Climate System: Other Saab 9-3 II

Filling

1. Remove the protective covers from the high and low-pressure pipes.
2. Attach the blue hose to the low-pressure pipe. Connect the red hose to the high-pressure pipe.
3. The quick couplings are designed as so-called Schrader valves. Connection is therefore done in two steps: Fit the quick coupling to the service connection. Turn the handle clockwise, so that the valve opens and the refrigerant can pass through the connection.
4. For manual and semiautomatic filling: Fill with compressor oil and tracing agent. See «FILLING AND ADJUSTING COMPRESSOR OIL»(ref-275884-S16316339272007122900000) .
5. For fully automatic filling: Fill with compressor oil and tracing agent as described in the machine's instructions.
6. Begin filling the systems. Follow the instructions for the machine.
7. Close the cocks and disconnect the machine.
8. Fit the service valves on the high-pressure and low-pressure pipes.

A/C system leakage tracing

The refrigerant contains a leakage tracing matter in the form of a tracing agent. The tracing agent dye is in the form of a tablet in the receiver. The tracing agent is dissolved in the compressor oil and spreads throughout the refrigerant system. The self-illuminated yellow color makes it possible to detect the smallest of leaks in the refrigerant system.

When refrigerant and compressor oil are drained, tracing agent is drained as well. When compressor oil is filled, an amount of tracing agent is added to make it easier to check for leaks. This is not the case if a new receiver is mounted as it already contains tracing agent.

Identification of the tracing agent requires use of an UV lamp and special glasses. The refrigerant system is illuminated with the UV lamp. The special glasses make leaking refrigerant visible due to the self-illuminating yellow color.

Note. When using the UV lamp and special glasses, pure engine oil in the form of a drop has a similar florescent effect as signal color.

Filling and adjusting the compressor oil

The A/C system is filled with 120 ml (B284 and Z18) or 135 ml (Z19 and B207) compressor oil. A certain amount of compressor oil is always lost when emptying refrigerant and changing components. This amount must be topped up again to maintain the function of the system.

Filling of compressor oil should be done on the high pressure side or through the oil plug.

When refrigerant and compressor oil are drained, tracing agent is drained as well. When compressor oil is filled, an amount of tracing agent is added to make it easier to check for leaks. This is not the case if a new receiver is mounted as it already contains tracing agent.

For information about which compressor oil should be used, see COMPRESSOR (170) .

The table below shows how much compressor oil is lost in connection with different types of work on the A/C system

COMPRESSOR OIL SPECIFICATION

Conditions

The following conditions must be satisfied

1. Door, windows and the bonnet must be closed.
2. All dashboard vents should be open.
3. The engine speed should be 1500-2000 r/min
4. The ambient temperature should be 20-25°C.

A/C SYSTEM REFERENCE

Functionality check of the A/C system's pressure sensor

1. Connect the diagnostic tool
2. Remove the connector from the Fan Variant.
3. Shut the bonnet until the catch locks. WARNING: Operating with the diagnostic tool must be done from inside the cabin for safety reasons. IMPORTANT: Ensure the engine is cold before starting the test.
4. Turn ON the ignition.
5. Read the A/C pressure by, via the diagnostic tool, selecting 9-3 (9440), Body, Heating, Ventilation and A/C, Air Conditioning. Select Read Values
6. Start the engine. Regulate to max fan speed (ventilation fan), max. heating and distribution mode VENT and RECIRC. NOTE: The pressure should be measured in absolute pressure, bar
7. Await the pressure build up. For approved operation the pressure build up should cease at 27 bar, i.e. the compressor switches off. The pressure build up should automatically start again when the pressure drops below 22 bar, i.e. the compressor switches on. WARNING: If the pressure exceeds 30 bar or if the engine coolant temperature is too high, turn off the engine!
8. With incorrect AC operation, read Fault diagnostics strategy for electronic systems. If the engine stops due to too high coolant temperature, repeat from point 6 to the indication on the pressure sensor's breaking limit is reached.
9. With approved operation, turn off the engine.
10. Turn ON the ignition. Allow the pressure to drop to 20 bar.
11. Open the bonnet. Connect the connector to the fan variant.
12. Note in the report the read values for the compressor's cut-in and turn-off pressure. Reset the car and check the A/C operation.

Scheme 65

Scheme 66

Scheme 67

1. Put the seat in its rearmost position.
2. Remove the glow box's lower screws.
3. Open the cover to the glove box.
4. Remove the upper screws and the screws inside the glove box.
5. Lift out the glove box
6. Detach the cables for the glove box lighting.
7. On cars with ACC: Remove the cooling hose from the glove box.
8. Remove «SOUND INSULATION PANEL, PASSENGER»(ref-275837-S08591073902007122900000) .
9. Remove the lower air duct and lift out the air duct through the glove box opening.
10. Dismantle the connector for the ventilation fan control.
11. Remove the cooling hose from the clip on the fan housing.
12. Remove the fan's 7 screws.
13. Fold under the clips holding the low section of the fan housing, 3.
14. Pull the fan housing down.
15. Transfer the fan control unit if the fan is to be replaced.

Scheme 68

Scheme 69

Scheme 70

1. Reposition the fan housing. The groove should grip the flange on the heating and ventilation unit.
2. Insert the clips holding the lower section of the fan housing.
3. Fit the fans 7 screws.
4. On cars with ACC Fit the cooling hose to the heating and ventilation unit.
5. Connect the ventilation fan control's connector.
6. Fit the lower air duct.
7. Fit «SOUND INSULATION PANEL, PASSENGER»(ref-275837-S08591073902007122900000) .
8. Fit the connector for the floor lighting
9. On cars with ACC: Fit the cooling hose in the clip on the fan housing and connect the hose to the glove box.
10. Connect the cables to the glove box lighting.
11. Insert the glove box into position.
12. Fit the screws inside the glove box and the upper screws to the glove box.
13. Close the cover to the glove box.
14. Fit the glove box lower screws.

Climate control unit

Evaporator

Scheme 71

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Scheme 78

1. Drain the A/C system. See «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
2. Dismantle the cover on the windscreen wipers and dismantle the windscreen wipers. Use the puller «85 80 144 PULLER, WINDSCREEN WIPER ARM»(ref-275884-S24533917022007122900000) .
3. Remove «BULKHEAD COVER»(ref-275838-S29414109442007122900000) .
4. Dismantle «WINDSCREEN WIPER ASSEMBLY»(ref-275863-S41261808992007122900000) .
5. Lift out the air filter.
6. Dismantle the air filter housing.
7. Dismantle the high and low pressure pipe's PAD connection from the expansion valve. Plug the openings.
8. Dismantle the expansion valve.
9. Dismantle the expansion valve's rubber seal and the foam seal.
10. Dismantle the locking clasp holding the high and low pressure pipes on the heating and ventilation unit.
11. Remove «GLOVE BOX»(ref-275837-S35412718882007122900000) .
12. Dismantle the floor console's front side panel on the passenger side.
13. Remove «SOUND INSULATION PANEL, PASSENGER»(ref-275837-S08591073902007122900000) .
14. Dismantle the air duct for the floor vent.
15. Dismantle the connector from the ventilation fan control.
16. Dismantle the connector from the recirculation motor and the hose from the clips on the fan housing.
17. Dismantle the top and bottom sections of the fan unit.
18. Dismantle the evaporator's cover.
19. Carefully pull out the evaporator.

Scheme 79

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Scheme 86

1. Adjust the oil quantity in the A/C system. See «FILLING AND ADJUSTING THE COMPRESSOR OIL»(ref-275884-S16316339272007122900000) .
2. Carefully slide in the evaporator. Take care so that the foam seal aligns correctly.
3. Fit the evaporator's cover.
4. Fit the top and bottom sections of the fan unit.
5. Fit the clip that holds the hose on the fan housing. Connect the recirculation motor's connector.
6. Connect the connector to the fresh-air fan control.
7. Fit the air duct for the floor vent.
8. Fit «SOUND INSULATION PANEL, PASSENGER»(ref-275837-S08591073902007122900000) .
9. Fit the floor console's front side panel on the passenger side.
10. Fit «GLOVE BOX»(ref-275837-S35412718882007122900000) .
11. Fit the locking clasp holding the high and low pressure pipes on the heating and ventilation unit.
12. Fit the expansion valve's foam seal and rubber seal.
13. Fit the expansion valve. Tightening torque 15 Nm (lbf ft)
14. Replace the sealing washer and fit the high and low pressure pipe's PAD connection to the expansion valve. Tightening torque 15 Nm (11 lbf ft)
15. Fit the air filter housing.
16. Fit the air filter.
17. Dismantle «WINDSCREEN WIPER ASSEMBLY»(ref-275863-S41261808992007122900000) .
18. Fit «BULKHEAD COVER»(ref-275838-S29414109442007122900000) .
19. Fit the windscreen wipers Tightening torque 20 Nm (15 lbf ft)
20. Vacuum pump and fill the A/C system. See «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
21. Check the performance of the A/C system. See «A/C SYSTEM PERFORMANCE TEST»(ref-275884-S19834467772007122900000) .

Scheme 87

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Scheme 94

1. Place a container under the car and drain the coolant from the cooling system.
2. Dismantle the pipe from the heat exchanger by pulling up the clasp and pulling the pipe straight forwards.
3. Place a container under the car. Hold one of the pipes with a cloth. Blow compressed air into the other pipe so that the heat exchanger is drained of coolant.
4. Remove «GLOVE BOX»(ref-275837-S35412718882007122900000) .
5. Dismantle the floor console's front side panel on the passenger side.
6. Dismantle «SOUND INSULATION PANEL, PASSENGER»(ref-275837-S08591073902007122900000) .
7. Dismantle the ACC module or the MCC module.
8. Remove «ASHTRAY»(ref-275837-S04443275152007122900000) .
9. Remove the dashboard's side cover and the passenger side's A-pillar trim.
10. Dismantle the nuts holding the dashboard on the passenger side.
11. Dismantle the nuts holding the dashboard.
12. Remove the heat exchanger's cover.
13. Dismantle the pipe clamps from the heat exchanger.
14. Pull the pipes out from the heat exchanger.
15. Carefully pull out the dashboard on the passenger side. Carefully pull out the heat exchanger.

Scheme 95

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Scheme 101

Scheme 102

1. Replace the O-rings. Insert the heat exchanger into position.
2. Carefully insert the dashboard into position on the passenger side.
3. Fit the pipes onto the heat exchanger and fit the pipe clamps.
4. Fit the heat exchanger's cover.
5. Fit the nuts that hold the center of the dashboard.
6. Fit the nuts holding the dashboard on the passenger side.
7. Fit the dashboard's side cover and the passenger side's A-pillar trim.
8. Fit «ASHTRAY»(ref-275837-S04443275152007122900000) .
9. Fit the ACC module or the MCC module.
10. Fit «SOUND INSULATION PANEL, PASSENGER»(ref-275837-S08591073902007122900000) .
11. Fit the floor console's front side panel on the passenger side.
12. Refit «GLOVE BOX»(ref-275837-S35412718882007122900000) .
13. Fit the pipes onto the heat exchanger.
14. Fill the cooling system with coolant and «BLEEDING THE COOLING SYSTEM»(ref-275852-S41098468482007122900000) .

Evaporator's high and low-pressure pipes, B207

Scheme 103

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Scheme 107

1. Drain the refrigerant from the system. See «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
2. Remove the windscreen wipers, use «85 80 144 PULLER, WINDSCREEN WIPER ARM»(ref-275884-S24533917022007122900000) .
3. Remove «BULKHEAD COVER»(ref-275838-S29414109442007122900000) .
4. RHD: Remove «WINDSCREEN WIPER ASSEMBLY»(ref-275863-S41261808992007122900000) .
5. LHD: Remove the fresh-air filter and fresh-air filter housing.
6. Remove the hose between the turbo inlet pipe and the turbo. Remove the mass air flow sensor connector.
7. Remove the cover from the air filter housing and take out the filter.
8. Dismantle the lower part of the air filter housing. Press out the intake manifold so that it becomes loose before the air filter housing is lifted out.
9. Dismantle the manifold absolute pressure sensor's connector.
10. Dismantle the high and low pressure pipes' PAD connections from the expansion valve. Plug the openings.
11. Dismantle the high and low pressure pipes from the PAD connection near the right-hand front structural member. Plug the openings.
12. Dismantle the high and low pressure pipes from the clips and lift out the pipes.

