manual clima

8/9/2019 Manual Clima

1/48

87-11

Manual A/C

Heating and A/C components in passengercompartment, servicing

CAUTION!

Before beginning repairs on the electrical system:

Note:

System components identified with an * must only be serviced or replaced after discharging refrigerant system.

Use Kent Moore ACR4 or equivalent.

Obtain the anti-theft radio security code.

Switch the ignition off.

Disconnect the battery Ground (GND) strap. After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows according to Repair Manual and/or Owner's Manual.


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87-12

Repair Manual, Body Interior, Repair Group 70.

1 - Clip

Lift out with screwdriver.

2 - Dust and pollen filter

Vehicles 10.00 , replacing Page 87-41 .

3 - Air intake housing

4 - Defroster air outlet

Removing and installing

5 - Side window air outlet

Removing Fig. 1


3/48

87-13

6 - Heating and A/C controls

With:

A/C switch -E35-

Fresh air blower switch -E9-

Switch for fresh air blower and recirculated air -E184-

Removing and installing Page 87-27

Assembly Page 87-30

7 - Air outlets

Center and side air outlets, removing (early prod.)Fig. 2

Center air outlet, removing (later prod.) removingFig. 3

Side air outlets, removing (later prod.) Fig. 4

8 - Instrument panel cross member

Always follow installation instructions for bolt Fig.7


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87-14

Repair Manual, Body Interior, Repair Group 70


9 - Defroster duct

Replacing:

- Remove instrument panel

10 - Servo motor for fresh/recirculating air door -V154-


11 - Ambient temperature switch -F38-

Switches off A/C clutch -N25- at low ambienttemperatures

Switching point: 5 C (41.5 F)

Replacing:

- Remove glove box

- Reach behind heating and A/C unit from belowand pull out switch.


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87-15

CAUTION!

Area around dust and pollen filter and air intake housing must be free from debris, leaves etc. before reaching into housing. Debris entering heating and A/C unit will block evaporator water drain and cause subsequent (water) damage.

Note:

If unable to access and remove gasket as described,proceed as follows:


12 - Gasket

Replace if damaged

Replacing:

- Remove ambient temperature switch -F38-

- Remove dust and pollen filter

- Set fresh air/recirculation flap in "fresh air" position

- Reach down into air intake housing and pull outgasket



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- Loosen cross member - 10 - .

Always follow installation instructions for bolt Fig.7


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87-16

13 - Evaporator water drain guide


14 - Heating and A/C unit*

Contains:

Heater core

Evaporator

Removing/assembly Page 87-164 .

15 - Fresh air blower -V2-

Removing and installing Fig. 6

16 - Fresh air blower series resistance with fuse -N24-

Replacing Fig. 5

17 - Center air outlet duct

18 - Control panel trim

Unclip using screwdriver

19 - Center trim


8/48

87-17

20 - Heating and A/C cables

Installing Page 87-32

21 - Heater core*

Always use new coolant after replacement

22 - Left rear duct

23 - Lower duct

24 - Upper duct

25 - Footwell air outlet

26 - Instrument panel cross member and left sidemember securing bolt

Always follow installation instruction for bolt Fig.7


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87-18

27 - Relay

Coolant Fan Control (FC) Relay -J26-

Control number 214

First Speed Coolant Fan Control (FC) relay -J279-

Vehicles 10.00: Control number 214

Vehicles 10.00 : Control number 373

Second Speed Coolant Fan Control (FC) Relay -J280-

Vehicles 10.00: Control number 213

Vehicles 10.00 : Control number 370

Component locations Electrical Wiring Diagrams,Troubleshooting and Component Locations.

28 - A/C cut-off control module -J314-

Control number 384

Component location Electrical Wiring Diagrams,Troubleshooting and Component Locations.


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87-19

Fig. 1 Side window air outlet, removing

- Carefully pull out using needle-nose pliers.

Fig. 2 Center and side air outlets, removing (early prod.) - With flashlight, locate the two retaining tabs inside housing, lift tabs with two

small screwdrivers and carefully pull outlet from instrument panel.


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87-20

Note:

Fig. 3 Center air outlet, removing (later production)

- Insert fingers of both hands into lower row of grille -A- and push center vent -1-down suing force until locking lugs -B- are released from their mounts.

Sit between front seats to apply the force required.

If outer locking lugs -B- will not release, grip at this point and push center vent down while simultaneously pulling out slightly.

- Grip center vent -1- at point -C- which has been raised up slightly frominstrument panel opening by action of pushing down.

- Push center vent in direction -D- to release locking lugs and pull it outwardslightly.


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87-21

- Disconnect electrical connectors -2- from center vent before removing indirection of -arrow-.

Note:

Removal of both sides is identical.

