Air Intake Housing Of Front A/C Unit
Air Intake Housing Of Front A/C Unit
Removing
- Switch on the ignition.
- Move the right front seat (front passenger seat) as far back as possible.
- Switch off the ignition.
- Remove the glove compartment.
- Remove the right (front passenger) footwell vent, refer to => [ Right Footwell Vent ] Right Footwell Vent.
- Remove the air duct for glove compartment cooling, refer to => [ Air Duct For Glove Compartment Cooling ] Air Duct For Glove Compartment Cooling.
- Remove screw clips - A -.
- Loosen and remove insulation mat - B - from bracket - C -.
• There are retaining straps with hooks - A - at the glove compartment - D - that act as assembly aids, and which are installed in the noise insulation openings - B - as shown in the illustration. If the glove compartment - D - is not installed correctly ( press the retaining straps with hooks - A - from underneath against the noise insulation - B -), the noise insulation - B - can only be removed if the glove compartment is already removed.
- Release and remove connector - C - at the fresh air blower (V2) (with the fresh air blower control module (J126) ). Refer to => [ Fresh Air Blower (V2)/Control Module (J126) ] Fresh Air Blower (V2)/Control Module (J126).
• Press the locking mechanism down with a small screwdriver, for example, to release the connector.
- Disengage bracket - A - and remove acoustic cover - B - (from control motors Airflow door motor (V71) and Recirculation door motor (V113) ).
• A/C system malfunctions in the case of interchanged control motors and/or connectors, refer to => [ A/C Control Motor Block Diagram ] A/C Control Motor Block Diagram.
• The control motors and connectors are identical. If they are installed or connected incorrectly, the corresponding doors cannot be properly adapted and/or activated.
• Clearly label control motors and connectors prior to removal to prevent incorrect installation.
- Label connectors - A - to the Airflow door motor and connector - B - to the Recirculation door motor (to prevent confusion since several connectors are disconnected at the same time) and remove => [ Air Flow Door Motor (V71) ] Air Flow Door Motor (V71).
- Remove wiring harness - C - to the Airflow door motor and Recirculation door motor from the mounting points on air intake housing - D -.
- Remove bolts - A - and - B -.
- Remove bracket - C -.
- Remove screws - A -.
- Disengage locking mechanism - B - (between the A/C unit and air intake housing - E -) for example, using a screwdriver (lift slightly).
• If locking mechanism - B - between the A/C unit and air intake housing - E - no longer holds properly following an earlier installation, the two components can also be bolted together with an additional bolt via bolting point - C -.
Additional steps in a vehicle in which the A/C unit and air intake housing - E - are connected via an additional bolt.
• Remove the dust and pollen filter, refer to => [ Dust and Pollen Filter ] Service and Repair.
• Remove bolt - A - at bolting point - C - via the installation shaft for dust and pollen filter - E -.
Continuation of the steps for all vehicles
- Pull air intake housing - E - (after disengaging locking mechanism - B -) to the right and down (in the direction of the arrow).
- Disengage the lower tabs of air intake housing - E - from the mount of A/C unit - D -.
- Remove the air intake housing.
Installing
Installation is carried out in the reverse order, when doing this note the following.
- Check the evaporator - A - and the air guide in the A/C leading to the evaporator - B - for dirt and clean is necessary.
- Check the dust and pollen filter and the air guide in the air intake housing leading to the A/C - C - for dirt and clean if necessary.
- Check foam seal - D - around the air intake housing and the contact surface/bevel - E - around the A/C unit for damage.
• If foam seal - D - or contact surface/bevel - E - is damaged, air can escape here and noises can occur when operating the A/C system.
• If the A/C unit and the air intake housing are not correctly joined, air can escape at the connection point and noises can occur when operating the A/C system.
• If the contact surface/bevel - E - is damaged, fill the damaged area with, for example, silicone sealant D176 001 A3. Refer to Electronic Parts Catalog.
• If foam seal - D - is damaged, replace it. Refer to Electronic Parts Catalog.
- Insert the lower tabs of air intake housing - E - into the mount of A/C unit - D -.
- Join air intake housing - E - with the A/C unit so that locking mechanism - B - of the A/C unit engages securely with the air intake housing.
• Do not use force when attaching the air intake manifold to the air conditioner.
• If force is used to attach the air intake housing to the A/C unit, the lower tabs of air intake housing - E - can be permanently deformed.
• Deformed tabs of air intake housing - E - can cause the A/C system to make whistling noises during operation due to minor leaks at the connection points.
• For the A/C unit and the air intake housing to be joined properly, insertion aids that facilitate the joining of these two components are present in the area of locking mechanism - B -.
• If locking mechanism - B - does not engage immediately during joining, pull the air intake housing in the area of the upper catch backward while pressing the right side forward and upward.
- Check locking mechanism - B - (between the A/C unit and air intake housing - F -). If it does not hold properly, connect both components with an additional bolt.
Additional work in a vehicle in which locking mechanism - B - no longer engages properly with the A/C unit.
• Remove the air intake housing again.
• Remove the dust and pollen filter, refer to => [ Dust and Pollen Filter ] Service and Repair.
• Drill a hole at bolting point - D - (diameter 4 mm)
• Install the air intake housing again.
• Install bolt - A - at bolting point - C - via the installation shaft for dust and pollen filter - E -.
• Make sure to use the correct version of the bolt - A - to prevent damaging the attaching point - C - with a bolt that is too large. Refer to Electronic Parts Catalog (ETKA).
Install the dust and pollen filter, refer to => [ Dust and Pollen Filter ] Service and Repair.
Continuation of the steps for all vehicles
- According to the markings, connect the connectors to the air flow door motor - A - and to the recirculation door motor - B -.
- Route wiring harness - C - to the air flow door motor and recirculation door motor in the mounting points at air intake housing - D - so that it cannot come in contact with moving parts.
- Install the removed parts in the opposite order.
- Perform the basic setting and the output diagnostic test mode of the A/C system using the Vehicle Diagnostic Tester in the "Guided Fault Finding" function.
• In this vehicle, the control motors are equipped with electronics. During the basic setting, a new control motor learns its position on the A/C unit and can then be activated by the Climatronic control module (currently all control motors are identical). Check using the Vehicle Diagnostic Tester in the "Guided Fault Finding" function.
• During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform with the specification, the control motors will adapt incorrectly and the door control will be wrong, refer to => [ A/C Control Motor Block Diagram ] A/C Control Motor Block Diagram.
- Check the event memory of the Climatronic control module and erase any displayed malfunctions using the Vehicle Diagnostic Tester in the "Guided Fault Finding" function.