REFRIGERANT CIRCUIT, DRAINING
Refrigerant is never to be allowed to escape into the atmosphere, but rather it is to be extracted from the refrigerant circuit using an extractor or A/C service station. The drained refrigerant will be locally recycled or is send to an environment-recycling place to the manufacturer (different or additional laws may apply in individual companies). For this reason, bring the vehicle to a workshop that has the necessary tools and qualified personnel, refer to SPECIAL TOOLS .
Reason
If refrigerant R134a is released into the environment, it enhances the green house effect.
Note. Refrigerant R134a has far less of a greenhouse effect than R12. Because R-134a does not contain chlorine atoms, the major catalyst in ozone depletion, refrigerant R-134a has no ozone depletion potential. Depletion of the ozone layer in the upper atmosphere is however only brought about by the splitting of carbon-chlorine bonds (as is the case, for example, with refrigerant R12).
After draining the A/C system, disconnect the connector from the A/C Compressor Regulator Valve -N280- or from the High Pressure Sensor -G65-.
Reason
The A/C compressor regulator valve is no longer activated and the A/C compressor runs at idle. The A/C compressor is designed so the lubrication of the A/C compressor components at idle is guaranteed by an internal oil circuit (as long as there is enough refrigerant oil in the A/C compressor).
CHECKING AND CLEANING PLENUM CHAMBER WATER DRAIN
Note. The draining of water from plenum chamber may be impaired by deposits (leaves, diverse tree needles etc.) accumulating in plenum chamber water drains -A-. The water level in the plenum chamber then rises if the vehicle is taken to an automatic car wash or in the event of heavy rain, water enters via intake housing into the heating and A/C unit and is blown by the fresh-air blower onto the evaporator together with the air conveyed. If both water drains -A- (right and left in plenum chamber) are blocked by leaves and pine needles, it may cause the drains to freeze up in winter and water can no longer drain out. After a short drive, heat emitted from engine and exhaust system melts the ice in the drains again and water may drain off again before vehicle arrives at the workshop.
Checking and Cleaning
Remove the windshield wipers and the cowl panel (plenum chamber cover). Refer to [For engine(s) CBRA, BPY, CCTA, CBFA] Removal and Installation and Removal and Installation .
Check both water drains -A- (on the right and left sides inside the plenum chamber) and clean them if necessary.
Scheme 3
CONDENSATE DRAIN HOSE
Note. Only one condensation water drain hose is installed in this vehicle. There is no door at valve for condensation water drain -C-.
For complaints of moisture in passenger compartment, check the following components as well as condensation water drain
Water drain for plenum chamber, refer to CHECKING AND CLEANING PLENUM CHAMBER WATER DRAIN
Plenum chamber cover and cover for fresh air intake housing for correct installation and damage, refer to AIR INTAKE COVER .
Dust and pollen filter for soiling and correct installation, refer to DUST AND POLLEN FILTER
Forced air extraction vents in luggage compartment, refer to VENT FRAME, CHECKING .
Function of air flow door, refer to AIR FLOW DOOR MOTOR AND POTENTIOMETER and recirculating air door, refer to RECIRCULATION DOOR MOTOR . Check using Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
Vehicles with automatically regulated A/C system only: signal for detecting windshield wiper operation at Climatronic Control Module -J255-. Check using Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
Check vent temperature of air from evaporator via measured value of Evaporator Vent Temperature Sensor -G263- under the conditions of use specified by customer (or at the following setting)
Setting onA/C Control Module -J301- (vehicles with manually regulated A/C system)
- Temperature setting rotary switch at cold stop, fresh air mode and lowest possible fresh air blower speed set (fresh air blower speed rotary switch at speed 1)
Setting on Climatronic control module (on vehicles with automatically regulated A/C system).
- At the temperature preset Lo for the driver and passenger side, fresh air mode and an average fresh air blower speed of approximately 7 V using Vehicle Diagnosis, Testing and Information System VAS 5051 under "Guided Fault Finding".
The measured value for the evaporator vent temperature sensor is too low (at an ambient temperature of 0 °C, a longer time colder than 0 °C) or too high. although the A/C system is working properly, higher than, for example, 10 °C. Refer to the information regarding the cooling output test COOLING PERFORMANCE - WITH AUTOMATICALLY REGULATED A/C SYSTEM, CHECKING or COOLING PERFORMANCE - WITH MANUALLY REGULATED A/C SYSTEM, CHECKING .
Removing and Checking
Remove the glove compartment and the center console. Refer to Removal and Installation .