Scheme 108

Scheme 109

Scheme 110

Scheme 111

Scheme 112

1. Adjust the oil quantity in the A/C system. See «FILLING AND ADJUSTING THE COMPRESSOR OIL»(ref-275884-S16316339272007122900000) .
2. Lift in and fit the high and low pressure pipes in the clips. Take care so that the rubber seals by the bulkhead partition space's front partition are fitted correctly.
3. Replace the sealing washers and fit the high and low pressure pipe's PAD connection on the front right structural member. Tightening torque 15 Nm (11 lbf ft)
4. Replace the sealing washers and fit the high and low pressure pipe's PAD connection to the expansion valve. Tightening torque 15 Nm (11 lbf ft)
5. Connect the manifold absolute pressure sensor's connector.
6. Fit the lower part of the air filter housing. Make sure the inlet manifold is positioned correctly.
7. Fit the air filter and the air filter cover.
8. Fit the hose between the intake manifold and the turbo. Plug in the mass air flow sensor connector.
9. LHD: Fit the fresh-air filter and fresh-air filter housing.
10. RHD: Fit «WINDSCREEN WIPER ASSEMBLY»(ref-275863-S41261808992007122900000) .
11. Fit «BULKHEAD COVER»(ref-275838-S29414109442007122900000) .
12. Fit the windscreen wipers Tightening torque 20 Nm (15 lbf ft)
13. Vacuum pump and fill the A/C system with refrigerant. See «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
14. Check the performance of the A/C system. See «A/C SYSTEM PERFORMANCE TEST»(ref-275884-S19834467772007122900000) .

Evaporator high and low pressure pipes, Z19DT/DTH

Scheme 113

Scheme 114

Scheme 115

Scheme 116

1. Drain the refrigerant from the A/C system, see «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
2. Remove the windscreen wipers. Use the puller «85 80 144 PULLER, WINDSCREEN WIPER ARM»(ref-275884-S24533917022007122900000) .
3. Remove «BULKHEAD COVER»(ref-275838-S29414109442007122900000) .
4. RHD: Remove «WINDSCREEN WIPER ASSEMBLY»(ref-275863-S41261808992007122900000) .
5. LHD: Remove the fresh-air filter and fresh-air filter housing.
6. Remove the high and low pressure pipes' PAD connection from the expansion valve. Plug the openings.
7. Remove the hose between the turbo inlet pipe and air filter housing.
8. Unplug the mass air flow sensor connector.
9. Remove the cover from the air filter housing
10. Remove the filter.
11. Dismantle the pressure sensor connector. Exercise care so that the pressure sensor is not damaged.
12. Dismantle the lower part of the air filter housing. Press out the induction manifold so that it becomes loose before the air filter housing is lifted out.
13. Dismantle the high and low pressure pipes' PAD connection by the front right structural member. Plug the openings.
14. Remove the evaporator's high and low pressure pipes from the clips and seals. Lift out the pipes.

Scheme 117

Scheme 118

Scheme 119

Scheme 120

1. Adjust the oil quantity in the A/C system. See «FILLING AND ADJUSTING THE COMPRESSOR OIL»(ref-275884-S16316339272007122900000) .
2. Insert the high and low pressure pipes into position, and secure the pipes in the clips and seals.
3. Replace the sealing washers and fit the high and low pressure pipes PAD connection to the expansion valve. Tightening torque 18 Nm (13 lbf ft)
4. Replace the sealing washers and fit the high and low pressure pipes PAD connection by the front right structural member. Tightening torque 15 Nm (11 lbf ft)
5. Fit the lower part of the air filter housing. Make sure the induction manifold is positioned correctly in the lower part of the air filter housing.
6. Fit the air filter and fit the cover to the filter housing.
7. Plug in the pressure sensor's connector.
8. Fit the hose between the intake manifold and turbocharger.
9. Plug in the mass air flow sensor connector.
10. LHD: Fit the fresh-air filter and fresh-air filter housing.
11. RHD: Fit «WINDSCREEN WIPER ASSEMBLY»(ref-275863-S41261808992007122900000) .
12. Fit «BULKHEAD COVER»(ref-275838-S29414109442007122900000) .
13. Fit the windscreen wipers Tightening torque 20 Nm (15 lbf ft)
14. Vacuum pump and fill the A/C system with refrigerant R134a. See «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
15. Test the A/C system. See «A/C SYSTEM PERFORMANCE TEST»(ref-275884-S19834467772007122900000) .

Evaporator's high and low-pressure pipes, B284

Scheme 121

Scheme 122

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Scheme 126

1. Drain the refrigerant from the system. See «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
2. Remove the windscreen wipers, use «85 80 144 PULLER, WINDSCREEN WIPER ARM»(ref-275884-S24533917022007122900000) .
3. Remove «BULKHEAD COVER»(ref-275838-S29414109442007122900000) .
4. RHD: Remove «WINDSCREEN WIPER ASSEMBLY»(ref-275863-S41261808992007122900000) .
5. LHD: Remove the fresh-air filter and fresh-air filter housing.
6. Remove the cover from the air filter housing and take out the filter.
7. Dismantle the lower part of the air filter housing. Press out the intake manifold so that it becomes loose before the air filter housing is lifted out.
8. Detach the mass air flow sensor pipe. IMPORTANT: Take care when releasing the locking mechanism on the connector so as not to damage the connector. Pull the halves straight apart to avoid bending the pins. For further information regarding connectors, refer to «CONNECTORS, HANDLING AND INSPECTION»(ref-275884-S07002899182007122900000) .
9. Dismantle the manifold absolute pressure sensor's connector.
10. Dismantle the high and low pressure pipes' PAD connections from the expansion valve. Plug the openings.
11. Dismantle the high and low pressure pipes from the PAD connection near the right-hand front structural member. Plug the openings.
12. Dismantle the high and low pressure pipes from the clips and lift out the pipes.

Scheme 127

Scheme 128

Scheme 129

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Scheme 132

1. Adjust the oil quantity in the A/C system. See «FILLING AND ADJUSTING THE COMPRESSOR OIL»(ref-275884-S16316339272007122900000) .
2. Lift in and fit the high and low pressure pipes in the clips. Take care so that the rubber seals by the bulkhead partition space's front partition are fitted correctly.
3. Fit the high and low pressure pipe's PAD connection on the front right structural member using a new seal. Tightening torque 15 Nm (11 lbf ft)
4. Fit the high and low pressure pipe's PAD connection to the expansion valve using a new seal. Tightening torque 15 Nm (11 lbf ft) IMPORTANT: Take care when plugging in the connector so as not to damage or press out the pins/sleeves in the connector. For further information regarding connectors, refer to «CONNECTORS, HANDLING AND INSPECTION»(ref-275884-S07002899182007122900000) .
5. Connect the manifold absolute pressure sensor's connector.
6. Attach the mass air flow sensor pipe.
7. Fit the lower part of the air filter housing. Make sure the inlet manifold is positioned correctly.
8. Fit the air filter and the air filter cover.
9. LHD: Fit the fresh-air filter and fresh-air filter housing.
10. RHD: Fit «WINDSCREEN WIPER ASSEMBLY»(ref-275863-S41261808992007122900000) .
11. Fit «BULKHEAD COVER»(ref-275838-S29414109442007122900000) .
12. Fit the windscreen wipers Tightening torque 20 Nm (15 lbf ft)
13. Vacuum pump and fill the A/C system with refrigerant. See «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
14. Check the performance of the A/C system. See «A/C SYSTEM PERFORMANCE TEST»(ref-275884-S19834467772007122900000) .

Condenser

Scheme 133

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Scheme 136

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Scheme 140

1. Put the car on a lift.
2. Drain the refrigerant from the A/C system, see «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
3. Remove the headlamp screws.
4. Remove the bumper's two-stage rivets.
5. Dismantle «UPPER RADIATOR CROSSMEMBER»(ref-275838-S28612485712007122900000) .
6. Raise the car.
7. Remove the lower engine cover.
8. Remove the right hand radiator mounting.
9. Dismantle the condenser's lower PAD connection. Plug the openings.
10. Lower the car.
11. Dismantle the bumper's 3 screws in the right front wheel housing.
12. Carefully pull out the bumper on the right hand side and then move the bumper a little forwards.
13. Dismantle the right «HEADLAMPS»(ref-275862-S26035034062007122900000) .
14. Dismantle the condenser upper PAD connection. Plug the openings.
15. Dismantle the condenser's upper screws.
16. Carefully lift out the condenser.

Scheme 141

Scheme 142

Scheme 143

Scheme 144

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Scheme 149

1. Adjust the oil quantity in the A/C system. See «FILLING AND ADJUSTING THE COMPRESSOR OIL»(ref-275884-S16316339272007122900000) .
2. Insert the condenser into position. Take care so that the lower PAD connection does not catch on the condenser. Make sure the condenser lower mounting is fitted correctly.
3. Fit the condenser's upper screws.
4. Replace the sealing washer and fit the condenser's upper PAD connection. Tightening torque 18 Nm (13 lbf ft)
5. Fit the right hand «HEADLAMPS»(ref-275862-S26035034062007122900000) and its connector.
6. Fit the bumper on the right hand side.
7. Fit the bumper's 3 screws in the right front wheel housing.
8. Raise the car.
9. Replace the sealing washer and fit the condenser's lower PAD connection. Tightening torque 18 Nm (13 lbf ft)
10. Fit the right hand radiator mounting.
11. Fit the lower engine cover.
12. Lower the car.
13. Fit «UPPER RADIATOR CROSSMEMBER»(ref-275838-S28612485712007122900000) .
14. Fit the two-stage rivets on the bumper.
15. Fit the screws on the headlamps
16. Vacuum pump and fill the A/C system with refrigerant. See «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
17. Check the performance of the A/C system. See «A/C SYSTEM PERFORMANCE TEST»(ref-275884-S19834467772007122900000) .

Condenser, B284

Scheme 150

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Scheme 152

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Scheme 154

1. Put the car on a lift.
2. Drain the refrigerant from the A/C system, see «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
3. Raise the car.
4. Remove the spoiler shield.
5. Lower the car.
6. Remove «FRONT BUMPER SHELL»(ref-275838-S30477349582007122900000) .
7. Remove the right side cover.
8. Remove the screws holding the receiver to the radiator.
9. Detach the power steering pipe from the charge air cooler.
10. Remove the nuts from the PAD connections.
11. Dismantle the condenser's upper screws.
12. Lift up the condenser from the lower support. At the same time, pull the PAD connections out of the condenser. Plug the openings.
13. Lower the condenser.

Scheme 155

Scheme 156

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Scheme 159

1. Adjust the oil quantity in the A/C system. See «FILLING AND ADJUSTING THE COMPRESSOR OIL»(ref-275884-S16316339272007122900000) .
2. Fit new seals on the PAD connections.
3. Reposition the condenser. At the same time, attach the PAD connection to the condenser. Fit the condenser to the charge air cooler.
4. Tighten the PAD connection. Tightening torque 18 Nm (13 lbf ft)
5. Fit the screws holding the receiver to the radiator.
6. Fit the right side cover.
7. Fit the power steering pipe to the charge air cooler.
8. Fit «FRONT BUMPER SHELL»(ref-275838-S30477349582007122900000) .
9. Raise the car.
10. Fit the spoiler shield.
11. Lower the car.
12. Vacuum pump and fill the A/C system with refrigerant. See «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
13. Check the performance of the A/C system. See «A/C SYSTEM PERFORMANCE TEST»(ref-275884-S19834467772007122900000) .

Scheme 160

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Scheme 162

1. Drain the refrigerant from the car. See «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
2. Raise the car.
3. Remove the lower engine cover.
4. Remove «DRIVE BELT, AUXILIARIES»(ref-275854-S18106657652007122900000) .
5. Unplug the connector.
6. Remove and plug the pipe connection. Use «82 92 948 PLUGS, A/C SYSTEM, KIT»(ref-275884-S29925890502007122900000) .
7. Remove the A/C compressor.