Fig. 4 Side air outlet, removing (later prod.)

- Unclip and remove instrument panel side cover -1- using screwdriver.


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87-22

- Guide a flat screwdriver between vent and seal alternately into side openings -A-and -B-.

- Pry vent -2- in direction -C- alternately through these openings.

7

- Disconnect electrical connector -3- when removing vent -2- in direction -C-.


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87-23


Fig. 5 Fresh air blower series resistance with fuse -N24- , replacing

- Remove glove box.

- Disconnect electrical connector and remove bolt -arrow-.

- Seal surface between series resistance -1- and air duct before installing withAMV 176 000 05 (or equivalent).


Fig. 6 Fresh air blower -V2-, removing and installing - Remove glove box

- Disconnect electrical connector -1-.

- Remove three screws -arrows- and remove fresh air blower -2- downwards.


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87-24

To avoid damage to instrument panel wiring harness -2-, ensure that the protectivecap -1- is installed on the securing bolt for upper instrument panel cross member -4- at left side member -3-.

Fig. 7 Instrument panel cross member and left side member securing bolt,installation note:


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87-25

Evaporator water drain guide, removing andinstalling

Removing



- Release instrument panel cross member frombulkhead Page 87-13 .

For the next step, an assistant must lift and holdthe heating and A/Cunit.

Installing

When installing, ensure water drain valve -3- sealing lip completely encloses theguide -2-. If necessary, lubricate to aid installation.

Water drain valve, checking Page 87-40 , Fig. 1

- Remove nuts -1- (2.5 Nm / 23 in lb) and remove guide -2- from bulkhead.


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18/48

87-27

Heating and A/C controls, removing andinstalling

Removing

- Carefully remove trim panel by depressinglocating lugs -arrows-with a covered screwdriver.Do not damage instrument panel.

- Remove instrument panel screws -arrows-.

- Remove center trim panel Page 87-16 .

- Pull controls with cables attached from instrument panel.

- Release cables on controls.

- Disconnect electrical connector.


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87-28

Installing

Notes:

Cable sleeve ends are color coded.

Check cables before installing and replace binding or damaged cables.

All air flaps must audibly move onto end stops when turning controls.

- Mount eyelet on end of cable -1- onto control - arrow 2-.

Footwell/defrost flap cable sleeve marking: White

- Press footwell/defrost or central flap cable -1- into mount -2- until it engages.


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Central flap cable sleeve marking: Black


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87-29

Temperature flap cable sleeve marking: Red

- Insert temperature flap cable -1- into mount opening -arrow B-.

- Turn -arrow A- temperature flap cable -1- until it engages into air distributorhousing -2-.


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87-30

Heating and A/C controls, assembly


With:

A/C switch -E35-

Fresh air blower switch -E9-

Switch for fresh air blower and recirculated air -E184-


2 - Illumination filter

3 - Trim panel

4 - Fresh air control lever light -L16-

12V, 1.2W

Removing:

- Un-clip trim panel - 7 - and rotary control - 5 -.

- Remove bulb (if necessary, slide a short piece fuel

hose over bulb and pull out).

5 - Rotary control

For blower speed

To remove: Use pliers with suitable plastic or rubber


23/48

protection on jaws


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87-31

6 - Rotary control

For air distribution To remove: Use pliers with suitable plastic or rubberprotection on jaws

7 - Trim panel

8 - Rotary control

For interior temperature

To remove: Use pliers with suitable plastic or rubberprotection on jaws


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87-32

Heating and A/C cables, installing

Notes: Cable sleeve ends are color coded.

Check cables before installing and replace binding or damaged cables.

All air flaps must audibly move onto end stops when turning controls.

1 - Central flap cable

From air distribution rotary control to central flap

Cable sleeve marking: Black



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87-33


2 - Footwell/defrost flap cable

From air distribution rotary control to footwell/defrostflap

Cable sleeve marking: White

Replacing:

- Remove controls for heating and A/C systemPage 87-27

- Remove driver side shelf

- Unclip cable at heating and A/C unit.

- When installing, attach cable to heating and A/Cunit first.


Removing Page 87-27

4 - Temperature flap cable

From temperature rotary control to temperature flap

Cable sleeve marking: Red



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87-34

Temperature and central flap cables,removing and installing

Notes:

Cable sleeve ends are color coded.

When installing secure cable to heating and A/C unit first.

Check cables before installing and replace

binding or damaged cables.

Removing

- Remove heating and A/C controls Page 87-27



- Remove footwell air outlet Page 87-17 .


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- Disconnect cable for central flap or temperature

flap on heating and A/C unit.


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87-35

Installing

Illustration shows right-hand drive version.

1- Central flap cable, sleeve marking: Black

2- Temperature flap cable, sleeve marking: Red

3- When attaching inner cable note: Do not press end of wire (arrow) against lever.


