2 Assembly overview - condenser
  48
• 2.3 Removing and installing evacuating and charging valves on low and high-pressure side
  50
• 2.4 Removing and installing high-pressure sender G65
  52
• 2.5 Removing and installing condenser
  54
• 2.6 Removing and installing desiccant bag or cartridge
  57
• 2.7 Removing and installing expansion valve
  60
• 3 Air conditioner compressor
  64
• 3.1 Assembly overview - drive unit of air conditioner compressor
  64
• 3.2 Assembly overview - pulley
  65
• 3.3 Removing air conditioning compressor from and installing on bracket
  66
• 3.4 Removing and installing air conditioner compressor
  67
• 3.5 Removing and installing pulley
  73
• 3.6 Checking high-pressure safety valve on air conditioner compressor
  74
• 4 Control motors
  75
• 4.1 Overview of fitting locations - front control motors
  75
• 4.2 Removing and installing temperature flap control motor V68
  79
• 4.5 Removing and installing fresh air/air recirculation, air flow flap control motor V425
  86
• 4.6 Removing and installing air distribution flap control motor V428
  88
• 4.7 Locally manufacturing an adapter cable to activate control motors
  90
• 5 Front heater and air conditioning unit
  92
• 5.1 Assembly overview - heater and air conditioning unit
  92
• 5.2 Assembly overview - evaporator housing
  101
• 5.3 Removing and installing evaporator
  102
• 5.4 Removing and installing heater and air conditioning unit
  102
• 5.5 Dismantling and assembling heater and air conditioning unit
  109
• 5.6 Removing and installing fresh air blower V2
  111
• 5.7 Removing and installing fresh air blower series resistor with overheating fuse N24
  114
• 5.8 Removing and installing dust and pollen filter
  115
• 5.9 Dismantling and assembling evaporator housing
  116
• 5.10 Checking auxiliary air heater element Z35
  117
• 5.11 Removing and installing auxiliary air heater element Z35
  120
• 5.12 Checking condensation drain
  121
• 5.13 Removing and installing fresh air blower control unit J126
  121
• 5.14 Removing and installing heat exchanger
  123
• 5.15 Removing and installing evaporator temperature sensor G308
  127
• 5.16 Removing and installing flexible shaft
  129
• 6 Air duct
  130
• 6.1 Assembly overview - air duct and air distribution in passenger compartment
  130
• 6.2 Removing and installing centre vent at front
  131
• 6.3 Removing and installing right or left vent
  132
• 6.4 Removing and installing driver side footwell vents
  132
• 6.5 Removing and installing front passenger side footwell vents
  133
• 6.6 Removing and installing rear footwell vent
  134
• 6.7 Removing and installing forced ventilation for passenger compartment
  134
• 6.8 Checking forced ventilation for passenger compartment
  135
• 6.9 Removing and installing fresh air intake
  136
• 6.10 Removing and installing air duct for defroster vent
  138
• 6.11 Removing and installing air duct for centre vent
  138
• 7 Operating and display unit
  139
• 7.1 Overview of fitting locations - operating and display unit
  139
• 7.2 Removing and installing operating and display unit
  141
• 7.3 Multi-pin connector pin assignment on back of operating and display unit
  143
• 8 Other controlling and regulating components
  144
• 8.1 Removing and installing sunlight penetration photosensor G107
  144
• 8.2 Removing and installing centre vent temperature sender G191
  145
• 8.3 Removing and installing footwell vent temperature sender G192
  146
• 8.4 Removing and installing radiator fan control unit J293
  146
• 8.5 Removing and installing ambient temperature sensor G17
  147