Scheme 163

Scheme 164

Scheme 165

1. Fill with fluid as described under Filling and adjusting the compressor oil.
2. Fit the A/C compressor. Tightening torque: 24 Nm (18 lbf ft)
3. Fit the pipe connections using new seals. Tightening torque: 18 Nm (13 lbf ft)
4. Plug in the connector.
5. Fit «DRIVE BELT, AUXILIARIES»(ref-275854-S18106657652007122900000) .
6. Fit the lower engine cover.
7. Lower the car.
8. Vacuum pump and fill the A/C system with refrigerant. See «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
9. Running in the compressor to distribute the compressor oil around the system: Activate the A/C and allow it to run for at least 2 minutes at an engine speed of <1350 rpm.
10. Test the A/C system. See «A/C SYSTEM PERFORMANCE TEST»(ref-275884-S19834467772007122900000) .

A/C compressor, B207

Scheme 166

Scheme 167

Scheme 168

Scheme 169

1. Put the car on a lift.
2. Drain the refrigerant from the A/C system, see «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
3. Raise the car. CV: Remove «CHASSIS REINFORCEMENT, FRONT SUBFRAME, CV, PETROL»(ref-275876-S05650643942007122900000) .
4. Remove the lower engine cover.
5. Loosen the 3 plastic screws from the right front wing liner.
6. Release the belt tensioner and take off the multigroove V-belt. Use «83 96 095 RELEASE TOOL, BELT CIRCUIT B207E/L»(ref-275884-S17144776942007122900000) .
7. Dismantle the hose clip from the charge air pipe and fold down the rubber hose.
8. Remove the screws from the mounting that holds the charge air pipe to the oil pan. Carefully move the charge air pipe a little.
9. Dismantle the A/C compressor's connector.
10. Dismantle the PAD connection from the A/C compressor. Plug the openings.
11. Dismantle the screws that hold the A/C compressor and move the compressor down.

Scheme 170

Scheme 171

Scheme 172

1. Adjust the oil quantity in the A/C system. See «FILLING AND ADJUSTING THE COMPRESSOR OIL»(ref-275884-S16316339272007122900000) .
2. Push up and fit the A/C compressor. Tightening torque 24 Nm (18 lbf ft)
3. Remove the plugs, replace the sealing washers and the PAD connection to the A/C compressor. Tightening torque 18 Nm (13 lbf ft)
4. Connect the connector to the A/C compressor.
5. Fit the charge air pipe to the oil pan.
6. Fit the hose and its clamp to the charge air pipe.
7. Fit the multigroove V-belt. Check that it sits correctly.
8. Fit the front right wing liner.
9. Fit the lower engine cover.
10. CV: Fit «CHASSIS REINFORCEMENT, FRONT SUBFRAME, CV, PETROL»(ref-275876-S05650643942007122900000) .
11. Lower the car.
12. Vacuum pump and fill the system with refrigerant. See «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
13. Running in the compressor to distribute the compressor oil around the system: Activate the A/C and allow it to run for at least 2 minutes at an engine speed of <1350 rpm.
14. Test the A/C system. See «A/C SYSTEM PERFORMANCE TEST»(ref-275884-S19834467772007122900000) .

Scheme 173

Scheme 174

Scheme 175

Scheme 176

Scheme 177

Scheme 178

1. Drain the refrigerant from the car. See «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
2. Remove the air filter housing cover.
3. Detach the mass air flow sensor pipe.
4. Remove the engine cover.
5. Remove the upper turbocharger delivery pipe.
6. Remove the upper screws of the turbocharger delivery pipe.
7. Raise the car.
8. Remove the front spoiler shield.
9. Remove secondary air injection pump, B284
10. Detach the turbocharger delivery pipe on the front of the engine from the hose and A/C compressor. Lower the car.
11. Detach the A/C compressor's PAD connection. Plug the openings.
12. Unplug the connector.
13. Remove the upper screw of the A/C compressor.
14. Raise the car.
15. Relieve tension on the belt using a 1/2" articulated handle and life the belt off of the A/C compressor pulley.
16. Remove the A/C compressor.

Scheme 179

Scheme 180

Scheme 181

Scheme 182

Scheme 183

Scheme 184

1. Fill with fluid as described under «FILLING AND ADJUSTING THE COMPRESSOR OIL»(ref-275884-S16316339272007122900000) .
2. Fit the A/C compressor. Insert the lower screws.
3. Lower the car.
4. Fit the upper screw of the A/C compressor. Tightening torque 24 Nm (18 lbf ft)
5. Fit the pipe connections using new seals. Tightening torque 18 Nm (13 lbf ft)
6. Fit the connector.
7. Raise the car.
8. Tighten the A/C compressor's lower screws. Tightening torque 24 Nm (18 lbf ft)
9. Attach the turbocharger delivery pipe to the hose and A/C compressor. Insert the screw.
10. Fit secondary air injection pump, B284.
11. Relieve tension on the belt tensioner and fit the belt.
12. Fit the spoiler shield.
13. Lower the car.
14. Fit the upper screws of the turbocharger delivery pipe.
15. Raise the car.
16. Tighten the turbocharger delivery pipe screw.
17. Lower the car.
18. Fit the upper turbocharger delivery pipe.
19. Fit the engine cover.
20. Attach the mass air flow sensor pipe.
21. Fit the air filter housing cover.
22. Vacuum pump and fill the A/C system with refrigerant. See «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
23. Running in the compressor to distribute the compressor oil around the system: Activate the A/C and allow it to run for at least 2 minutes at an engine speed of <1350 rpm.
24. Test the A/C system. See «A/C SYSTEM PERFORMANCE TEST»(ref-275884-S19834467772007122900000) .

Scheme 185

1. Remove «A/C COMPRESSOR, B284»(ref-275884-S09728937722007122900000)
2. Remove the mounting.

Scheme 186

1. Fit the mounting. Tightening torque 38 Nm (28 lbf ft)
2. Fit «A/C COMPRESSOR, B284»(ref-275884-S09728937722007122900000) .

Receiver, B207

Scheme 187

Scheme 188

Scheme 189

Scheme 190

1. Put the car on a lift.
2. Drain the refrigerant from the A/C system, see «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
3. Remove the upper engine cover.
4. Dismantle the PAD connection from the receiver. Plug the openings.
5. Raise the car.
6. Remove the lower engine cover.
7. Remove the turbocharger hose from the charger air cooler. Move the hose to one side.
8. Loosen the right hand radiator mounting from the subframe.
9. Dismantle the receiver.

Scheme 191

Scheme 192

Scheme 193

Scheme 194

1. Adjust the oil quantity in the A/C system. See «FILLING AND ADJUSTING THE COMPRESSOR OIL»(ref-275884-S16316339272007122900000) .
2. Fit the receiver. Take care so that the receiver pipe aligns correctly in the air panel.
3. Fit the right hand radiator mounting on the subframe.
4. Fit the turbocharger hose on the charge air cooler.
5. Fit the lower engine cover.
6. Lower the car.
7. Remove the plugs, replace the sealing washers and the PAD connection to the receiver. Tightening torque 18 Nm (13 lbf ft)
8. Fit the upper engine cover.
9. Vacuum pump and fill the system with refrigerant. See «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
10. Check the performance of the A/C system. See «A/C SYSTEM PERFORMANCE TEST»(ref-275884-S19834467772007122900000) .

Receiver, Z19DT/DTH

Scheme 195

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

1. Put the car on a lift.
2. Drain the refrigerant from the A/C system, see «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
3. Remove the upper engine cover.
4. Remove the upper hose from the turbocharger pipe.
5. Remove the screw to the turbocharger pipe's upper mounting.
6. Remove the high pressure pipe's PAD connection from the receiver. Plug the openings.
7. Raise the car.
8. Remove the front lower engine cover.
9. Remove the hose from the charge air cooler and turbocharger pipe.
10. Remove the screw from the turbocharger pipe's lower mounting. Move down the turbocharger pipe.
11. Remove the receiver and move it down.

Scheme 201

Scheme 202

Scheme 203

Scheme 204

Scheme 205

Scheme 206

1. Fill the compressor oil. See «FILLING AND ADJUSTING THE COMPRESSOR OIL»(ref-275884-S16316339272007122900000) .
2. Move the receiver up into position and fit it.
3. Move the turbocharger pipe up into position and fit the screw to the turbocharger pipe's lower mounting.
4. Fit the hose to the charge air cooler and turbocharger pipe.
5. Fit the front lower engine cover.
6. Lower the car.
7. Remove the sealing washer and fit the high pressure pipe's PAD connection to the receiver. Tightening torque 18 Nm (13 lbf ft)
8. Fit the screw to the turbocharger pipe's upper mounting.
9. Fit the upper hose to the turbocharger pipe.
10. Fit the upper engine cover.
11. Vacuum pump and fill the A/C system with refrigerant. See «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
12. Check the performance of the A/C system. See «A/C SYSTEM PERFORMANCE TEST»(ref-275884-S19834467772007122900000)

Receiver, B284

Scheme 207

Scheme 208

Scheme 209

Scheme 210

1. Put the car on a lift.
2. Drain the refrigerant from the A/C system, see «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
3. Raise the car.
4. Remove «FRONT SPOILER SHIELD»(ref-275838-S05457380322007122900000) .
5. Remove the right «HEADLAMPS»(ref-275862-S26035034062007122900000) .
6. Remove the right cover.
7. Detach the air cleaner intake pipe.
8. Remove receiver screws.
9. Detach the upper and lower PAD connections from the condenser. Plug the openings.
10. Detach the high pressure pipe's PAD connection from the receiver. Plug the opening.
11. Dismantle the receiver.

Scheme 211

Scheme 212

Scheme 213

Scheme 214

1. Fill the compressor oil. See «FILLING AND ADJUSTING THE COMPRESSOR OIL»(ref-275884-S16316339272007122900000) .
2. Replace the seal and attach the high pressure pipe's PAD connection to the receiver. Tightening torque 18 Nm (13 lbf ft)
3. Attach the PAD connections to the condenser using new seals. Tightening torque 18 Nm (13 lbf ft)
4. Fasten the receiver to the radiator.
5. Attach the air cleaner intake pipe.
6. Fit the right cover.
7. Fit the right «HEADLAMPS»(ref-275862-S26035034062007122900000) .
8. Raise the car.
9. Fit «FRONT SPOILER SHIELD»(ref-275838-S05457380322007122900000) .
10. Lower the car.
11. Vacuum pump and fill the A/C system with refrigerant. See «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
12. Check the performance of the A/C system. See «A/C SYSTEM PERFORMANCE TEST»(ref-275884-S19834467772007122900000)

Compressor's high and low-pressure pipes, B207

Scheme 215

Scheme 216

Scheme 217

Scheme 218

Scheme 219

Scheme 220

Scheme 221

Scheme 222

Scheme 223

1. Put the car on a lift.
2. Drain the refrigerant from the A/C system, see «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
3. Dismantle the upper engine cover.
4. Dismantle the PAD connection from the A/C compressor. Plug the openings.
5. Dismantle the PAD connection from the front right structural member. Plug the openings.
6. Dismantle the two-stage rivets from the bumper, use 84 71 179 removal tool, clips.
7. Raise the car.
8. Dismantle the bumper's 3 screws in the right front wheel housing.
9. Remove the lower engine cover.
10. Carefully pull out the bumper on the right hand side and then move the bumper a little forwards.
11. Lower the car.
12. Dismantle «HEADLAMPS»(ref-275862-S26035034062007122900000) and its connector.
13. Dismantle the fan variant's connector
14. Dismantle the upper PAD connection from the condenser. Plug the openings.
15. Lift out the compressor's high and low pressure pipes.