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87-36

Heating and A/C components in enginecompartment, servicing

CAUTION!

Before beginning repairs on the electrical system:

Notes:

Obtain the anti-theft radio security code.

Switch the ignition off.

Disconnect the battery Ground (GND) strap.

After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows according to Repair Manual and/or Owner's Manual.

System components identified with an * must only be serviced or replaced after discharging refrigerant system.Use Kent Moore ACR4 or equivalent.

Illustration shows vehicle with engine code AHA.


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87-37

1 - Accumulator*

2 - Refrigerant hose*

Between evaporator and accumulator


Between evaporator and condenser

4 - Low pressure service valve*

5 - High pressure service valve*


Vehicles 10.00 , replacing Page 87-41

Ambient temperature switch -F38- located belowdust and pollen filter in lower air intake housing.

7 - Evaporator*

In heating and A/C unit.


32/48

87-38

8 - Evaporator water drain valve

Checking Fig. 1 .

9 - Pressure relief valve*

Zexel compressor illustrated

Checking, Zexel compressor Page 87-159

Checking, Denso compressor Page 87-160

10 - Compressor*

11 - A/C clutch -N25-

Servicing: Zexel Page 87-43

Servicing: Denso Page 87-49

12 - Condenser*


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87-39

13 - A/C pressure switch -F129-

-

Tightening torque 8 Nm (71 in lb)

- Replace O-ring (note Part No.).

Function:

Switches coolant fan -V7- to next highest speedwhen pressure increases in refrigerant circuit.

Switches off A/C clutch -N25- when refrigerantpressure is excessive (e.g.: insufficient enginecooling).

Switches off A/C clutch -N25- when refrigerantpressure is too low (e.g.: refrigerant loss).

Checking Page 87-154

Replacing, 10.00 Page 87-156, Fig. 4 .

Replacing, 10.00 Page 87-157, Fig. 5 .


Between compressor and condensor


Between compressor and accumulator.


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87-40

Check drain valve as follows:

Note:

Catalytic converter heat shield from 10.00 differs from illustration.

Check valve as follows to ensure proper function:

Fig. 1 Evaporator water drain valve, checking

- Remove nuts -arrows- on right catalytic converter heat shield -1-.

- Remove catalytic converter heat shield.

The valve must not be stuck together.

The opening in the sealing cap of the valve must point downwards.

The right catalytic converter heat shield plate must not be deformed ordamaged in the area of the valve.

- Remove valve -1- from bulkhead -2-.

The valve sealing lip -1- must cover the water drain guide outlet completelyPage 87-25 .


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87-41

Dust and pollen filter 10.00 , removingand installing

Removing

- Lift front hood. Remove air intake plenumcover.

Installing

- Unclip spring -1-. Remove dust and pollen filter upwards from housing.

- Installation in reverse order of removal.

Filter housing, assembly

1 - Filter housing


3 - Nut (2Nm)


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87-42

Ventilation system, checking

Notes:

Passenger compartment air is vented to the outside trough openings in the luggage compartment trim.

In order for the ventilation system to work properly, these openings must not be blocked.

Vent frames are located in both rear quarter panels, behind the bumper cover.

Checking

- Remove rear bumper cover

Repair Manual, Body Exterior, Repair Group 63

- Sealing lips -1- in vent frame -2- must move and close freely.


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87-43

A/C clutch -N25-, servicing (Zexel)

Special tools, workshop equipment, test and measuringappliances and auxiliary items required

Not illustrated:

3212 Two hole pin wrench

VAG 1719 A/C Clutch set

VAG 1719/1 Adapter

VAG 1719/2 Adapter

Torque wrench (5 - 50 Nm)

Locally available two-arm puller (e.g. Kukko 20-10) withfixtures for a depth of 100 mm.

Feeler gauge


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87-44

Notes:

Refrigerant circuit does not need to be opened to service

A/C clutch. If unable to service A/C clutch on compressor installed in vehicle, discharge refrigerant Page 87-173 and remove compressor from compressor bracket.

1 - Hex head combination bolt

15 Nm (11 ft lb)


2 - Clutch plate

Removing Fig. 2

Checking clutch plate gap Fig. 6

3 - 45Shims

Used to adjust gap between clutch plate and pulley

Gap: 0.3 - 0.6 mm (0.011 - 0.023 in)

6 - Circlip

Always replace - Install correctly: thick side faces compressor

Ensure correct seating in groove


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87-45

Note:

A thermo-fuse is incorporated into the clutch coil. Current to the clutch coil is interrupted in the event of compressor overheating (e.g. a binding compressor).

