Pipes/Hoses, Replacing
Pipes/hoses, replacing
The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Preparations (operations common to all methods)
Warning! Follow the safety instructions for work on air conditioning systems. See Refrigerant, safety regulations Technician Safety Information.
Note! Read the instructions covering slow and fast leaks. See Oil Air Conditioning (A/C) System, Filling
Always plug the pipes and connections when working on the climate control system.
Drain the refrigerant from the air conditioning (A/C) system. See Refrigerant, draining Refrigerant, Draining.
Remove:
- the battery lead. See Battery, disconnecting Battery Disconnecting
- the rear side panel. See Side panel cargo compartment, replacement Side Panel Cargo Compartment, Replacement.
Removing pipes/hoses (operations common to all methods)
Remove:
- the engine stabilizer brace in the engine compartment
- the servo oil reservoir. Place it on top of the engine
- the hose from the expansion tank using cutting nippers or Oetiker pincers
- the connector for the level sensor
- the connector at the cable duct
- the expansion tank and place it on top of the engine
- the outlet air pipe to the firewall from the control module box.
Open the clamp for the refrigerant pipe on the side member.
Remove:
- the plastic nut from the drainage duct to the gutter in the right-hand corner
- the drainage channel.
- the heat shield for the expansion valve
- the screw and the pipe holder that secure the refrigerant pipes to the expansion valve.
Remove:
- the pipes from the expansion valve. Pull the pipe holder backwards
- the pipe lock from the pipe holder. Remove the lock and the holder.
To replace the pipes for the expansion valve - junction block on the side member, see replace.
To replace the expansion valve in the receiver drier, see replacing.
To replace the junction block in the cowl, rear expansion valve, see replacing.
Finishing work (operations common to all methods)
Install the battery lead. See Battery, disconnecting Battery Disconnecting.
Vacuum pump the air conditioning (A/C) system. See Vacuum pumping Vacuum Pumping.
Fill the air conditioning (A/C) system with refrigerant. See Refrigerant, filling Refrigerant, Filling.
Leak trace the air conditioning (A/C) system. See Leak tracing, fluorescent tracing agent / UV lamp Leak Tracing, Fluorescent Tracing Agent/UV Lamp or Leak tracing, electronic leak tracer Leak Tracing, Electronic Leak Tracer.
Install the rear side panel. See Side panel cargo compartment, replacement Side Panel Cargo Compartment, Replacement.
Pipes expansion valve - junction point side member, replace
Removing pipes from the expansion valve - junction block on the side member
Remove:
- the hose/pipe from the member to the compressor
- the pipe from the receiver drier to the expansion valve from the mounting at the junction block
- the pipe from the member at the pipe coupling.
Detach the pipe at the expansion valve.
Position the front section of the pipe above the front cover plate.
Pull the rear edge of the pipe up and out. Remove the pipe.
Installing pipes for the expansion valve - junction block on the side member
Position the refrigerant pipe against the firewall.
Install the front section of the pipe.
Note! Use new O-rings lubricated with compressor oil.
Install:
- the pipe on the member at the pipe connection using 1 M8 screw. Tighten
- the hose / pipe from the member to the compressor
- the pipe lock on the pipe holder
- the pipe on the expansion valve using 1 M6 screw. Tighten
- the heat shield for the expansion valve
- the drainage channel and the plastic nut
- the clamp for the refrigerant pipe
- the outlet air pipe
- the expansion tank
- the connector at the cable duct
- the switch for the level sensor
- the hose on the expansion valve
- the servo oil reservoir
- the engine stabilizer brace in the engine compartment.
Carry out finishing work. See Finishing work (operations common to all methods).
Pipes receiver drier - expansion valve, replacing
Removing pipes from the receiver drier pipe - expansion valve
Remove:
- the pipe for the expansion valve - junction block. See replace
- the protective panel and the right-hand outer panel on the bumper.
Detach the pipe coupling from the receiver drier.
Position the pipe at the front.
Pull the rear edge of the pipe up and out. Remove the pipe.
Installing the pipes for the receiver drier pipe - expansion valve
Position:
- the front section of the pipes in the engine compartment
- the rear section of the pipes against the firewall.
Note! Use new O-rings lubricated with compressor oil.
Connect the pipe to the receiver drier.
Install:
- the hose / pipe from the member to the compressor
- the pipe lock on the pipe holder
- the pipe on the expansion valve using 1 M6 screw. Tighten
- the heat shield for the expansion valve
- the drainage channel and the plastic nut
- the clamp for the refrigerant pipe
- the outlet air pipe
- the expansion tank
- the connector at the cable duct
- the switch for the level sensor
- the hose on the expansion valve
- the servo oil reservoir
- the engine stabilizer brace in the engine compartment.
Carry out finishing work. See Finishing work (operations common to all methods).
Pipe/hose junction block cowl - rear expansion valve, replacing
Removing the pipe / hose from the junction block on the cowl - rear expansion valve
Remove:
- the left front seat. See Upholstery back rest, replacing Upholstery Backrest, Replacing (-2004) or Front seat, replacing Front Seat, Replacing (2005-)
- the dashboard. See Dashboard, replacing Dashboard, Replacing.
Angle out the climate control unit. See Climate unit, replacing Climate Unit, Replacing.
Remove the rear sill trim panel. See Sill trim panel, replacing Sill Trim Panel, Replacing.
Lift the rear floor carpet and the lower floor surface to one side.
Remove the rear side panel. See Side panel cargo compartment, replacement Side Panel Cargo Compartment, Replacement.
Detach the connection at the junction block in the engine room for the rear pipes.
Remove the heat deflector and the seal on the cowl panel.
Disconnect the terminal at the rear air conditioning (A/C) unit.
Installing the pipe / hose on the junction block on the cowl - rear expansion valve
Position the pipe/hose against the cowl panel. Route the pipe into the passenger compartment along the left-hand side of the center console and on along the right-hand side to the rear air conditioning (A/C) unit.
Secure the pipe at the various mounting points (see the illustration).
Connect the pipe at the rear air conditioning (A/C) unit.
Install:
- the heat deflector and the seal on the cowl panel.
- the connection at the junction block in the engine room for the rear pipes (see the illustration).
- the rear floor carpet and the lower floor surface
- the rear sill trim panel. See Sill trim panel, replacing Sill Trim Panel, Replacing
- the climate control unit. See Climate unit, replacing Climate Unit, Replacing
- the dashboard. See Dashboard, replacing Dashboard, Replacing
- the left front seat. See Upholstery back rest, replacing Upholstery Backrest, Replacing (-2004) or Front seat, replacing Front Seat, Replacing (2005-).
Carry out finishing work. See Finishing work (operations common to all methods).