Scheme 224

Scheme 225

Scheme 226

Scheme 227

Scheme 228

Scheme 229

Scheme 230

Scheme 231

1. Adjust the oil quantity in the A/C system. See «A/C SYSTEM PERFORMANCE TEST»(ref-275884-S19834467772007122900000) .
2. Fit the upper PAD connection to the condenser. Tightening torque 18 Nm (13 lbf ft)
3. Connect the fan variant's connector.
4. Fit the right hand «HEADLAMPS»(ref-275862-S26035034062007122900000) and its connector.
5. Raise the car.
6. Fit the bumper on the right hand side.
7. Fit the lower engine cover.
8. Fit the bumper's 3 screws in the right front wheel housing.
9. Lower the car.
10. Fit the two-stage rivets on the bumper.
11. Replace the sealing washers and fit the PAD connection by the front right structural member. Tightening torque 15 Nm (11 lbf ft)
12. Replace the sealing washer and fit the PAD connection to the A/C compressor. Tightening torque 18 Nm (13 lbf ft)
13. Fit the upper engine cover.
14. Vacuum pump and fill the A/C system with refrigerant. See «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
15. Check the performance of the A/C system. See «A/C SYSTEM PERFORMANCE TEST»(ref-275884-S19834467772007122900000) .

Compressor high and low pressure pipes, Z19DT/DTH

Scheme 232

Scheme 233

Scheme 234

Scheme 235

Scheme 236

Scheme 237

Scheme 238

Scheme 239

Scheme 240

Scheme 241

Scheme 242

1. Put the car on a lift.
2. Drain the refrigerant from the A/C system, see «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
3. Remove the PAD connection from the front right structural member. Loosen the pipe from the clips and lift up the pipe.
4. Raise the car.
5. Remove the front and rear lower engine covers.
6. Remove the high and low pressure pipes' PAD connection from the A/C compressor. Plug the openings.
7. Remove the lower rubber hose from the turbocharger pipe.
8. Remove the screw from the turbocharger pipe's lower mounting.
9. Lower the car.
10. Remove the screws holding the bumper from the right front wing liner.
11. Dismantle the 6 two-stage clips from the top of the bumper.
12. Pull out the right hand side of the bumper a little.
13. Dismantle the right, 3 screws, headlamp and its connector.
14. Remove the screw that holds the headlamp in position.
15. Remove the upper PAD connection from the condenser. Plug the openings.
16. Remove the upper rubber hose from the turbocharger pipe.
17. Remove the screw from the turbocharger pipe's upper mounting. Lift out the turbocharger pipe.
18. Remove the low pressure pipe's clips from the radiator cross member.
19. Fit the hose pinch-off pliers on the hose from the pressure pipe for the power steering.
20. Remove the pressure pipe from the power steering pump.
21. Remove the high and low pressure pipes by first carefully moving out the low pressure pipe's PAD connection through the hole by the radiator core.
22. Move the high pressure pipe down behind the engine's subframe.
23. Raise the car.
24. Carefully coax the low pressure pipe down so that the high and low pressure pipes come behind the subframe.

Scheme 243

Scheme 244

Scheme 245

Scheme 246

Scheme 247

Scheme 248

Scheme 249

Scheme 250

Scheme 251

Scheme 252

Scheme 253

Scheme 254

Scheme 255

1. Fill the compressor oil. See «FILLING AND ADJUSTING THE COMPRESSOR OIL»(ref-275884-S16316339272007122900000) .
2. Fit the high and low pressure pipes by moving the low pressure pipe up behind the subframe.
3. Move the low pressure pipe up to the hole by the radiator core.
4. Lower the car.
5. Carefully insert the high pressure pipe's PAD connection through the hole by the radiator core.
6. Fit the high pressure pipe's PAD connection to the condenser. Tightening torque 18 Nm (13 lbf ft)
7. Change the seal and fit the pressure pipe to the power steering pump. Tightening torque 32 Nm (24 lbf ft)
8. Remove the hose pinch-off pliers from the hose on the pressure pipe to the power steering.
9. Fit the screw that holds the headlamp in position.
10. Connect the right headlamp's connector and fit the headlamp.
11. Insert the right hand side of the bumper into position.
12. Fit the screws on the wing liner for the bumper.
13. Fit the 6 two-stage clips on the top of the bumper.
14. Insert the turbocharger pipe into position, and secure the screw to the turbocharger pipe's upper mounting.
15. Raise the car.
16. Replace the sealing washer and fit high and low pressure pipes' PAD connection to the A/C compressor. Tightening torque 18 Nm (13 lbf ft)
17. Fit the screw to the turbocharger pipe's lower mounting.
18. Fit the lower rubber hose to the turbocharger pipe.
19. Fit the lower engine covers.
20. Lower the car.
21. Secure the high and low pressure pipes in their clips. Replace the sealing washer and fit high and low pressure pipes' PAD connection to the front right structural member. Tightening torque 15 Nm (11 lbf ft)
22. Tighten the screws on the turbocharger pipe's upper mounting.
23. Fit the upper rubber hose to the turbocharger pipe.
24. Fit the low pressure pipe's clips to the radiator member.
25. «BLEEDING THE POWER STEERING SYSTEM»(ref-275874-S14538374012007122900000) .
26. Vacuum pump and fill with refrigerant. See «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
27. Check the performance of the A/C system. See «A/C SYSTEM PERFORMANCE TEST»(ref-275884-S19834467772007122900000) .

Compressor's high and low-pressure pipes, B284

Scheme 256

Scheme 257

Scheme 258

Scheme 259

Scheme 260

Scheme 261

Scheme 262

Scheme 263

1. Drain the refrigerant from the A/C system, see «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
2. Remove the right headlamp.
3. Remove the upper engine cover.
4. Remove the air filter housing cover.
5. Detach the mass air flow sensor pipe.
6. Remove the upper turbocharger delivery pipe.
7. Remove the upper screws of the turbocharger delivery pipe.
8. Raise the car.
9. Detach the turbocharger delivery pipe from the hose and A/C compressor.
10. Lower the car.
11. Remove the battery cover.
12. Detach the battery coolant pipe.
13. Remove the upper mountings of the radiator core.
14. Press the radiator core forward and remove the front turbocharger delivery pipe.
15. Dismantle PAD connection on the front right structural member. Plug the openings.
16. Remove the plastic clip. Detach the upper PAD connection on the condenser. Plug the openings.
17. Detach the PAD connection on the receiver. Detach the hose.
18. Detach the PAD connection from the compressor. Plug the openings.
19. Detach the compressor's high and low pressure pipes. Remove them downward.

Scheme 264

Scheme 265

Scheme 266

Scheme 267

Scheme 268

Scheme 269

Scheme 270

Scheme 271

1. Adjust the oil quantity in the A/C system. See «FILLING AND ADJUSTING THE COMPRESSOR OIL»(ref-275884-S16316339272007122900000) .
2. Position the compressor's high and low pressure pipes. Mount them from underneath.
3. Attach the compressor's high and low pressure pipes to the PAD connection on the compressor. Use a new seal.
4. Fit the receiver's high pressure pipe to the receiver using a new seal. Tightening torque 18 Nm (13 lbf ft)
5. Attach the upper PAD connector to the condenser using a new seal. Tightening torque 15 Nm (11 lbf ft)
6. Fit the plastic clips to the pipes. Fit the receiver high pressure pipe to the PAD connection on the front right structural member using a new seal. Tightening torque, PAD connection 15 Nm (11 lbf ft)
7. Press the radiator core forward and fit the front turbocharger delivery pipe. Insert the screws.
8. Fit the upper mountings of the radiator core.
9. Attach the battery coolant pipe.
10. Fit the battery cover.
11. Raise the car.
12. Attach the turbocharger delivery pipe on the front of the engine.
13. Lower the car.
14. Tighten the upper screws of the turbocharger delivery pipe.
15. Fit the upper turbocharger delivery pipe.
16. Attach the mass air flow sensor pipe.
17. Fit the air filter housing cover.
18. Fit the upper engine cover.
19. Fit «HEADLAMPS»(ref-275862-S26035034062007122900000) .
20. Vacuum pump and fill the A/C system with refrigerant. See «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
21. Test the A/C system. See «A/C SYSTEM PERFORMANCE TEST»(ref-275884-S19834467772007122900000)

Scheme 272

1. Dismantle the manifold absolute pressure sensor's connector.
2. Dismantle the manifold absolute pressure sensor.

Scheme 273

1. Fit the manifold absolute pressure sensor.
2. Connect the manifold absolute pressure sensor's connector.

Scheme 274

Scheme 275

Scheme 276

1. Remove the cover from the air filter housing and take out the filter.
2. Dismantle the lower part of the air filter housing. Press out the intake manifold so that it becomes loose before the air filter housing is lifted out.
3. Dismantle the manifold absolute pressure sensor's connector.
4. Dismantle the manifold absolute pressure sensor.

Scheme 277

Scheme 278

Scheme 279

1. Fit the manifold absolute pressure sensor.
2. Connect the manifold absolute pressure sensor's connector.
3. Fit the lower part of the air filter housing. Make sure the inlet manifold is positioned correctly.
4. Fit the air filter and the air filter cover.

Receiver high pressure pipe, Z19DT/DTH

Scheme 280

Scheme 281

Scheme 282

Scheme 283

1. Put the car on a lift.
2. Drain the refrigerant from the A/C system, see «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
3. Raise the car.
4. Remove the front lower engine cover.
5. Remove the rubber hose from the lower part of the turbocharger pipe.
6. Remove the screw from the turbocharger pipe's lower mounting.
7. Lower the car.
8. Remove the rubber hose from the upper part of the turbocharger pipe and move the hose to one side.
9. Remove the screw from the turbocharger pipe's upper mounting and lift out the turbocharger pipe.
10. Remove the screw from the clip that holds the A/C compressor low pressure pipe on the radiator member.
11. Detach the PAD connection on the front right structural member. Plug the openings.
12. Remove the PAD connection from the receiver's high pressure pipe. Plug the openings.
13. Remove the receiver's high pressure pipe.

Scheme 284

Scheme 285

Scheme 286

Scheme 287

1. Adjust the oil quantity in the A/C system. See «FILLING AND ADJUSTING THE COMPRESSOR OIL»(ref-275884-S16316339272007122900000) .
2. Insert the receiver's high pressure pipe into position.
3. Replace the sealing washer and fit the PAD connection for the high pressure pipe on the receiver. Tightening torque 18 Nm (13 lbf ft)
4. Lift the turbocharger pipe into position and insert the screw for the upper mounting.
5. Raise the car.
6. Fit the screw for the turbocharger pipe's lower mounting.
7. Fit the rubber hose to the lower part of the turbocharger pipe.
8. Fit the front lower engine cover.
9. Lower the car.
10. Tight the screw on the turbocharger's pipes upper mounting.
11. Fit the rubber hose to the upper part of the turbocharger pipe.
12. Replace the sealing washer and fit the PAD connection for the receiver high pressure pipe on the front right structural member. Tightening torque 15 Nm (11 lbf ft)
13. Fit the screw to the clip that holds the A/C compressor's low pressure pipe on the radiator member.
14. Vacuum pump and fill the A/C system with refrigerant. See «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
15. Test the A/C system. See «A/C SYSTEM PERFORMANCE TEST»(ref-275884-S19834467772007122900000) .

Receiver, high pressure pipe, B284

Scheme 288

Scheme 289

Scheme 290

Scheme 291

1. Drain the refrigerant from the A/C system, see «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
2. Remove the air filter housing cover.
3. Detach the mass air flow sensor pipe.
4. Remove the right «HEADLAMPS»(ref-275862-S26035034062007122900000) .
5. Detach the upper PAD connection on the condenser. Plug the openings.
6. Dismantle the PAD connection from the receiver. Plug the openings.
7. Dismantle PAD connection on the front right structural member. Plug the openings.
8. Lift out the receiver's high pressure pipe.

