Note: All electrical wiring ties must be installed in their original places. The electrical wiring harness is removed together with the climate control system housing.
1. On some engines, it may be necessary to remove the top engine cover to gain access to the expansion valve (see Chapter 2), turbocharger inlet hose, diesel particulate filter cover and air cleaner inlet hose (see Chapter 4).
2. Drain the refrigerant.
3. Disconnect the negative cable from the battery.
4. Remove the center console and instrument panel (see Chapter 11).
5. Remove the lower trim of the right A-pillar (see Chapter 11).
6. Clamp the coolant hoses (1 in illustration 13.2) heater radiator, mark them, pull out the clamps and disconnect the hoses from the radiator, collecting the leaking coolant. If the radiator is supposed to be replaced, the coolant should also be replaced, so in this case it can be drained (see Section 2).
7. Connect the compressor to the upper fitting of the heater radiator (1 in illustration 13.3) and blow out the remaining coolant from the radiator (3) into a previously prepared container (2).
8. Remove the bolts (1 on the accompanying illustration) refrigerant line fasteners (2) and disconnect them from the expansion valve (3). Seal the connections to prevent dirt from entering the refrigerant circuit.
15.8 Bolts (1) for fastening refrigerant lines (2)
9. Cover the flooring under the heater radiator with waterproof material and absorbent paper.
10. Remove the beam (7 on the accompanying illustration) instrument panels (see Chapter 11), pull out and remove the wiring harness from the climate control system housing. Remove the wiring harness from the holder (4).
15.10 Air conditioning system housing fastening parts
1 Bolt, 4.5 Nm
2 Wiring Holder
3 Climate system housing
4 Right bracket
5 Nuts, 8 Nm
6 Bolts, 8 Nm
7 Instrument panel beam
8 Bolt, 2 Nm
9 Support
10 Left bracket
11. Remove the diagnostic interface J533 (see Chapter 12).
12. Tilt the climate control housing slightly and lift it up from the rear air duct. Remove the climate control housing from the vehicle, carefully pulling the wiring harness out of the right bracket.
13. If it is necessary to disassemble the housing, follow the accompanying illustrations.
15.13a Assembly details of the "Climatic" climate system housing
1 Temperature flap actuator V68
2 Bracket
3 Lid
4 Activator V113 of the circulation flap
5 Air intake, with recirculation flap
6/7 Upper/lower evaporator housing
8 Evaporator
9 Glove box cooling hose, not installed from week 46 of 2010
10 Assembly of N₂4 fan resistors 11
11 Fan V2
12 Diesel particulate filter
13 Filter cover 12
14 Heater radiator
15 Radiator cap 14
16 Auxiliary heating element Z35, on some diesel models
17 Distribution casing
18 V145 Front Distribution Valve Actuator
15.13b Climate system housing assembly parts "Climatronic"
1 V426 Activator Front Distribution Valve
2 Activator V158 left temperature flap
3 Activator V107 for windshield blower valve
4 Bracket
5 V425 Activator of the recirculation flap
6 Air intake, with recirculation flap
7/8 Upper/lower evaporator housing
9 Evaporator
10 Glove box cooling hose
11 Fan V2 with control unit J126
12 Diesel particulate filter
13 Filter cover 12
14 Heater radiator
15 Radiator cap 14
16 Auxiliary heating element "Z35", on some diesel models
17 V159 actuator right temperature flap
18 Distribution casing
14. Installation is performed in the reverse order. When installing, ask an assistant to direct both coolant pipes from the engine compartment. Use new expansion valve sealing rings.