7 - Clutch pulley

Removing Fig. 3

Installing Fig. 4

8 - Circlip

Always replace

- Install correctly: Flat side faces compressor

Ensure correct seating in groove

9 - Clutch coil

Installing Fig. 5

10 - Felt ring

Always replace

11 - Bolt

12 - Compressor

Manufacturer: Zexel


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87-46

When removing and installing bolt, counter-hold with 2 hole pin wrench -A- (3212 orequivalent) with pin diameter: 4 mm.

Fig. 1 Combination bolt for clutch plate, removing and installing

- Remove bolt.

Tightening torque: 15 Nm (11 ft lb)

When removing, counter-hold with 2 hole pin wrench -A- (3212 or equivalent).

Fig. 2 Clutch plate, removing

- Mount VAG 1719 and turn in center bolt to extract clutch plate.


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87-47

Fig. 3 Clutch pulley, removing

- Remove felt ring.

- Fit adapter VAG 1719/1 (or equivalent).

- Fit locally available 2 arm puller -B- on shoulder -A- and extract pulley.

Fig. 4 Clutch pulley, installing

- Drive on belt pulley with plastic head hammer and VAG 1719/2 (or equivalent).


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87-48

Fig. 5 Clutch coil, installing

- Install coil on compressor.

- Position pin -A- in recess.

Notes:

Fig. 6 Clutch plate gap, checking

- Check gap with feeler gauge.

Gap: 0.3 - 0.6 mm (0.011 - 0.023 in)

Gap must be within tolerance around entire circumference.

If gap is outside tolerance range, remove clutch plate and adjust gap by adding or removing shims Page 87-44 .


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87-49

A/C clutch -N25-, servicing (Denso)

Special tools, workshop equipment, test and measuringappliances and auxiliary items required

Not illustrated:

Torque wrench (5 - 50 Nm)

Locally available two-arm puller (e.g. Kukko 20-10) withfixtures for a depth of 100 mm.

Locally available strap wrench

Depth gauge


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87-50

Notes:

Refrigerant circuit does not need to be opened to service

the A/C clutch.

If unable to service A/C clutch on compressor installed in vehicle, discharge refrigerant Page 87-173 and remove compressor from compressor bracket.

1 - Hex head combination bolt

15 Nm (11 ft lb)


2 - Clutch plate

Removing Fig. 2

Checking clutch plate gap Fig. 4

3 - Shims

Used to adjust gap between clutch plate and pulley

Gap: 0.4 - 0.6 mm (0.015 - 0.023 in)

4 - Circlip

Always replace

- Install correctly: Thick side faces compressor.

Ensure correct seating in groove.


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87-51

Note:

A thermo-fuse is incorporated into the clutch coil. Current to the clutch coil is interrupted in the event of compressor overheating (e.g. a binding compressor).

5 - Clutch pulley

- Remove with locally available 2 or 3 arm puller.

Ensure puller is seated correctly to prevent damage topulley.

6 - Circlip

Always replace

- Install correctly: Flat side faces compressor.

Ensure correct seating in groove.

7 - Clutch coil

Installing Fig. 3

8 - Screw

9 - Compressor

Manufacturer: Denso


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87-52

When removing and installing bolt, counter-hold with locally available strap wrench-A-.

Fig. 1 Combination bolt for clutch plate, removing and installing

- Remove bolt.

Tightening torque: 15 Nm (11 ft lb)

Use locally available 2 or 3 arm puller if plate is securely seated (difficult toremove).

Fig. 2 Clutch plate, removing

- Pry off clutch plate carefully with two large screwdrivers.


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87-53

Fig. 3 Clutch coil, installing

- Install coil on compressor.

- Locate locking pin -A- in recess -B-.

Note:

Repair Manual, Body Exterior, Repair Group 50.

Determine "Dimension 1"

Fig. 4 Clutch plate gap, checking

Gap: 0.4 - 0.6 mm (0.015 - 0.023 in)

In order to check gap with compressor installed in vehicle:

- Bring front end assembly (lock carrier) into service position.

- Using depth gauge -C-, measure gap between top of clutch plate and belt pulleyat three equally spaced locations (measurement must not deviate).

87 54


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87-54

Determine "Dimension 2"

The allowable gap (0.4 - 0.6 mm / 0.015 - 0.023 in) is the difference between"Dimension 1" and "Dimension 2".

Notes:

- If compressor is installed in vehicle, disconnect compressor electrical connector -A- from vehicle wiring harness.

- Using a jumper wire, energize clutch coil by applying 12V to connector -A-(battery terminal B+). If compressor is removed from vehicle, compressor -B-must be grounded.

- With clutch energized, measure gap between belt pulley and clutch plate withdepth gauge -C-:

Gap must be within tolerance around entire circumference.

If gap is outside the permitted tolerance range, remove clutch plate and adjust gap by adding or removing shims Page 87-50 .

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