Scheme 292

Scheme 293

Scheme 294

Scheme 295

Scheme 296

1. Adjust the oil quantity in the A/C system. See «FILLING AND ADJUSTING THE COMPRESSOR OIL»(ref-275884-S16316339272007122900000) .
2. Insert the receiver's high pressure pipe into position.
3. Fit the receiver's high pressure pipe to the receiver using a new seal. Tightening torque 18 Nm (13 lbf ft)
4. Fit the receiver high pressure pipe to the PAD connection on the front right structural member using a new seal. Tightening torque 15 Nm (11 lbf ft)
5. Attach the upper PAD connector to the condenser using a new seal. Tightening torque 15 Nm (13 lbf ft)
6. Fit «HEADLAMPS»(ref-275862-S26035034062007122900000) .
7. Attach the mass air flow sensor pipe.
8. Fit the air filter housing cover.
9. Vacuum pump and fill the A/C system with refrigerant. See «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
10. Test the A/C system. See «A/C SYSTEM PERFORMANCE TEST»(ref-275884-S19834467772007122900000)

Electromagnetic clutch, A/C compressor

Scheme 297

1. Remove «A/C COMPRESSOR, B207»(ref-275884-S34254569902007122900000) , «A/C COMPRESSOR, Z19»(ref-275884-S23834570182007122900000) or «A/C COMPRESSOR, B284»(ref-275884-S09728937722007122900000)
2. Dismantle the compressor's ground cable and the locking plate from the compressor housing.
3. Dismantle the driver by using a 14 mm spanner and a suitable support. Pull it out of the shaft.
4. Dismantle the circlip that holds the belt pulley and lift off the belt pulley. NOTE: If the belt pulley jams, knock the edge using a plastic mallet so that it becomes loose.
5. Dismantle the circlip holding the magnet winding and lift off the magnet winding. NOTE: If the magnet winding jams, carefully pry using a screwdriver so that the guide pin loosens from the slot.

Scheme 298

1. Position the magnet winding in position with the guide pin in the slot on the compressor housing. Check that the cables are routed correctly. Fit the circlip.
2. Fit the belt pulley and fit the circlip.
3. Put the shim in the driver and position the driver on the shaft. Tighten the screw.
4. Measure the play between the driver and the belt pulley using a feeler gauge. The play should be 0.5 ± 0.15 mm. Adjust the play if necessary but changing the shim on the compressor shaft. NOTE: The top of the feeler gauge must be angled to measure the play.
5. Fit the compressor's ground cable and locking plate on the compressor housing.
6. Fit «A/C COMPRESSOR, B207»(ref-275884-S34254569902007122900000) , «A/C COMPRESSOR, Z19»(ref-275884-S23834570182007122900000) or «A/C COMPRESSOR, B284»(ref-275884-S09728937722007122900000)

Service position, windscreen wipers

1. Turn ON the ignition switch
2. Turn the ignition key to LOCK
3. Move the lever downwards until the windscreen wipers are in the vertical position.

To fit

1. Fit the compressor solenoid coil: Instructions: Fit the catch (3) on the compressor solenoid coil in the recess of the housing (4) Position the solenoid coil Fit the circlip (2) Fit the cable kit (1)
2. Fit the compressor belt pulley see method description, «COMPRESSOR BELT PULLEY, TO REMOVE AND TO FIT, Z18XE»(ref-275884-S05642034902007122900000)

Scheme 299

1. Air conditioning, draining see method description «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
2. Remove the refrigerant line as follows: IMPORTANT: Release any residual pressure in the installation by opening the refrigerant system, close lines and connections. Unscrew bolt (1) Pull away block joint, refrigerant line (2)
3. Remove the compressor's pressure relief valve: Unscrew the compressor pressure relief valve (3)

Scheme 300

1. Fit the compressor's pressure relief valve: Use a new sealing ring Instructions: Moisten the sealing ring with mineral oil (part no. 90 001 8100, catalogue no. 19 49 870) before fitting. Tighten the compressor's pressure relief valve (10 Nm)
2. Fit the refrigerant line as follows: Change the seal (2) Attach the refrigerant line (1) Tighten the bolt (20 Nm)
3. Air conditioning, draining and filling see method description «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .

Scheme 301

1. Automatic climate control ACC (216)
2. MCC controls (504)
3. Fresh-air filter (Particle filter)
4. Combination filter (Optional)
5. Ventilation fan (36)
6. Heat exchanger
7. Motor, recirculation flap (38)
8. Motor, air mixing damper (222)
9. Motor, air distribution damper (221)
10. Evaporator
11. Expansion valve

A/C system

1. Compressor, A/C(170)
2. Condenser
3. Pressure sensor A/C(620)
4. Receiver
5. Expansion valve
6. Evaporator
7. A/C compressor relay (156)
8. Motor, ventilation fan (36)
9. Direct current motor, air recirculation flap (38)

Cars with ACC

The heating and ventilation unit and the glove box are connected with a hose and controls located inside the glove box in order to allow cool air to enter the glove box and cool its contents.

Scheme 302

1. Fresh-air filter (Particle filter)
2. Combination filter (Optional)
3. Ventilation fan (36)
4. Heat exchanger
5. Motor, recirculation flap (38)
6. Motor, air mixing damper (222)
7. Motor, air distribution damper (221)
8. Evaporator
9. Expansion valve

Scheme 303

1. Compressor, A/C (170)
2. Condenser
3. Pressure sensor A/C(620)
4. Receiver
5. Expansion valve
6. Evaporator
7. A/C compressor relay (156)

P-bus and I-bus

Cars with MCC: The system has no bus communication. See diagnostics, MCC .

Cars with ACC: The system is connected to the I-bus.

Scheme 304

Climate zones

Cars with MCC maintain the same climate zone for the entire cabin. Cars with ACC provide climate zones for which the driver and front seat passenger can maintain separate air temperatures. This is accomplished with two air mixing dampers, one for the driver zone and one for the front seat passenger zone. The passengers in the rear seat receive an air mixture from the two front temperature zones.

Scheme 305

Air mixture, MCC

Based on the desired temperature, the air mixing damper directs the incoming air through the heat exchanger before the air is released into the cabin. In this way, warm and cool air is mixed to achieve the desired temperature. If a low temperature is selected, the air mixing damper closes so that the air is prevented from passes through the heat exchanger.

Scheme 306

Cars with MCC are equipped with a air mixing damper which is controlled by a DC motor. The mixed-air temperature is affected by fan speed and the air mixing damper position.

Air mixture, ACC

A stepping motor for each climate zone helps to control the temperature of the air mixture. The air mixture is adjusted with one air mixing damper for the driver zone and one for the front seat passenger zone. The air mixture temperature from the heat exchanger is affected by fan speed and the air mixing damper position. Depending on the desired temperature, the corresponding air mixing damper can direct a specific amount of the incoming air through the heat exchanger before the air enters the cabin. In this way, warm and cool air can be mixed to achieve the desired temperature. If a low temperature is selected, the air mixing damper closes so that the air is prevented from passing through the heat exchanger.

Scheme 307

Air distribution, MCC

The climate control unit directs air from the air distribution damper to the defroster, panel or floor vents. The controls can be adjusted with the three main settings. Air is then distributed between the defroster and panel vents or between the panel and floor vents. From the air distribution damper, air is directed via a number of outlets to different vents located throughout the cabin.

Scheme 308

Air distribution, ACC

The heating and ventilation unit contains separate dampers for air distribution to the defroster, floor and panel vents. There is one damper for either side of the panel. Each damper is rotated by a stepping motor with a feed from the control module.

Scheme 309

The climate control unit directs air from the air distribution damper to the defroster, panel or floor vents. From the air distribution damper, air is directed via a number of outlets to different vents located throughout the cabin.

Defroster setting

Air is directed to the vents on the top side of the dashboard and to the front side window defroster vents. There are four defroster vents; two direct the air to the windshield and two smaller vents on either side of the dashboard direct air to the front side windows.

Scheme 310

Panel setting

The air is directed to the dashboard vents and vents in the rear edge of the center console.

Scheme 311

Of the three panel vents in the dashboard, the center panel vent is divided for use by the driver and passenger. Air distribution is controlled individually and the air flow direction can be adjusted horizontally and vertically while the amount of air can be variably adjusted.

Two panel vents for rear seat passengers are located on the rear edge of the center console. The amount of air and distribution can be adjusted individually.

Floor setting

Air is directed to vents under the dashboard and under the front seats to the rear floor outlets.

Scheme 312

At the same time, a smaller amount of air flows to the defroster vents to prevent side window downdraft.

Of the four floor air outlets, the two that lead to the underside of the dashboard direct air to the floor by the driver and passenger. Two air outlets lead to the underside of the front seats and direct air to the floor for the rear seat passengers.

TRI setting

Air is directed to the defroster, panel and floor settings simultaneously.

BI mode

Air is directed to the panel and floor positions at the same time.

Heating mode

Air is directed to the defroster, and floor positions at the same time.

Air recirculation

The climate control unit is equipped with a recirculation flap located near the ventilation fan. The recirculation flap has two settings; fresh air and recirculation. If recirculation is activated, no air enters the climate control unit from outside the car. Instead, the cabin air is recirculated.

Scheme 313

The recirculation flap is opened and closed with a direct current motor.

Fresh-air filter

The filter is located in the bulkhead partition space on the passenger side. There are two types of fresh-air filters.

Scheme 314

Particle air filter

The fibres in the particle air filter stop larger particles but must rely on an electrostatic charge to trap smaller particles. Because of the electrostatic charge, the filter attracts particles much in the same way as a magnet attracts metal filings.

Combination filter

A combination filter is available as optional equipment. The fibres in the particle air filter stop larger particles but must rely on an electrostatic charge to trap smaller particles. Because of the electrostatic charge, the filter attracts particles much in the same way as a magnet attracts metal filings.

Besides removing all visible particles, the filter removes particles such as pollen, plant spores and different types of dust from the cabin air. The active charcoal in the filter reduces the concentration of hazardous substances such as benzene and toluene.

Air conditioning lowers the cabin air temperature to a comfortable level when ambient temperatures are high and provides the ACC system with a fixed temperature setting with which to balance the cabin temperature setting. The unit reduces cabin humidity in wet weather without raising the cabin air temperature, which in turn keeps the windows free from mist with a low fan speed.

Scheme 315

The A/C unit does not produce cold air but instead removes warmth from incoming air or air recirculated inside the cabin. In order to achieve this, a substance which has a lower temperature than the air due to pressure difference is used since heat is always transferred from a warmer object to a cooler object.

The refrigerant boils and vaporizes at low temperatures. The refrigerant maintains a constant pressure/temperature ratio which means that if the pressure is altered, the temperature is altered and vice versa. This condition remains constant if the volume remains the same.

By allowing the refrigerant to circulate in a closed system where the pressure can be altered, the temperature can be changed. If the pressure and temperature are altered sufficiently, the refrigerant begins to vaporize. When the system pressure is at the correct level, the refrigerant vaporizes at approximately 0 to +4°C. The process occurs in the A/C system evaporator.

A necessary condition for refrigerant vaporization is the presence of heat extracted from the air around the evaporator. When heat is extracted from the air surrounding the evaporator, the air becomes cooler. It is this cooler air which is directed into the cabin.

Heat which the refrigerant has gathered in the evaporator is transported to the engine bay where it is released into the ambient air via an air-cooled condenser.

Refrigerant

A liquid with the designation R134a is used as a refrigerant. R134a heats and vaporizes at a temperature of approximately -30°C in normal air pressure. When the refrigerant vaporizes in the evaporator, it extracts heat from the surrounding air. This cooled air is directed into the cabin.

R134a is a chlorine-free refrigerant.

For information regarding refrigerants, see DRAINING AND FILLING REFRIGERANT .

Cooled glove box

Cars with ACC are equipped with a hose connecting the heating and ventilation unit to the glove box. With controls inside the glove box, a vent allowing cool air into the glove box can be opened or closed. In this way, the contents of the glove box can be kept cool.

