Contents: Loading the contact terminals of the…⬇ Assembly diagram ⬇ Removal and installation the middle…⬇ Assembly position - seals ⬇ Disassembling and assembling the air…⬇ Air conditioner connecting parts ⬇ Assembly diagram of the air…⬇ Removal and installation of sun…⬇ Removal and installation the fresh…⬇ Removal and installation the…⬇
Loading the contact terminals of the plug connectors A, B and C on the rear side of the Climatronic control unit J255-
12-pin plug connector "A"
- 3 - Air conditioner control and regulation unit "J127" for fan control
- 4 - Fan response message (-)
- 5 - Fan response message (+)
- 8 - Sunlight sensor "G107"
- 9 - CAN-High bus (optional)
- 10 - CAN-Low bus (optional)
20-pin plug connector
- 1 - Temperature flap actuator "V68"
- 2 - Temperature flap actuator "V68"
- 3 - Defrost heater flap actuator "V107"
- 4 - Defrost heater flap actuator "V107"
- 5 - "Ground" (housing) of the actuator engine signal sensor
- 6 - Central air distribution flap actuator "V70"
- 7 - Central air distribution flap actuator "V70"
- 8 - actuator for ram air flap "V71"
- 9 - actuator for ram air flap "V71"
- 11 - Temperature sensor in the air supply area in the middle "G191"
- 12 - Temperature sensor at the point of air supply to the footwell "G192"
- 13 - Not busy
- 14 - +5 V 10 mA for actuators
- 15 - Temperature sensor at the point of air supply to the evaporator "G263"
- 16 - Temperature flap actuator motor potentiometer "G92"
- 17 - Potentiometer of the actuator motor of the heater flap for defrosting "G135"
- 18 - Potentiometer of the actuator motor of the central air distribution flap "G112"
- 19 - Potentiometer of the actuator motor of the high-speed pressure flap "G113"
Sixteen-pin plug connector "C"
- 2 - sunlight sensor "G107"
- 4 - Air conditioning compressor regulating valve "N280"
- 7 - High pressure sensor "G65"
- 8 - Stage 1 of the radiator fan control unit "J293"
- 9 - Stage 2 of the radiator fan control unit "J293"
- 12 - Clamp 30 (optional)
- 13 - Clamp 31
- 14 - Clamp 31
- 15 - Clamp 15
Assembly diagram
1 - Defrost heater grille, built into the instrument panel; 2 - Sunlight sensor "G107", tasks: depending on the light intensity, it controls the temperature flap and the fan for fresh air intake, emergency mode in case of failure: the Climatronic control unit "J255" will take a constant value; 3 - Center instrument panel air vent with hazard warning light switch; 4 - Instrument panel; 5 - Heater grille for defrosting the side window, carefully remove using a lever action of the mounting wedge; 6 - Side instrument panel air vent, carefully remove using a lever action of the mounting wedge at the top and bottom (similar to the middle instrument panel air vent); 7 - Spacer (air duct) middle blower nozzles, attached to the heater with clamps, to remove the instrument panel; 8 - Middle part of the instrument panel; 9 - Central pipe; 10 - Spacer (air duct)medium blower nozzles, attached to the heater with clamps; 11 - Right air duct nozzle in the footwell, screwed with the heater (1.5 Nm); 12 - Air conditioning; 13 - Air distributor spacer for the rear body floor; 14 - Air distributor for the rear body floor; 15 - Rear floor air distributor tip, retained in rear floor air distributor and seat frame crossmember; 16 - Air intake grille, fixed in the rear cross member of the frame in front of the spare wheel well on the outside, the curtains must be freely movable and must close spontaneously, the area in front of the air intake grille must be free, otherwise the ventilation of the interior of the vehicle would not work; 17 - Left air duct nozzle in the footwell, screwed to the support (1.5 Nm); 18 - Seal for connecting the heat exchanger in the transverse wall (mounting plate); 19 - Seal for connecting the expansion valve in the cross wall (mounting plate)
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Removal and installation the middle blower nozzle
Remove the key from the ignition and turn off all electrical consumers. Carefully lever the plastic wedge away from the "arrow" clips. Disconnect the plug connector from the hazard warning light switch or the airbag indicator. Ensure the clips are properly engaged during installation.
