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
• 1.4 Safety precautions when working on the cooling system
  2
• 1.5 Safety precautions when handling refrigerants
  2
• 1.6 Safety precautions when working on SCR system
  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 for vehicles with start-stop system
  9
• 4 Repair instructions
  11
• 4.1 Rules for cleanliness
  11
• 4.2 General information
  11
• 4.3 General repair instructions
  11
• 4.4 Contact corrosion
  12
• 4.5 Nuts and bolts
  12
• 4.6 Routing and attachment of lines
  12
• 4.7 Fitting radiators and condensers
  12
• 4.8 Working on refrigerant circuit
  13
• 4.9 Refrigerant circuit seals
  14
• 5 Technical data
  15
• 5.1 Refrigerant capacity
  15
• 5.2 Refrigerant oil capacities
  15
• 5.3 Oil distribution
  16
• Heating
  17
• 1 Overview of fitting locations - heating
  17
• 1.1 Overview of fitting locations - components not located in passenger compartment
  17
• 2 Actuators
  22
• 2.1 Overview of fitting locations - front actuators
  22
• 2.2 Removing and installing temperature flap actuator
  24
• 2.3 Removing and installing air distribution flap actuator
  24
• 2.4 Removing and installing flexible shaft for air distribution
  24
• 2.5 Removing and installing flexible shaft for temperature flap
  24
• 3 Heater
  25
• 3.1 Assembly overview – heater unit
  25
• 3.2 Removing and installing fresh air blower V2
  27
• 3.3 Removing and installing fresh air blower series resistor with overheating fuse N24
  27
• 3.4 Removing and installing heat exchanger
  27
• 3.5 Removing and installing heater unit
  28
• 3.6 Dismantling and assembling heater unit
  28
• 4 Air duct
  29
• 5 Operating and display unit
  30
• 5.1 Overview of operating and display unit
  30
• 5.2 Removing and installing operating and display unit
  30
• 6 Other controlling and regulating components
  32
• Air conditioning system
  33
• 1 Overview of fitting locations - air conditioning system
  33
• 1.1 Overview of fitting locations - components not located in passenger compartment
  33
• 2 Refrigerant circuit
  37
• 2.1 System overview - refrigerant circuit
  37
• 2.2 Assembly overview – condenser
  39
• 2.3 Removing and installing refrigerant circuit pressure sender G805
  41
• 2.4 Removing and installing expansion valve
  42
• 2.5 Removing and installing condenser
  46
• 2.6 Removing and installing desiccant bag or cartridge
  50
• 2.8 Commissioning air conditioning system after filling refrigerant circuit
  62
• 3 Air conditioner compressor
  73
• 3.1 Assembly overview – drive unit of air conditioner compressor
  73
• 3.2 Assembly overview - pulley
  77
• 3.3 Removing air conditioning compressor from and installing on bracket
  81
• 3.4 Removing and installing air conditioner compressor
  83
• 3.5 Checking high-pressure safety valve on air conditioner compressor
  88
• 3.6 Removing and installing pulley
  90
• 4 Control motors
  99
• 4.1 Overview of fitting locations – control motors at front
  99
• 4.2 Removing and installing defroster flap control motor V107
  104
• 4.3 Removing and installing front air distribution flap control motor V426
  107
• 4.4 Removing and installing fresh air and air recirculation flap control motor V154
  108
• 4.5 Removing and installing left temperature flap control motor V158
  110
• 4.6 Removing and installing right temperature flap control motor V159
  113
• 4.7 Removing and installing fresh air/air recirculation, air flow flap control motor V425
  116
• 4.8 Removing and installing air distribution flap actuator
  119
• 4.9 Removing and installing temperature flap actuator
  122
• 4.10 Removing and installing flexible shaft for temperature flap
  124
• 4.11 Removing and installing flexible shaft for air distribution
  124
• 5 Front heater and air conditioning unit
  126
• 5.1 Assembly overview – heater and air conditioning unit
  126
• 5.2 Assembly overview – evaporator housing
  128
• 5.3 Removing and installing evaporator
  130
• 5.4 Checking auxiliary air heater element Z35
  131
• 5.5 Removing and installing auxiliary air heater element Z35
  132
• 5.6 Removing and installing heater and air conditioning unit
  134
• 5.7 Removing and installing holder for heater and air conditioning unit
  139
• 5.8 Dismantling and assembling heater and air conditioning unit
  140
• 5.9 Removing and installing air distribution housing
  140
• 5.10 Removing and installing dust and pollen filter
  141
• 5.11 Removing and installing fresh air blower V2
  145
• 5.12 Removing and installing fresh air blower control unit J126
  146
• 5.13 Removing and installing heat exchanger
  147
• 5.14 Removing and installing coolant pipes on heat exchanger
  155
• 5.15 Removing and installing evaporator temperature sensor G308
  157
• 5.16 Removing and installing flexible shafts
  159
• 5.17 Removing and installing condensation drain
  163
• 5.18 Checking condensation drain
  166
• 5.19 Removing and installing fresh air blower series resistor with overheating fuse N24
  166
• 6 Air duct
  168
• 6.1 Assembly overview – air duct and air distribution in passenger compartment
  168
• 6.2 Removing and installing driver side footwell vents
  170
• 6.3 Removing and installing front passenger side footwell vents
  172
• 6.4 Removing and installing rear footwell vent
  174
• 6.5 Removing and installing forced ventilation for passenger compartment
  175
• 6.6 Checking forced ventilation for passenger compartment
  176
• 6.7 Removing and installing fresh air intake
  177
• 6.8 Removing and installing cover for fresh air intake
  178
• 6.9 Removing and installing air intake duct
  178
• 6.10 Removing and installing air duct for defroster vent
  179
• 6.11 Removing and installing air duct for centre vent
  180
• 7 Operating and display unit
  181
• 7.1 Overview of operating and display unit
  181
• 7.2 Removing and installing operating and display unit
  184
• 8 Other controlling and regulating components
  187
• 8.1 Removing and installing sunlight penetration photosensor G107
  187
• 8.2 Removing and installing ambient temperature sensor G17
  188
• 8.3 Removing and installing humidity sender for air conditioning system G260
  188
• 8.4 Removing and installing left vent temperature sender G150
  189
• 8.5 Removing and installing right vent temperature sender G151
  190
• 8.6 Removing and installing footwell vent temperature sender G192
  192