Scheme 316

Scheme 317

1. Compressor The refrigerant is led to the compressor from the evaporator under low pressure and in gas form where it is compressed, allowing the pressure and temperature to increase. The heated and vaporized refrigerant is then directed to the condenser.
2. Condenser The heated, high-pressure refrigerant is pumped by the compressor into the condenser coil. The coil is equipped with cooling fins through which air flows with help from the radiator fan and the air stream. Because heat always moves from a warmer object to a cooler object, the heated refrigerant will release some of its heat into the cooler air. The heated refrigerant in vapor form loses heat and begins to condense and return to liquid form.
3. Receiver
4. The receiver stores and dehumidifies the refrigerant. Refrigerant enters the receiver in liquid form at high pressure and temperature. It passes through a filter unit where it is dehumidified and cleaned of any particles. The refrigerant is then directed, in liquid form, to the expansion valve. The system pressure sensor is located on the pipe between the receiver and the expansion valve.
5. Expansion valve The refrigerant entering the expansion valve in liquid form is at high pressure and temperature. The purpose of the expansion valve is to control the amount of refrigerant which is injected into the evaporator. The valve does not permit more refrigerant to enter than the amount which can be vaporized for each cycle.
6. Evaporator When the refrigerant expands when it enters the evaporator from the expansion valve. The evaporator maintains a much lower pressure due to the compressor suction effect. When the refrigerant expands, it returns to gas form (evaporation). In order for vaporization to occur, heat must be extracted from the surrounding air. The cool air is then led into the cabin. The refrigerant is led to the compressor in gas form.

A/C request

MCC

The A/C button must be pressed. A request is sent to BCM pin 18. The BCM sends the A/C cut-in request on an engine management bus.

Scheme 318

ACC

A/C in on position.

The ACC sends the A/C engagement request if the ambient temperature exceeds 0°C.

The fan must be operating.

ACC

Evaporator temperature exceeds 0°C.

A/C cut-in and cut-off

A/C cut-in is processed by the engine control module when an A/C request is sent via bus. The engine control module uses engine temperature, A/C pressure sensor, battery voltage and rpm information to determine if the A/C compressor should be engaged.

Conditions for starting or stopping the A/C compressor, B207E/L/R (petrol) and D223L (diesel)

1. If the engine temperature exceeds 126°C (petrol), 123°C (diesel), the compressor will be stopped. In order for it to start, the engine temperature must be below 125°C (petrol), 122°C (diesel).
2. If the A/C pressure exceeds 28 bar, the compressor is stopped. The compressor will be restarted once the pressure is below 23 bar. When the pressure is below 3.2 bar, the compressor stops. In order for restart to occur, the pressure must be above 3.28 bar.
3. Petrol only: If the engine speed is below 450 rpm the compressor is stopped. In order for the compressor to be restarted, the engine speed must exceed 575 rpm.

Conditions for starting or stopping the A/C compressor, Z18XE (petrol)

1. If the engine temperature exceeds 126°C the compressor is stopped. In order for the compressor to be started the engine temperature must be below 125°C.
2. If the A/C pressure exceeds 31 bar, the compressor is stopped. The compressor will be restarted once the pressure is below 24 bar. When the pressure is below 2.8 bar, the compressor stops. In order for restart to occur, the pressure must exceed 3.2 bar.
3. If the rpm is below 450, the compressor is stopped. In order to restart the compressor, the rpm must be above 575.

Conditions for starting or stopping the A/C compressor, B284 (petrol)

1. If the engine temperature exceeds 123°C the compressor is stopped. In order for the compressor to be started the engine temperature must be below 122°C.
2. If the A/C pressure exceeds 30 bar, the compressor is stopped. The compressor will be restarted once the pressure is below 23 bar. When the pressure is below 2.8 bar, the compressor stops. In order for restart to occur, the pressure must be above 3.2 bar.
3. If the rpm is below 450, the compressor is stopped. In order for the compressor to restart, the rpm must be above 575.

Pressure sensor

Pressure in the A/C system is measured with a pressure sensor mounted on the A/C pipe on the RH side of the condenser. The pressure sensor is connected to the engine control module which receives pressure information. The information is used to start or stop the compressor and radiator fan adjustment.

The radiator fans are controlled in accordance with the table below.

Radiator fan logic, B207E/L/R (petrol), D223L (diesel) and B284

RADIATOR FAN LOGIC, B207E/L/R (PETROL), D223L (DIESEL) AND B284 REFERENCE

Radiator fan logic, Z18XE (petrol)

RADIATOR FAN LOGIC, Z18XE (PETROL) REFERENCE

Compressor

The A/C compressor, mounted on the RH side of the engine, provides the necessary refrigerant pressure increase for A/C system function.

Scheme 319

The large amount of power required to achieve this pressure increase is taken from the crankshaft by the compressor via a drive belt system. Start and stop occurs with an electromagnetic clutch integrated in the compressor belt pulley. The electromagnetic clutch solenoid coil protects the clutch from overheating (182.5 ± 5°C). If the overheat protection is activated, the solenoid coil must be replaced as it is not possible to reset the overheat protection function.

The compressor has a variable swept volume, also called displacement. A compressor with variable swept volume adjusts the swept volume to the current cooling requirements in the cabin.

Because the swept volume is always adjusted according to the cooling requirement, the evaporator temperature remains more or less constant. This means that the compressor will not cycle as when a compressor with a fixed displacement is used.

When the compressor is coupled with the electromagnetic clutch, the compressor starts with 5% of the maximum swept volume. After start, the swept volume increases until it matches the cooling requirement.

Scheme 320

The crankshaft torque requirement increases gradually, which results in a considerable pressure reduction during cut-in compared with a compressor with fixed displacement.

The compressor is a piston-type compressor with seven axial cylinders. The pistons move back and forth in the cylinders and create a pump effect for the refrigerant with help from the inlet and outlet valves. The power from the rotating compressor shaft is transferred to the piston motion using a rocker disc. The pistons are controlled by sliders which remain in contact with both sides of the rocker disc.

Change the piston stroke in order to change the compressor displacement. By changing the rocker disc angle against the compressor shaft, the piston stroke can be lengthened or shortened.

In order to change the rocker disc angle, the pressure differential between the compressor cylinders and the compressor crankcase is used. If the pressure in the crankcase is lower than the pressure on top of the pistons, the pistons and rocker disc move together axially in the direction of the belt pulley. Through a linkage with two locating studs between the rocker disc and the shaft, the rocker disc angle will increase gradually as the pistons and rocker disc move. The increased angle results in an increased swept volume.

The compressor swept volume can therefore be adjusted by changing the compressor crankcase pressure.

Condenser, Z18, Z19, B207

The condenser cools the heated refrigerant which has assumed a gaseous form in order for the refrigerant to condense. For this process to become as efficient as possible, the refrigerant is led by four coils through the condenser, the first of which is divided into 13 channels. The second coil is divided into 10, the third into 7 and the fourth and last coil is divided into 5 channels. This design makes it possible to minimize the size of the condenser without a reduction in capacity.

Scheme 321

The condenser cools the heated refrigerant which has assumed a gaseous form in order for the refrigerant to condense. For this process to become as efficient as possible, the refrigerant is led by four coils through the condenser, the first of which is divided into 17 channels. The second coil is divided into 11, the third into 8 and the fourth and last coil is divided into 6 channels. This design makes it possible to minimize the size of the condenser without a reduction in capacity.

Receiver

The receiver, which is located on the RH side of the radiator, filters, stores and dehumidifies from the refrigerant.

Scheme 322

When servicing the A/C system, it is important to plug all open connections to prevent the receiver from absorbing moisture from the air. If the A/C system has been open for more than a total of 15 minutes, the receiver should be replaced since it will have absorbed too much moisture to allow normal function.

Replace the receiver in connection with hose rupture and major leakage as well as compressor breakdown. As long as pressure remains in the system, replacement is not necessary.

Expansion valve

The expansion valve regulates the amount of refrigerant that is released into evaporator. The expansion valve is located in the bulkhead partition space near the A/C hose passage into the bulkhead in all models.

The expansion valve consists of a spring-loaded ball located on the high-pressure side. The ball is connected via a pressure lever to a diaphragm in a gas-filled chamber on the low-pressure side of the valve. The spring maintains a constant pressure on the ball. The pressure from the pressure lever exerted on the ball is dependent on the pressure inside the gas-filled chamber. The pressure in the chamber is dependent on the refrigerant temperature in the evaporator outlet.

If the temperature of the refrigerant from the evaporator passing through the expansion valve low pressure side decreases, the pressure inside the gas-filled chamber is also decreased. The spring exerts pressure on the ball and pressure lever. The diaphragm cannot withstand the pressure and the expansion valve restricts the flow area.

If the temperature of the refrigerant from the evaporator increases, the pressure inside the gas-filled chamber also increases. The diaphragm presses against the pressure lever and the ball, the spring is compressed and the expansion valve opens. A larger amount of refrigerant is allowed through, which increases the cooling effect and decreases the evaporator temperature.

The evaporator, which is located in the climate control unit, consists of a heat exchanger (cabin air/refrigerant) through which refrigerant via through a pipe system equipped with cooling fins.

Scheme 323

The incoming refrigerant expands and boils (vaporizes) in the evaporator pipe system and absorbs heat from the pipes and cooling fins. The cooling fins are warmed, in turn, by the incoming/recirculating cabin air. The incoming cabin air is then cooled to a temperature of approximately 5-10°C, providing the cabin with cooling to the desired temperature.

When heat is absorbed, condensation is formed on the evaporator pipes and cooling fins. This condensation drains out underneath the engine compartment through a drainage hose. During certain climatic conditions, relatively large amounts of water can collect under a parked car.

Pipes, hoses and sealing washers

The pipes and hoses in the A/C system must withstand extremes of both heat and pressure. These components must meet requirements regarding leak integrity and hose diffusion characteristics, or refrigerant leakage through the hose material. Only pipes and hoses manufactured specifically for the A/C system should be used. In order to fulfil these requirements, the inside of the hose is constructed with butyl rubber and the outside is constructed with EPDM rubber.

Sealing washers are used on connections. The sealing washer is a metal washer with a vulcanized rubber seal. The sealing washers should always be checked and replaced when connecting A/C components. It is very important that the right tightening torque is used when assembling.

Service connections

The low pressure side's service connection is located on the low pressure pipe behind the right headlamp between the A/C compressor and the evaporator.

The high pressure side service connection is on the high pressure pipe behind the right headlamp between the receiver and the evaporator.

Main task

The A/C compressor's electromagnetic clutch connects the belt pulley driven by the belt circuit and the A/C compressor's shaft.

Scheme 324

Type

The compressor clutch consists of a coil, belt pulley and follower. When the coil is supplied with voltage, the belt pulley and follower are coupled together as one unit.

Scheme 325

Connection, petrol engine B207, B284

The compressor clutch is activated through a voltage feed from relay 156 in the underhood electric center (727) and is grounded through grounding point G7.

Scheme 326

Connection, Z18XE petrol engine

The compressor clutch is activated through a feed from relay 156 in the engine bay main fuse box (342) and is connected to ground through grounding point G2.

Scheme 327

Connection, Z19DT/DTH diesel engine

The compressor clutch is activated through a feed from relay 156 in the engine bay main fuse box (342) and is connected to ground through grounding point G2.

Scheme 328

Principal use

The value is used by ECM for load compensation based on the A/C compressor's load on the engine. Also used for radiator fan logic and block conditions (pressure monitor) in the A/C system.

The pressure sensor contains two metal plated ceramic discs mounted in close proximity. The disc located closest to the pressure connection is thinner and bends when subjected to pressure. By this means, capacitance between the metal plating of the discs is changed based on the pressure. A circuit integrated in the sensor converts the capacitance to an analogue voltage.

Scheme 329

Scheme 330

T8

CONNECTION SPECIFICATION

The pressure sensor is secured to the A/C pipe of the high-pressure side. Based on the pressure in the intake manifold, the pressure sensor yields a proportional voltage to control module pin A7.

Measures the pressure of the A/C system.

Capacitive sensor with integrated electronics for signal conversion.

Connect

CONNECT SPECIFICATION

Scheme 331

Function

The pressure sensor contains two metal-coated ceramic discs mounted close together. The disc closest to the pressure connection is thinner and bends when it comes under pressure. This modifies the capacitance between the metal coatings of the discs as a function of the pressure. Built into the sensor is a circuit which converts the capacitance to an analogue voltage.

The value is used by ECM for load compensation based on the A/C compressor's load on the engine. Also used for radiator fan logic and block conditions (pressure monitor) in the A/C system.

The pressure sensor contains two metal plated ceramic discs mounted in close proximity. The disc located closest to the pressure connection is thinner and bends when subjected to pressure. By this means, capacitance between the metal plating of the discs is changed based on the pressure. A circuit integrated in the sensor converts the capacitance to an analogue voltage.

