A/C Unit Air Intake Housing
A/C Unit Air Intake Housing
• From 01.2008, A/C units which have an additional connection for the glove compartment cooling are being installed. On vehicles without glove compartment cooling, this connection is sealed with a plug. Refer to => [ Glove Compartment Cooling to Air Intake Manifold Connection ] Glove Compartment Cooling to Air Intake Manifold Connection. Make sure that the correct right heater housing and air intake housing are installed. Refer to Electronic Parts Catalog (ETKA).
• From MY 12, a new version is being used. Read all the information regarding this component. Refer to => [ A/C Unit and Air Intake Housing Overview, Basis A/C System ] A/C Unit and Air Intake Housing Overview, Basis A/C System.
Removing
- Switch on the ignition.
- Set the air flow direction to "DEF" on the Climatronic control module (J255).
- Move the passenger seats as far back as possible.
- Turn off the ignition.
- Remove the glove compartment.
- Remove the right (passenger) footwell vent. Refer to => [ Right Footwell Vent ] Right Footwell Vent.
- Remove the screw clips - A - and remove the insulation mat - B -.
- Remove bolts - A -.
- Loosen the air duct for the right instrument panel vent from the instrument panel crossmember, but do not remove it.
• The air guide from the air guide channel - B - is attached to the right instrument panel vent with two screws. To loosen, remove the screw which is installed at the bottom and is accessible.
- Remove the air guide channel - B - leading to the right instrument panel vent (passenger side).
- Remove the lower A-pillar trim - C - and the bracket - B -.
- Disconnect the terminal - A - from the Fresh Air Blower Control Module (J126).
- Remove the headlamp range control module (J431) - 1 - ( headlamp range/cornering lamp control module (J745) ) and mount.
- Remove the fresh air blower (V2). Refer to => [ Fresh Air Blower (V2) ] Service and Repair.
• The A/C unit air intake housing can be removed and installed with the fresh air blower still installed, however since space it limited, it is better to remove the fresh air blower.
- Loosen the cables - A - from the mounting points on the air intake housing.
- Disengage locking mechanism - C - (between the A/C and the air intake housing - B -) for example, using a screwdriver - D - (lift slightly and pull in the direction of the arrow)
- Pull the air intake housing - B - (after disengaging the locking mechanism - C -) to the right and down (in the direction of the arrow).
- Mark the terminals leading to the Air Flow Door Motor (V71) - E - and - F - leading to the Recirculation Door Motor (V113) (due to the danger of confusing them with other identical terminals) and disconnect them from these control motors.
- Loosen the upper A/C strap - E - from the air intake housing bracket - D -.
- Loosen both lower mounting points between the A/C - B - and the air intake housing - A -.
- Remove the air intake housing.
Installing
Installation is carried out in the reverse order while observing 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 the groove around the A/C - D - and the bevel around the air intake housing - E - for damage.
• If the groove or the bevel are damaged, fill the damaged spot with, for example, silicone sealant D176 001 A3. Refer to Electronic Parts Catalog (ETKA). When using the A/C, air could leak from here and this could result in noises.
- Check the seal on the fresh air intake shaft - A - for damage before installing the air intake manifold - C -. Replace the seal if it is damaged.
- Check the position of the lock, only if the latch - B - is in the position shown, can the air intake housing - C - and the A/C - D - be joined together.
- According to the markings, connect the terminals leading to the Air Flow Door Motor - E - and leading to the Recirculation Door Motor - F - with the control motors.
- Insert both lower air intake housing straps - A - into the mounting points on the A/C - B -.
- Lift the air intake housing to the right far enough so that the upper A/C strap - C - fits into the air intake housing bracket - D - and then press both parts together.
• Do not use force when attaching the air intake manifold to the air conditioner.
• If you use force to attach the air intake manifold to the air conditioner, the tabs on the air intake manifold - A - will bend.
• If the tabs on the air intake manifold - A - bend, the air conditioner will make a whistling noise when it is running due to the slight air leakage.
• If the latch - E - should slip forward while installing, both parts cannot be joined together
• When joining the two parts together, make sure no other components get jammed in and that the bevel on air intake housing fits into the groove on the A/C all around.
- Slide the latch - C - opposite the direction of the arrow (this locks the A/C with the air intake housing - B - ).
- Loosen the cables - A - into the mounting points on the air intake housing.
• When routing the wires, make sure that they are routed on the control motors so that they cannot get caught in any moving parts on the motors.
- Reinstall the removed parts in the opposite order.
- Switch on the ignition.
- Perform a basic setting and the output Diagnostic Test Mode (DTM) on the A/C system using the Vehicle Diagnostic Tester under "Guided Fault Finding".
• On this vehicle, the control motors are equipped with electronics. During the first basic setting, a new control motor learns its position on the air conditioner and can then be controlled by the Climatronic Control Module (J255) (currently all control motors are identical). Check using the Vehicle Diagnostic Tester under "Guided Fault Finding".
• 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 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.
• Make sure then both control motors, the airflow door motor (V71) and the recirculation door motor (V113) are connected correctly. Check the activation using the "A/C output diagnostic test mode". When the glove compartment is removed, the air recirculation door - F - is visible. Refer to Vehicle Diagnostic Tester in "Guided Fault Finding" function.
- Check the DTC memory for the Climatronic control module control head and erase any entries if necessary using the Vehicle Diagnostic Tester in "Guided Fault Finding" function.