Right Heater Core Housing and Right Motor Mounting Plate
Right Heater Core Housing and Right Motor Mounting Plate
• From 01.2008, A/C units which have an additional connection for the glove compartment cooling are being installed => [ Glove Compartment Cooling to Air Intake Manifold Connection ] Glove Compartment Cooling to Air Intake Manifold Connection. Make sure the correct right radiator housing and air intake hosing (different versions) are installed. Refer to Electronic Parts Catalog (ETKA).
• The activation of the temperature doors and with it the right radiator housing is different between vehicles equipped with "Comfort" and "Basis" A/C systems. Refer to => [ A/C Unit and Air Intake Housing Components ] A/C Unit and Air Intake Housing Components and to the Parts Catalog.
• To maintain the A/C stability, only one radiator housing (the left or right side) may be removed with the A/C installed.
• Depending on the production date, there are different versions of the levers and connections on the A/C unit. Refer to => [ Air Conditioner, Levers and Connecting Elements ] Air Conditioner, Levers and Connecting Elements and to Electronic Parts Catalog (ETKA).
• Vehicles with the "Comfort" A/C system can have the right radiator housing and the mounting plate installed/removed for the motors removed/installed. Vehicles with the "Basis" A/C system do not have this mounting plate.
Do not remove the left and right radiator housing at the same time.
• Both radiator housings support components of the air conditioner and must not be removed at the same time. Otherwise the air conditioner will become unstable.
• If necessary, remove the left and right radiator housing one after the other.
• The right motor mounting plate is installed only on vehicles with the "Comfort" 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 air intake housing. Refer to => [ A/C Unit Air Intake Housing ] A/C Unit Air Intake Housing.
- Remove the 2 screws - B - and remove the bracket - A -.
- Carefully disconnect the connector rod - B - (so the lever does not get damaged) from the lever on the right temperature door - A -.
• Depending on the production date, there are different versions of the levers and connections on the A/C unit. Refer to => [ Air Conditioner, Levers and Connecting Elements ] Air Conditioner, Levers and Connecting Elements and the Electronic Parts Catalog (ETKA).
- Loosen the bolt - C -.
- Loosen or remove the bolt - F - (installed beginning 07.2007, different versions).
• At the start of production, A/C units were installed, where the left and right side of the heater core housing - D - and - E - were bolted together on the underside with the bolt - C -. Beginning 07.2007 as a running change, A/C units are being installed, where both heater core housings - D - and - E - are bolted together with the bolt - F -.
• From 07.2007 through 09.2007 and screw - F - and nut - G - was installed on the left heater core housing - D -. The left heater core housing - D - has a single hole and not a threaded connection. To remove and install the bolt - F - and the nut - G - on this control motor version, the Temperature Regulator Door Motor (V68) or the Rear Temperature Door Motor (V137) must be removed. Refer to => [ Temperature Regulator Door Motor (V68) and Rear Temperature Door Motor (V137) ] Temperature Regulator Door Motor (V68) and Rear Temperature Door Motor (V137).
• You can place a catch on the holes on the right side of the heater core housing - E - which will prevent the bolt - C - (and the bolt - F -) from falling in the hole after being loosened.
- Disconnect the connector - A - from the evaporator vent temperature sensor (G263). Refer to => [ Evaporator Vent Temperature Sensor (G263) ] Evaporator Vent Temperature Sensor (G263).
- Mark the connectors - B - (for the Right Footwell Door Motor (V109) ), - C - (for the Right Center Vent Motor (V111) ) and - D - (for the Right Temperature Door Motor (V159) ) to avoid confusion.
- Disconnect the connectors - B -, - C - and - D - from the motor.
- Loosen the wiring harness - E - from the mounting points on the mounting plate.
- Carefully loosen the different connecting rods (from - A - to - D -) from each door.
• The connecting rods ( from - A - through - D -) are clipped on to the levers; unclip them carefully so that the lever does not get damaged.
• Depending on the production date, there are different versions of the levers and connections on the A/C unit. Refer to => [ Air Conditioner, Levers and Connecting Elements ] Air Conditioner, Levers and Connecting Elements and the Electronic Parts Catalog (ETKA).
- Remove bolts - E -.
- On vehicles with an auxiliary air heater heating element, loosen the wiring from the right heater core housing. Refer to => [ Auxiliary Air Heater Heating Element (Z35)/Honey Comb ] Service and Repair.
- Pull the right heater core housing - A - (together with the mounting plate, motors and levers, curved washers and connecting rods) from the A/C unit.
Installing
Installation is carried out in the reverse order while observing the following.
- Check the heater core - A - and evaporator - B - for dirt; clean if necessary.
- Check the foam seals on the heater core - A - and on the Auxiliary Air Heater Heating Element - C - (or on the honey comb on vehicles without an Auxiliary Air Heater Heating Element) for damage.
- Check the springs on the A/C unit - B - and the grooves - A - on the right heater core housing - C - for damage.
• If the groove - A - on the right heater core housing - C - or the spring on the A/C unit - B - are damaged, seal these with, for example, Silicone Adhesive D176 001 A3. Refer to Electronic Parts Catalog (ETKA).
- Insert the grooves - A - on the right heater core housing into the springs on the A/C unit - B - and push the right heater core housing - C - just a little into the A/C unit.
• On vehicles with an auxiliary air heater heating element pay attention when pushing the housing - C - onto the wiring.
• Pay attention to the door lever for the instrument panel vent - C - "right center" and the different connecting rods for the doors on the air distribution housing.
- Slide the lever on the door for the instrument panel vent - C - all the way up in the direction of arrow.
• Since the air flow direction was set to "DEF" on the Climatronic control module (J255) before removing the heater core housing, the curved washer - D - is now positioned so that the pin - B - fits into the groove in the washer - E - when the heater core housing is installed.
- Line up the door connecting rods so they do not get caught when the heater core housing is completely installed.
- Carefully push the heater core housing - A - all the way into the A/C unit.
- Check the position of the pin - B - inside the groove in the curved washer - E - using an illuminated mirror or endoscope.
- Install the screws - E -.
- Carefully connect the various connector rods - A - through - D - to the lever of each door.
• The connecting rods ( from - A - through - D -) are clipped into the levers; unclip them carefully so that the lever does not get damaged.
• Depending on the production date, there are different versions of the levers and connections on the A/C unit. Refer to => [ Air Conditioner, Levers and Connecting Elements ] Air Conditioner, Levers and Connecting Elements and the Electronic Parts Catalog (ETKA).
- Install the screws - C - and - F -.
- Carefully attach the connecting rod - B - (so the lever does not get damaged) on the lever on the right temperature flap - A -.
• Depending on the production date, there are different versions of the levers and connections on the A/C unit. Refer to => [ Air Conditioner, Levers and Connecting Elements ] Air Conditioner, Levers and Connecting Elements and the Electronic Parts Catalog (ETKA).
- Route the wiring - E - into the mounting point on the mounting plate as illustrated so that any moving components cannot come in contact.
- Connect the connector - B -, - C - and - D - according to the markings on the motors.
- Install 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 in "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). Refer to the Vehicle diagnostic tester in "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.
- Check the Climatronic Control Module DTC memory and erase any displayed malfunction if necessary using the Vehicle diagnostic tester in "Guided Fault Finding".
- Adjust and check the air flow direction on the different air ducts via Climatronic control module, if the quantity of air actually changes at each setting.