Carefully fold back the carpet near the condensation water drain just enough until the drain is visible. Refer to Removal and Installation .
Scheme 4
Make sure the condensation water drain -B- is routed correctly and is not block with dirt or constricted.
Cover area beneath opening -D- for condensation water drain -C-) with absorbent paper (so that any water present does not flow under carpet).
Remove condensation water drain -B-.
Check condensation water drain of A/C unit -A- for soiling (e.g. using a piece of wire).
Check gap between insulation mat installed in center tunnel and valve for condensation water drain -C- above opening -D- in floor panel, there must be a sufficient large gap to allow water condensation to flow out of valve for condensation water drain -C-.
Installing
Installation is carried out in the reverse order, when doing this note the following
Install the condensation water drain -B- so that it is not twisted or pinched.
When installing the carpet, take special care that it does not compress the condensation water drain -B-.
FLUID RESERVOIR
Note. Fluid reservoir -C- and condenser -B- are available in different versions (one or two mounting bolts -D- and -E- for fluid reservoir). The reservoir is attached with two screws. Screw -E- on a front end module -A- without an opening -F- (the introduction of the opening is still open), or make a hole if the condenser is being replaced (diameter approximately 14 mm). Be careful not to damage the radiator and/or the condenser when drilling. The removed reservoir contains refrigerant oil that must be returned to the refrigerant circuit (with the new reservoir). Refer to RECEIVER OR ACCUMULATOR, REPLACING WITHOUT FLUSHING REFRIGERANT CIRCUIT . Adjustment of oil quantity depends on nature of complaint. If the reservoir is damaged, for example, due to a crash (not refrigerant has leaked out and no dirt or moisture has gotten into the refrigerant circuit), then drain the refrigerant out of the removed reservoir and fill the circuit plus 10 cm 3 so that the refrigerant circuit can be serviced. Refer to Removal and Installation . If an undefined amount of refrigerant oil escaped or dirt and moisture entered the system, refrigerant circuit must be cleaned. Refer to DRAINING REFRIGERANT CIRCUIT and refer to EVACUATING REFRIGERANT CIRCUIT . The reservoir may be attached to or integrated in the condenser, depending on the version of the condenser. Replace the dryer cartridge on a condenser that has an integrated reservoir, refer to DRYER CARTRIDGE .
Removing
Evacuate the refrigerant circuit, refer to EVACUATING REFRIGERANT CIRCUIT and refer to DRAINING REFRIGERANT CIRCUIT .
Remove front bumper. Refer to Removal and Installation .
Remove bolts -D- and -E- (bolt -E- not always present), tightening torque 10 Nm.
Scheme 5
Remove bolts -B- (tightening torque 10 Nm).
Scheme 6
Slide bracket -C- out of mount of condenser -E- downward -arrows-.
Remove the reservoir -D- from the condenser -E- -arrow-.
Seal open connections (against dirt and moisture penetration).
Installing
Note. There are different versions of the condenser and bracket -C- depending on the production time period. The bracket was changed from a metal one to the plastic one in MY 2006. It is held on by clips. Fluid reservoir -C- and condenser -B- is available in different versions. Reservoirs with only one O-ring were being installed at the start of production -A- and -B-. In MY 2005 as a running change, reservoirs, that had two seals on the connections, were installed. One seal -B- and one O-ring -C-.
Installation is carried out in the reverse order, when doing this note the following
Before installing fluid reservoir, refer to Removal and Installation .
Clean the contact surface on the condenser -C-.
Scheme 7
Replace O-ring seals -A- and -B-, refer to REFRIGERANT CIRCUIT O-RINGS .
Replace seals -B- and O-ring seals -C-.
Scheme 8
Place fluid reservoir -A- on condenser and tighten bolts.
Note. Coat the O-ring with refrigerant oil before installing. Refer to REFRIGERANT CIRCUIT O-RINGS . Check O-ring seals for correct allocation and proper seating in grooves of respective mount. Keep the reservoir sealed as long as possible and remove the caps just before installing it. The reservoir has a dryer cartridge, which will absorb moisture if the reservoir is opened for a short time. This will make it then unusable.
Evacuate and charge refrigerant circuit. Refer to EVACUATING REFRIGERANT CIRCUIT and refer to DRAINING REFRIGERANT CIRCUIT .
Operate the A/C system after filling the refrigerant circuit, refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .
Note. Note the information regarding operating the A/C system after filling, refer to CHARGING REFRIGERANT .