Simtec

CONNECTION SPECIFICATION

Scheme 332

Bus messages, A/C

For a detailed description of the car's bus system, see DETAILED DESCRIPTION .

DESCRIPTION TABLE

A/C compressor relay (156)

Location

Z18XE

in electrical center engine bay 342

Scheme 333

Z19

in electrical center engine bay 342

Scheme 334

Switch, A/C (169)

Location: In the ACC/MCC panel

Scheme 335

Compressor, A/C (170)

Location

on the front long side of the engine (right)

B207

Scheme 336

Z18XE

Scheme 337

B284

Scheme 338

Z19DT

Scheme 339

Z19DTH

Scheme 340

Automatic Climate Control (216)

Location: in the center of the dashboard

Scheme 341

Act as the electrical center for the front of the car and handle some parts of the logic for the front lighting as well as the visibility and signal systems.

Distributes current from the battery to the other electrical centers.

The electrical center contains the transport fuse (fuse 37).

Electrical center with relays, maxi and micro-fuses and integrated control module for logic operations.

Connect

The fuse box is connected to the battery and to grounding points G30A, G31 and G33S. The electrical center is connected via three switches in its base to the engine harness, front harness and main harness.

Power supply circuit for +30

Power supply circuit for +15

The engine harness is connected via switch M

Scheme 342

The front harness is connected via switch F

Scheme 343

The main harness is connected via switch B

Scheme 344

Scheme 345

The electrical center can contain a greater number of fuses than those listed below. In such cases, these are not connected to a wiring harness. For additional fuse information, see CIRCUIT PROTECTION DEVICES and POWER DISTRIBUTION .

FUNCTION CHART No. Amp Type Function Graphic 1 30 +30 Z18XE (Simtec) via main relay 229: Control module, Simtec (705) Heated oxygen sensors (271) EVAP canister purge valve (321) Control valve, VIM damper (454) Module, mass air flow sensor (686) Z19 (EDC16) via main relay 229: ECD16 control module (595B) Glow plug control module (596) Boost pressure control valve (179a) Heating element, oxygen sensor (271) Actuator, swirl throttle (403) Actuator, throttle body (604) Solenoid valve, EGR (606) - 2 10 +30 TCM (502a/b) Trionic T8 control module (589A) Control module, ME9 (608B) Simtec control module (705B) - 3 20 +30 Horn - 4 10 +15 TCM, AF 40 (502b) Battery disconnect switch (700) B207 (T8): Trionic T8 control module (589A) Z18XE (Simtec): Simtec control module (705B) Module, ignition coils (552) Module, power steering unit (745) B284 (ME9): Control module, ME9, switch B (608B) Mass air flow sensor (205) Z19 (EDC16): ECD16 control module (595B) Module, mass air flow sensor (686) Water level sensor, fuel filter (692) Module, power steering unit (745) - 5 - - - - 6 10 +30 TCM, FA 57 (502a) Immobilizer switch, automatic (77) Gear selector, automatic (245) Immobilizer switch (411) - 7 - - - 8 5 +15 Vacuum pump unit (459) - 9 - - - - 10 - - - - 11 - - - - 12 - - Washer fluid pump, rear window (63c) - 13 10 +30 EDC16 and Simtec: A/C compressor (170) - 14 - - - - 15 30 +30 Motor, high-pressure headlight washer pump (668) - 16 30 - Lighting, left front: Side direction indicators, dipped beam, fog light Lighting, right front: Position lamp, direction indicator, side direction indicator, main beam - 17 30 - Windscreen wiper motor, low-speed - 18 30 - Windscreen wiper motor, high-speed - 19 20 +30 Parking heater, diesel (597) Connection, accessories (711) - 20 10 +15 Motors, manual headlamp levelling (280) AHL control module (664) - 21 - - - - 22 30 +30 Washer fluid pump, windscreen (63b) - 23 - - - - 24 20 +30 Auxiliary lamp - 25 20 +30 Front amplifier (354F) - 26 30 +30 Lighting, left front: direction indicator, position lamp, main beam Lighting, right front: dipped beam, fog light - 27 60 maxi +30 B207 (T8): Main fuse for fuse box 727 - - 20 maxi - Z18XE and Z19 (Simtec and EDC16): fuel pump (323) - 8 28 40 maxi +30 Control module, TCS/ESP (382/671) - 29 60 maxi +30 Main fuse 2 for rear electrical center - 30 60 maxi +30 Main fuse 2 for dashboard electrical center - 31 40 maxi +30 Starter motor solenoid via relay 517 - 32 60 maxi +30 Main fuse 1 for dashboard electrical center - 33 40 maxi +30 Control module, TCS/ESP (382/671) - 34 60 maxi +30 Main fuse 1 for rear electrical center - 35 30 maxi +30 B207 and Z18XE: Radiator fan B248: Vacuum pump unit - 36 20 maxi +30 B207: Radiator fan EDC16: Heating element, fuel filter - 37 60 maxi +30 Transport lock. Main fuse 3. for rear electrical center

Scheme 346

Relays

The electrical center can contain a greater number of relays than those listed below. In such cases, these are not connected to a wiring harness. For additional relay information, see BUZZERS, RELAYS & TIMERS .

RELAYS DESCRIPTION Location No. Description Graphic Diagram R1 432b Relay, washer fluid pump, windscreen - R2 156 Relay, A/C compressor (Simtec and EDC16) AIR CONDITIONING A/C, B207/Z18XE AIR CONDITIONING A/C, DIESEL R3 - - - - R4 641 Relay, diesel preheating - R5 675 Relay, extra lights - - R6 68 Horn relay - R7 229 Main relay, engine management system (Simtec and EDC16) - R8 517 Relay, +50 STARTING SYSTEM, B207 STARTING SYSTEM, Z18XE STARTING SYSTEM, B284 STARTING SYSTEM, Z19 R9 83 Windscreen wiper relay - R10 432c Relay, washer fluid pump, rear window - R11 757F Relay, +15, UEC - R12 709 Relay, windscreen wiper, full/half speed - R13 - - - - R14 667 Relay, washer fluid pump, high-pressure, headlamp - R15 - - - - R16

Scheme 347

Scheme 348

Scheme 349

Scheme 350

Scheme 351

Scheme 352

Scheme 353

Scheme 354

Scheme 355

Scheme 356

List of components

LIST OF COMPONENTS

Control panel, manual climate control (504)

Location: in the center of the panel

Scheme 357

SID (541)

Location: at the top of the instrument panel

Scheme 358

Control module, Trionic, B207, switch A (589A)

Location: engine front

Scheme 359

EDC16 Control module, 4-cyl. diesel, connector B (595B)

Location: in the right wheel housing by the wing.

8V

Scheme 360

16V

Scheme 361

Control module, Motronic E9, B284, switch B, (608B)

Location: at the top of the rear cylinder bank, upper switch

Scheme 362

Pressure sensor A/C (620)

Location: near the left front corner of the air filter

B207

Scheme 363

Z18XE

Scheme 364

B284

Scheme 365

Z19DT

Scheme 366

Z19DTH

Scheme 367

Control module, Simtec, Z18XE, switch A (engine) (705A)

Location: behind/above connector on the engine control module

Scheme 368

Control module, Simtec, Z18XE, switch B (705B)

Location: front/lower connector on the engine control module

Scheme 369

Body Control Module (707)

Location: in the dashboard electrical distribution unit

Scheme 370

Scheme 371

Act as the electrical center for the engine management system T8 as well as the petrol pump relay 102, which is located in the compartment under the right A-pillar.

Electrical center with relays, maxi and micro-fuses.

The electrical center is integrated into the engine harness.

Power supply, main fuse box 727. See appropriate POWER DISTRIBUTION article.

Fuses

For additional fuse information, see CIRCUIT PROTECTION DEVICES and POWER DISTRIBUTION .

FUSES FUNCTION REFERENCE

For additional relay information, see BUZZERS, RELAYS & TIMERS .

RELAYS DESCRIPTION Location No. Description Graphic Diagram 2 156 A/C compressor relay - 3 443 Heated oxygen sensor relay - 4 229 Main relay, engine management system CRIMP J45, ENGINE HARNESS, TRIONIC CRIMP J37, ENGINE HARNESS, TRIONIC

Scheme 372

Scheme 373

Scheme 374

LIST OF COMPONENTS

Connector H7-1

Location: on engine at rear corner of upper intake manifold on gearbox side.

Scheme 375

Connector H10-15

Location: at the top of the engine left-hand short side

Scheme 376

Connector H10-16

Location: gray connector below left headlamp.

Scheme 377

Connector H10-17

Location: Blue connector on bracket in front of battery on side of left structural member

Scheme 378

Connector H11-1

Location: By the high-pressure pump on the right-hand side of the engine

EDC16 8V

Scheme 379

EDC16 16V

Scheme 380

Connector H27-1

Location: in the center console by the dashboard left-hand support.

Scheme 381

LIST OF COMPONENTS

CRIMP J39, ENGINE HARNESS, TRIONIC

CRIMP J44, ENGINE HARNESS, TRIONIC

LIST OF COMPONENTS

LIST OF COMPONENTS

LIST OF COMPONENTS

CRIMP J278, EDC16 ADAPTER HARNESS

LIST OF COMPONENTS

CRIMP J272, EDC16 ADAPTER HARNESS

Crimp J280, EDC16 adapter harness

LIST OF COMPONENTS

LIST OF COMPONENTS

LIST OF COMPONENTS

Scheme 382

Location: On the side of the LH structural member near the connector console

Connected components

CONNECTED COMPONENTS CHART

Scheme 383

Scheme 384

Location: On the side of the LH structural member near the connector console

CONNECTED COMPONENTS TABLE

Scheme 385

Scheme 386

Location: On the side of the LH structural member near the connector console

CONNECTED COMPONENTS TABLE

Scheme 387

Scheme 388

Location: Above the upper RH engine control module attachment eye

CONNECTED COMPONENTS TABLE

Scheme 389

Scheme 390

Location: On rear cylinder bank toward belt circuit side

Grounding point G2 is connoted to the grounding point via crimp J312.

CONNECTED COMPONENTS CHART

R134a

R134A SPECIFICATION

Compressor (170), Z18, B284

COMPRESSOR REFERENCE

Compressor oil

COMPRESSOR REFERENCE

Compressor (170), Z19 and B207

COMPRESSOR REFERENCE

COMPRESSOR REFERENCE

Scheme 391

EXPANSION VALVE SPECIFICATION

Scheme 392

SAFETY VALVE REFERENCE

No DTCs stored with the fault symptom in question.

For additional information, see ELECTRICAL COMPONENT LOCATOR .

LIST OF COMPONENTS No. Name location Graphic - Components - 156 A/C compressor relay Trionic T8: in the electrical center in front of the battery Simtec: in electrical center engine bay 342 16 Switch, A/C, in the MCC/ACC panel 170 Compressor, A/C, on the front long side of the engine (right) 216 ACC control module center of the dashboard 342 ENGINE BAY ELECTRICAL CENTER 342 (UEC) FUSE 13, ENGINE BAY ELECTRICAL CENTER 342 504 Control panel for manual climate control center of the panel 541 SID, at the top of the dashboard 589A Control module, Trionic, 4-cyl petrol, contact A engine front 620 Pressure sensor, A/C, near the left front corner of the air filter 705 Control module, Simtec, on top of left-hand end of engine CONTROL MODULE, SIMTEC, Z18XE, SWITCH A (ENGINE) (705A) CONTROL MODULE, SIMTEC, Z18XE, SWITCH B (705B) 707 Body control module, BCM, in the dashboard's main fuse box 727 MAIN FUSE BOX 727 FOR B207, IN ENGINE BAY FUSE 3, ELECTRICAL CENTER 727 - 10-pin connectors - H10-15 At the top of the engine left-hand short side - 27 pin connector - H27-1 In the center console by the dashboard left-hand support - Crimps - J40 Approximately 190 mm from crankshaft position sensor branching point towards the engine control module - J241 In engine cable duct by injector for cylinder 2 - J247 In engine cable duct by injector for cylinder 3 - - Grounding points - G2 On the side of the LH structural member near the connector console - G7 Above the upper RH engine control module attachment eye

Scheme 393

Scheme 394

Scheme 395

Scheme 396

Scheme 397

Scheme 398

Scheme 399

Scheme 400

Scheme 401

Scheme 402

For additional information, see ELECTRICAL COMPONENT LOCATOR .