Assembly position - seals
- 1 - Rubber seal of the cross wall and expansion valve, fastening - on the cross wall
- 2 - Transverse wall (mounting plate)
- 3 - Foam seal for expansion valve and cross wall, glued to evaporator body
- 4 - Foam seal with holder - cross wall, secured to the air conditioning unit
- 5 - Condensate drain valve, installed in holder "4" and on the air conditioning unit
- 6 - Rubber seal for the cross wall and condensate drain valve, fastening - on the cross wall
Disassembling and assembling the air conditioner (Climatronic)
1 - Air conditioning wiring harness, to remove it you should carefully cut the cable clamp, when installing you should install new cable clamps in the same place; 2 - Evaporator body - upper part, connection of the upper and lower parts of the evaporator with screws and clamps; 3 - Holder, screw connection on the heater, tightening torque on the air conditioner: 5 Nm; 4 - Fresh air intake fan control unit "J126"; 5 - Self-adhesive foam seal is glued to the evaporator body. Before installation, remove any remaining adhesive from the body with acetone; 6 - Expansion valve; 7 - Air inlet housing, with damper for fresh and circulated air, secured at the top and bottom with clamps; 8 - Seal, self-adhesive, before proceeding with assembly, remove any remaining glue from the housing with acetone to allow air to enter; 9 - Dust and pollen filter, also as a combination filter with an odor filter; 10 - Actuator motor for regulating the high-speed pressure damper "V71", secured in a holder; 11 - Holder, actuator motor for regulating the damper for fresh and circulated air "V154"; 12 - Fresh air intake fan "V2"; 13 - Fresh air intake fan holder "V2"; 14 - Evaporator body - lower part; 15 - Filter cover; 16 - Lower part of the air distributor housing; 17 - Heating element of the additional resistive heater (ARH) "Z35"; 18 - Heat exchanger; 19 - Holder of the actuator motor for regulation; 20 - Actuator motor for regulating the central air distribution flap "V70"; 21 - Evaporator seal, observe the assembly position: the water drainage holes must point downwards; 22 - Evaporator; 23 - The upper part of the air distributor housing is connected to the lower part of the air distributor housing with brackets; 24 - Support, is an integral part of the ventral pipe, screw connection to the air conditioner and to the support of the middle panel, tightening torque on the air conditioner: 5 Nm, tightening torque on the support of the middle panel: 10 Nm; 25 - Holder of actuator motors for regulation; 26 - Actuator motor for regulating the heater flap for defrosting "V107"; 27 - Actuator motor for controlling the mixing temperature flap "V68"
Air conditioner connecting parts
- 1 - Screw for plastic material, tightening torque: 1 Nm
- 2 - Before removing the bracket, mark the position and location on the housing; when installing, ensure that the clamping part of the clamp enters the fixed position in the groove of the housing.
Assembly diagram of the air conditioning unit
1 - Fresh air intake fan control unit "J126"; 2 - Actuator motor for regulating the flap for fresh and circulated air "V71", with built-in potentiometer "G143"; 3 - Fresh air intake fan "V2"; 4 - Dust and pollen filter, also as a combination filter with an odor filter; 5 - Actuator motor for regulating the central air distribution flap "V70"; 6 - Air conditioning control unit, replace only as a complete unit, as a set; 7 - Plug connector for footwell air temperature sensor "G192"; 8 - Footwell air temperature sensor "G192" - to remove, remove the center panel, disconnect the plug connector and turn the sensor 90° to the left; 9 - O-ring; 10 - Heating element of the auxiliary resistive heater (ARH) "Z35". Only on some vehicles; 11 - Heat exchanger; 12 - Mixing adjustment device (temperature) "V68" dampers with built-in "G92" potentiometer; 13 - Defrost heater flap control "V107"; 14 - Seal with holder, secured with clamps on the heater; 15 - Condensate drain valve, install together with holder "14" on the air conditioner; 16 - Plug connector for evaporator temperature sensor "G263"; 17 - Intake air temperature sensor in the middle "G191", built into the spacer (air duct) middle blower nozzles, to remove it you should remove the shock-absorbing panel under the instrument panel to the left and the air duct heat in the driver's footwell, turn the sensor 90° to the left, lower it down and disconnect; 18 - Evaporator temperature sensor "G263", to remove it you should remove the instrument panel, disconnect the plug connector and pull it to the side; 19 - Sealing ring; 20 - The fitting for cooling the glove compartment on the passenger side of the front seat is screwed to the housing; 21 - Connecting hose, to the glove compartment on the front passenger side
Removal and installation of sun light sensor "G107"
Turn off the ignition and all electrical consumers. Carefully lever the "G107" sun sensor "2" out of the instrument panel at the "arrow" clips using a plastic wedge and disconnect the connector "3.".
Installation is carried out in the reverse order of actions.
Removal and installation the fresh air intake fan control unit "J126"
Remove the instrument panel and take out the fresh air intake fan. Disconnect plug connector "1". Unscrew screw "2" (1 Nm) and remove control unit "3" in the direction of the "arrow" from the air conditioner.
Installation is carried out in the reverse order of actions.
Removal and installation the actuator motor for regulating the high-pressure damper "V71"
Remove the instrument panel. Remove the fresh air intake fan. Carefully release the (pipe) wire from the clamps "4". Disconnect the plug connector "2" from the throttle control device.
Unscrew screws "3" and "5". Pull out holder "1" with the actuator for adjusting the position of the damper forward to such an extent that the handles do not enter the device for controlling the actuator for adjusting the position. Pressing the outer retainer of the holder "1" at the top downwards towards the "arrow", remove the holder together with the actuator motor for adjusting the position of the damper. Remove the actuator motor for regulating the position of the high-speed pressure valve from the holder. To do this, press the "arrow" clamps outward and simultaneously remove the actuator for regulating the position of the high-speed pressure valve from the "1" mount.
Installation is carried out in the reverse order of actions. In this case, the following instructions must be observed.
Important: The ram pressure flap actuator "V71" is adjusted to the "recirculated air" end position as a replacement part. If necessary, connect the flap actuator to the wiring harness and move it to the "recirculated air" position.
Press the actuator motor to control the position of the high-speed pressure valve into the holder. The following operations must be carried out simultaneously: the holder with the actuator for position adjustment must be directed in such a way that the handles "2" enter the device for controlling the actuator for position adjustment "1".
Install the actuator motor for regulating the position of the dampers completely into the housing and screw it on. Connect the plug connector, turn on the ignition and press the recirculation button to check the stroke of the actuator motor to adjust the position.
Important: The damper for fresh and circulated air must be adjustable to the end positions without jamming. In case of malfunction, the test must be stopped immediately and the installation must be repeated. If the actuator motor for position control has been changed, then it must be reset to its original position.