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
  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
• 1.7 Safety precautions when working on SCR system
  4
• 2 General information
  6
• 2.1 Type plates
  6
• 2.2 Notes concerning odours in air conditioned vehicles
  7
• 3 Repair notes
  9
• 3.1 Rules for cleanliness
  9
• 3.2 General repair instructions
  9
• 3.3 Contact corrosion
  10
• 3.4 Nuts and bolts
  10
• 3.5 Routing and attachment of lines
  10
• 3.6 Checking cooling output
  11
• 3.7 Working on refrigerant circuit
  12
• 3.8 Refrigerant circuit seals
  14
• 4 Technical data
  15
• 4.1 Refrigerant capacity
  15
• 4.2 Refrigerant oil capacities
  15
• 4.3 Oil distribution
  17
• Heating
  18
• 1 Heater
  18
• 1.1 Assembly overview – heater unit
  18
• 1.2 Assembly overview - second heater unit
  20
• 1.3 Removing and installing rear warm air blower V47
  22
• 1.4 Removing and installing warm air blower control unit J350
  26
• 1.5 Removing and installing heat exchanger for second heater unit
  27
• 1.6 Removing and installing second heater unit
  28
• 1.7 Dismantling and assembling second heater unit
  31
• 2 Control motors
  35
• 2.1 Overview of fitting locations – control motors at front
  35
• 2.2 Removing and installing rear temperature flap control motor V137
  36
• 3 Air duct
  38
• 3.1 Removing and installing air ducts
  38
• 4 Operating and display unit
  41
• 4.1 Overview of operating and display unit
  41
• 5 Other controlling and regulating components
  42
• 5.1 Removing and installing rear vent temperature sender G174
  42
• Air conditioning system
  43
• 1 Overview of fitting locations - air conditioning system
  43
• 1.1 Overview of fitting locations - components not located in passenger compartment
  43
• 2 Refrigerant circuit
  51
• 2.1 System overview - refrigerant circuit
  51
• 2.2 Assembly overview - refrigerant lines
  56
• 2.3 Removing and installing refrigerant circuit pressure sender G805
  59
• 2.4 Removing and installing expansion valve
  62
• 2.5 Removing and installing condenser
  68
• 2.6 Separating and connecting refrigerant lines on condenser
  72
• 2.7 Removing and installing desiccant bag or cartridge
  76
• 2.9 Commissioning air conditioning system after filling refrigerant circuit
  82
• 2.13 Removing and installing refrigerant line to heater and air conditioning unit
  99
• 2.14 When is it necessary to purge the refrigerant circuit with refrigerant
  107
• 3 Air conditioner compressor
  110
• 3.1 Assembly overview – air conditioner compressor
  110
• 3.2 Assembly overview - pulley
  114
• 3.3 Removing air conditioning compressor from and installing on bracket
  115
• 3.4 Removing and installing air conditioner compressor
  119
• 3.5 Removing and installing 2nd air conditioner compressor
  124
• 3.6 Removing and installing air conditioning system magnetic clutch N25
  125
• 3.7 Checking high-pressure safety valve on air conditioner compressor
  128
• 3.8 Removing and installing air conditioner compressor regulating valve N280
  129
• 4 Control motors
  133
• 4.1 Overview of fitting locations – control motors at front
  133
• 4.2 Assembly overview - front control motors
  138
• 4.3 Removing and installing temperature flap control motor V68
  141
• 4.4 Removing and installing defroster flap control motor V107
  143
• 4.5 Removing and installing air recirculation flap control motor V113
  145
• 4.6 Removing and installing left temperature flap control motor V158
  147
• 4.7 Removing and installing right temperature flap control motor V159
  149
• 4.8 Removing and installing fresh air/air recirculation, air flow flap control motor V425
  150
• 4.9 Removing and installing front air distribution flap control motor V426
  153
• 4.10 Removing and installing air distribution flap control motor V428
  154
• 5 Front heater and air conditioning unit
  157
• 5.1 Assembly overview – heater and air conditioning unit
  157
• 5.2 Assembly overview – evaporator housing
  161
• 5.3 Removing and installing evaporator
  164
• 5.4 Checking auxiliary air heater element Z35
  164
• 5.5 Removing and installing auxiliary air heater element Z35
  165
• 5.6 Removing and installing heater and air conditioning unit
  167
• 5.7 Removing and installing holder for heater and air conditioning unit
  172
• 5.8 Dismantling and assembling heater and air conditioning unit
  173
• 5.9 Removing and installing air distribution housing
  174
• 5.10 Removing and installing dust and pollen filter
  176
• 5.11 Removing and installing fresh air blower V2
  177
• 5.12 Removing and installing fresh air blower control unit J126
  178
• 5.13 Removing and installing heat exchanger
  179
• 5.14 Removing and installing coolant pipes on heat exchanger
  181
• 5.15 Removing and installing evaporator temperature sensor G308
  185
• 5.16 Removing and installing condensation drain
  186
• 5.17 Checking condensation drain
  187
• 6 Rear heater and air conditioning unit
  188
• 6.1 Assembly overview – heater and air conditioning unit
  188
• 6.2 Removing and installing evaporator
  190
• 6.3 Dismantling and assembling evaporator housing
  192
• 6.4 Removing and installing heater and air conditioning unit
  195
• 6.7 Removing and installing rear evaporator temperature sensor G464
  204
• 6.8 Removing and installing condensation drain hose
  205
• 6.9 Checking condensation drain hose
  209
• 7 Air duct
  210
• 7.2 Removing and installing driver side footwell vents
  214
• 7.3 Removing and installing front passenger side footwell vents
  215
• 7.4 Removing and installing air ducts
  216
• 7.5 Removing and installing forced ventilation for passenger compartment
  221
• 7.6 Checking forced ventilation for passenger compartment
  223
• 7.7 Removing and installing fresh air intake
  224
• 7.8 Removing and installing cover for fresh air intake
  229
• 7.9 Removing and installing air intake duct
  230
• 7.10 Removing and installing air duct for defroster vent
  231
• 7.11 Removing and installing air duct for centre dash panel vent
  232
• 7.12 Removing and installing components of glove compartment cooling
  232
• 8 Operating and display unit
  235
• 8.1 Overview of operating and display unit
  235
• 8.2 Removing and installing operating and display unit
  239
• 9 Other controlling and regulating components
  243
• 9.1 Removing and installing sunlight penetration photosensor G107
  243
• 9.2 Working principles of air quality sensor G238
  244
• 9.3 Removing and installing air quality sensor G238
  245
• 9.4 Removing and installing ambient temperature sensor G17
  246
• 9.5 Removing and installing humidity sender for air conditioning system G260
  246
• 9.6 Removing and installing footwell vent temperature sender G192
  246
• 9.7 Removing and installing chest vent temperature sensors at front G385/ G386
  248