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). Transfer the vehicle to a workshop that has the necessary tools and equipment and where the work can be performed by qualified personnel. Refer to General, Technical Data (A/C Service Station).
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 discharging the air conditioner, disconnect harness connector from A/C Compressor Regulator Valve -N280- or from the High Pressure Sensor -G65-.
Reason
The A/C compressor regulator valve -N280- 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).
CONDENSATION WATER DRAIN HOSE, CHECKING
Note. Only one condensation water drain hose is installed in this vehicle. On vehicles with heating (without A/C system), a sealing plug is installed to seal the opening on the body center tunnel (no condensation water hose is present). There is no valve and no door at the end of the condensation water hose -C-.
- For complaints of moisture in passenger compartment, check the following as well as condensation water drain
Plenum chamber water drain. Refer to PLENUM CHAMBER WATER DRAIN, CHECKING AND CLEANING .
Plenum chamber cover and cover for fresh air intake housing for correct installation and damage. Refer to FRESH 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 PASSENGER COMPARTMENT FORCED AIR EXTRACTION, CHECKING .
Activation and function of back pressure door. Refer to AIR FLOW DOOR MOTOR -V71-, FUNCTION and recirculating air door RECIRCULATION DOOR MOTOR -V113 and Vehicle diagnosis, testing and information system VAS5051B under "Guided Fault Finding".
- Also, if there is a complaint about moisture in the passenger compartment that only occurs when the is A/C compressor is switched on and under certain environmental conditions, check the output temperature of air from the evaporator usingVehicle diagnosis, testing and information system VAS5051B under "Guided Fault Finding".
Guided Fault Finding, in "read measured values block", select the measured value for evaporator vent temperature sensor -G263-.
Check output temperature of air at evaporator under conditions reported by customer or at the following setting on the Climatronic control module -J255-, "Auto" operating mode, A/C compressor switched on (control light in A/C button lights up), temperature setting "Cold", middle fresh air blower speed at a voltage of approximately 7 volts on the Fresh Air Blower -V2-, fresh air mode (indicator light "recirculation button" does not light up) and open instrument panel vents, the air vent temperature at the evaporator.
If the evaporator vent temperature sensor -G263- measured value is too low (colder than 0 °C for a long period of time when the ambient temperature is above 0 °C) or too high (even though the A/C is working correctly, for example: higher than 10 °C), correct the cause for the difference. Follow the procedure for checking the cooling output. Refer to A/C UNIT, CHECKING COOLING OUTPUT .
Condensation water hose, removing, checking
Remove left and right center console trim and front center console. Refer to Removal and Installation .
Carefully fold back the carpet near the condensate drain hose just enough until the drain is visible. Refer to Removal and Installation .
Scheme 2
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 the distance between the insulation mat installed in the center tunnel and the end of the drain hose -B - for the condensation water -C- above the opening -D- in the floor panel. There must be enough distance so that the water can drain out of the hose -C-.
Installing
Installation is carried out in the reverse order while observing 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-.
PLENUM CHAMBER WATER DRAIN, CHECKING AND CLEANING
Preparation
Scheme 3
Remove wiper arms. Refer to [For transmission(s) 02E] Removal and Installation .
Remove the rubber seal -1- and remove plenum chamber cover -2- by carefully pulling it off retainers on windshield. Refer to Removal and Installation .
Checking
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 A/C unit and is blown by the Fresh Air Blower -V2- onto the evaporator together with the air conveyed. If both water grommets -B- in 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. The water drain grommets -B- are attached from the top into the openings in the mounts close to the suspension strut tower.
Cleaning
Perform the preliminary work.
Clean deposits (leaves, pine needles) and other contaminants from left and right water drains -A- and plenum chamber.
Removing
Perform the preliminary work.
Remove the grommets -B- from the openings for the water drain opening -A- in the mount.
Installing
Install the grommets -B- from above into water drain openings -A- in the mount.
Check the grommets -B- after installing to make sure they function correctly.
Install all removed components again in reverse order.
FLUID RESERVOIR
Does not apply to condensers, which have an attached reservoir.
Note. There are different versions of the fluid reservoir and condenser, ensure correct allocation. The reservoir may be attached to or integrated in the condenser, depending on the version of the condenser. If the condenser has an integrated reservoir, replace the dryer cartridge. Refer to DRYER CARTRIDGE . A different version condenser will be installed on 5 cylinder engines, as opposed to vehicles with a 4 cylinder engine. This condenser -A- has an integrated reservoir -B-. This reservoir -B- has a dryer cartridge installed in it, which currently is not available as a replacement part. Therefore, it may be necessary to replace the complete condenser if there is a complaint about this vehicle. Refer to DRYER CARTRIDGE Removal and Installation . Dryer cartridge (on a condenser with an integrated fluid reservoir), removing and installing, refer to DRYER CARTRIDGE .
- The removed reservoir contains refrigerant oil that must be returned to the refrigerant circuit (with the new reservoir). Refer to «Removal and Installation»(ref-505568-S11263489892012100100000) . Adjustment of oil quantity depends on nature of complaint.
If for example the fluid reservoir was damaged due to a vehicle accident (no refrigerant leaked out, no moisture and no dirt penetrated into refrigerant circuit), let refrigerant oil flow out of the removed fluid reservoir and add the drained quantity of refrigerant oil plus 10 cm 3 of fresh refrigerant oil to the refrigerant circuit (for example, condenser), this services the refrigerant circuit without extensive repair work. Refer to Removal and Installation .
If a certain amount of refrigerant oil has leaked due to an accident or contaminants or moisture has entered the refrigerant circuit, circuit must be flushed. Refer to REMOVAL AND INSTALLATION (Refrigerant Circuit and Components).
Removing
Switch off ignition.
Discharge refrigerant circuit. Refer to Description and Operation (A/C Service Station).
Remove the front bumper cover. Refer to Removal and Installation .
Remove bolts -E-.
Scheme 4
Remove bolt -B- and remove bracket -C- downward.
Pull fluid reservoir -D- upward out of condenser -A- -arrow
Note. Seal open connections on reservoir and condenser with suitable caps (to prevent dirt and moisture from entering).
Installing
Note. There are different versions of the condenser and bracket -C- depending on the production time period. As a running change in MY 2007, the mounting was changed from a metal bracket attached by screws to a plastic bracket held in place by a clip.
- Tightening specification: Bolts for securing fluid reservoir on condenser - 10 Nm.
Installation is done is reverse order, observe the following
Note. Coat the O-ring seals lightly with refrigerant oil prior to installation. Refer to REFRIGERANT CIRCUIT O-RINGS . Check O-ring seals for proper seating in grooves -arrows- on respective mount. Keep fluid reservoir closed as long as possible; do not remove caps until just before installing. Fluid reservoir contains a dryer cartridge which will become saturated with moisture in a short time if accumulator is left open. This makes the accumulator unusable.
Clean contact surface of condenser -D-.
Scheme 5
Replace seals -B- and O-ring seals -C-. Version.
Place fluid reservoir -A- on condenser and tighten bolts.
Install front bumper cover. Refer to Removal and Installation .
Discharge and fill the refrigerant circuit. Refer to Description and Operation (A/C Service Station).
Install remaining components.
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 Description and Operation (A/C Service Station).