LIST OF COMPONENTS No. Name location Graphic - Components - 156 A/C compressor relay in the electrical center in front of the battery 169 Switch, A/C, in the MCC/ACC panel 170 Compressor, A/C, on the front long side of the engine (right) 216 ACC control module center of the dashboard 504 Control panel for manual climate control center of the panel 541 SID, at the top of the dashboard 608B Control module, Motronic E9, switch B at the top of the rear cylinder bank, upper switch 620 Pressure sensor, A/C, near the left front corner of the air filter 707 Body control module, BCM, in the dashboard's main fuse box 727 MAIN FUSE BOX 727 FOR B207, IN ENGINE BAY FUSE 3, ELECTRICAL CENTER 727 - 7-pin connectors - H7-1 On engine at rear corner of upper intake manifold on gearbox side. - 10-pin connectors - H10-16 Grey connector at grey connector in front of battery on side of left structural member H10-17 Blue connector on bracket under grey connector in front of battery on side of left structural member - 27 pin connector - H27-1 In the center console by the dashboard left-hand support - Crimps - J310 Approx. 290 mm from branching of battery toward engine control module - J311 Approx. 290 mm from branching of battery toward engine control module - J312 Approx. 150 mm from branching of battery toward engine control module - - Grounding points - G2 On the side of the LH structural member near the connector console - G7 On rear cylinder bank toward belt circuit side

Scheme 403

Scheme 404

Scheme 405

Scheme 406

Scheme 407

Scheme 408

Scheme 409

For additional information, see ELECTRICAL COMPONENT LOCATOR .

LIST OF COMPONENTS No. Name location Graphic - Components - 156 A/C compressor relay in electrical center engine bay 342 169 Switch, A/C, in the MCC/ACC panel 170 Compressor, A/C, on the front long side of the engine (right) 216 ACC control module center of the dashboard 342 Electrical center, engine bay (UEC) beside the battery 13 504 Control panel for manual climate control center of the panel 541 SID, at the top of the dashboard 595B EDC16 control module, 4-cyl. diesel, connector B, between the front spoiler and right-hand wheel housing by the wing 620 Pressure sensor, A/C, near the left front corner of the air filter 707 Body control module, BCM, in the dashboard's main fuse box - 11-pin connectors - H11-1 At the high pressure pump on the RH side of the engine - 27 pin connector - H27-1 In the center console by the dashboard left-hand support - Crimps - J272 Approx. 320 mm from branching point starter motor towards reversing light switch - J278 Approx. 50 mm from branching of connector H24-5 toward starter motor - - Grounding points - G2 On the side of the LH structural member near the connector console

Scheme 410

Scheme 411

Scheme 412

Scheme 413

Scheme 414

MCC unit (504)

Carry out measures before dismantling the control module.

Scheme 415

Scheme 416

1. Remove the MCC unit by carefully pulling it out. Use «82 93 474 REMOVAL TOOL»(ref-275884-S18487896872007122900000) to remove the unit. IMPORTANT: Take care when releasing the locking mechanism on the connector so as not to damage the connector. Pull the halves straight apart to avoid bending the pins. For further information regarding connectors, refer to «CONNECTORS, HANDLING AND INSPECTION»(ref-275884-S07002899182007122900000) .
2. Remove the MCC unit's connector.
3. Lift out the MCC unit.

Scheme 417

Scheme 418

1. Connect the MCC unit's connector.
2. Lift the MCC unit into position and fit it. Carry out measures after fitting the control module

Scheme 419

Scheme 420

1. Remove «GLOVE BOX»(ref-275837-S35412718882007122900000) . The air recirculation flap stepping motor is located on the fan housing's outer end.
2. Dismantle the stepping motor's connector by pressing in the lock and pulling out the connector.
3. Dismantle the air recirculation flap stepping motor.

Scheme 421

1. Fit the air recirculation flap's stepping motor.
2. Connect the stepping motor's connector. Make sure the connector locks correctly.
3. Refit «GLOVE BOX»(ref-275837-S35412718882007122900000) .

Scheme 422

Scheme 423

1. Remove «GLOVE BOX»(ref-275837-S35412718882007122900000) .
2. Dismantle the screws from the air distribution flap stepping motor.
3. Dismantle the stepping motor's connector by pressing in the lock and pulling out the connector.

Scheme 424

Scheme 425

1. Connect the stepping motor's connector. Make sure the connector locks correctly.
2. Fit the screws on the air distribution flap stepping motor.
3. Refit «GLOVE BOX»(ref-275837-S35412718882007122900000) .

Scheme 426

Scheme 427

1. Remove «GLOVE BOX»(ref-275837-S35412718882007122900000) .
2. Remove «SOUND INSULATION PANEL, PASSENGER»(ref-275837-S08591073902007122900000) .
3. Remove the clip and move the ventilation fan control to the side so that is releases from the other clip.
4. Dismantle the ventilation fan control's connector
5. Lift out the ventilation fan control.

Scheme 428

Scheme 429

1. Insert the ventilation fan control into position.
2. Connect the ventilation fan control's connector.
3. Fit the ventilation fan control to the clips.
4. Fit «SOUND INSULATION PANEL, PASSENGER»(ref-275837-S08591073902007122900000) .
5. Refit «GLOVE BOX»(ref-275837-S35412718882007122900000) .

Scheme 430

Scheme 431

1. Dismantle the floor console's front side panel.
2. Dismantle «SOUND INSULATION PANEL, DRIVER»(ref-275837-S20291105042007122900000) .
3. Remove the screws from the stepping motor.
4. Dismantle the stepping motor's link arm from the heating and ventilation unit's link arm.
5. Remove the stepping motor's connector.
6. Lift out the mixed air damper's stepping motor.

Scheme 432

Scheme 433

1. Fit the mixed air damper's stepping motor into position.
2. Connect the stepping motor's connector.
3. Fit the stepping motor's link arm to the heating and ventilation unit's link arm.
4. Fit the screws on the stepping motor.
5. Fit «SOUND INSULATION PANEL, DRIVER»(ref-275837-S20291105042007122900000) .
6. Fit the floor console's front side panel.

Scheme 434

1. MCC unit control module (504)
2. Motor, air distribution (221)
3. Motor, air mixture (222)
4. Ventilation fan control (220)
5. Motor, ventilation fan (36)
6. Motor, air recirculation flap (38)
7. BCM (707)
8. Unit, steering column assembly, CIM (703)
9. ECM
10. Pressure sensor A/C (620)
11. A/C relay (156)
12. Compressor, A/C (170)
13. REC (701)
14. Rear window electric heater relay (113)

Temperature

The desired temperature is set using the panel temperature knob's 31 settings. A direct current motor with built-in potentiometer rotates the air mixing damper. This damper mixes cool air which has passed through the evaporator with warm air which has passed through the evaporator and heat exchanger. The temperature dial is connected to a potentiometer which receives an internal control module voltage feed. The potentiometer applies voltage to the internal control module inlet which increases when the knob is rotated to the right. The A/D value is converted in a control module memory table containing information regarding which air mixture setting (desired) is to be used for a specific A/D value.

Scheme 435

The control module activates the direct current motor until polarity causes the current air mixture setting measured from the motor potentiometer to be the same as the desired air mixture setting.

Scheme 436

Air distribution

Set the desired air mixture with the knob on the panel with the following 9 settings

1. Panel
2. Intermediate
3. Panel + Floor
4. Intermediate
5. Defrost
6. Intermediate
7. Defrost + Floor
8. Intermediate
9. Floor

A direct current motor with built-in potentiometer rotates the air distribution damper via linkage. The air distribution knob is connected to a potentiometer which receives an internal control module voltage feed. The potentiometer applies voltage to the internal control module inlet which increases when the knob is rotated to the right. The A/D value is converted in a control module memory table containing information regarding which air distribution setting (desired) is to be used for a specific A/D value.

Scheme 437

The control module activates the direct current motor until polarity causes the current air distribution setting measured from the motor potentiometer to be the same as the desired air distribution setting.

Scheme 438

Fan speed

The knob is connected to a potentiometer which is supplied with current internally from the control module. The potentiometer has 6 fixed positions and delivers a voltage to the control module's internal input which increases when the knob is turned clockwise. The value is A/D converted.

Scheme 439

A table in the control module memory contains the indicated voltage which is sent to the fan control unit at a specific A/D value. Control voltage is as follows

CONTROL MODULE VOLTAGE REFERENCE TABLE

When the starter motor is running, a control voltage of 0 V is set despite the knob setting. The MCC detects that the starter motor is running since +54 receives no voltage while +15 receives voltage.

The button is read by the control module which supplies current to a DC motor that drives the air recirculation flap to the desired setting. The motor is activated for a period of 10 s. An LED indicates that recirculation has been switched on. Fresh air can be selected if the air distribution knob is set to defrost, after which it is possible to select recirculation manually. The MCC stores recirculation status during ignition shut-off if the A/C is switched on and recirculation is active. The status is re-activated when the ignition is switched on.

Scheme 440

A/C

When the A/C button is activated, a ground feed is supplied from pin 18 to the ECM. A diode indicates that the function is active. The BCM requests A/C cut-in from the ECM. The MCC stores A/C status when the ignition is switched off and re-activates the same status once the ignition is switched on.

Scheme 441

Electrically heated rear window and rear view mirrors

The button is used to switch the rear window defrost on and off. When the button is depressed, a ground pulse is sent from pin 4 to the BCM. When the BCM sends a request for electrically heated rear window cut-in, the BCM will also supply B+ on the MCC unit pin 22 which will light a diode indicating that the function is operating. The REC activates the electrically heated rear window relay. The corresponding door module activates mirror heating.

Scheme 442

Parking heater

The parking heater is activated from the ICM via SID and SIDC. The parking heater relay is controlled by the BCM. The relay applies B+ on the MCC unit pin 32 (+54) when the heater is activated. When the ignition is switched of, the following setting is the result

Scheme 443

Scheme 444

1. Air mixture 100% heat
2. Air distribution defrost
3. Recirculation in fresh air setting
4. The fan speed is set to match knob position 1, irrespective of the actual setting of the knob

Main function

The ventilation fan provides the cabin interior with air from outside the car or inside the cabin depending on the position selected for the air recirculation flap.

Direct current motor.

Scheme 445

Connection

The ventilation fan motor is connected to the corresponding MCC fan control unit.

Scheme 446

Scheme 447

For MCC connection, see CONTROL UNIT, MCC VENTILATION FAN (220A) .

The motor is connected with linkage which controls the air recirculation flap. The flap regulates air flow to the fan so that the air is retrieved from outside the cabin or from inside the cabin; there is no intermediate setting.

The air recirculation flap has a DC motor. The ACC unit reverses output polarity in order to change the direction of motor rotation.

Scheme 448

MCC

The motor is connected to MCC unit pins 15 (K42) and 14 (K42). The output polarity is reversed in order to change motor rotation direction. The MCC unit applies a B+ feed on pin 15 and grounds pin 14 in order to operate the motor for fresh air setting and conversely in order to operate the motor for cabin air retrieval.

Connection, motor/MCC unit for LHD car: MCC unit pin 15 towards motor pin 5 MCC unit pin 14 towards motor pin 6

Scheme 449

Connection, motor/MCC unit for RHD car: MCC unit pin 15 towards motor pin 6 MCC unit pin 14 towards motor pin 5 Illustration interface

To quickly electrically heat the seat when starting in cold temperatures.

Scheme 450

The heating pad consists of two circuits, one circuit is the heating element and the other circuit provides information about the temperature in question. The temperature sensor consists of a NTC resistor whose resistance varies with the temperature of the heating pad.

If the heating pad is connected to the ACC unit

Heating element

Relay 511R is fed with +15 from fuse 16 in the rear electrical center. The circuit continues through the seat and backrest cushion and is ground at grounding point G34P.

The relay is connected to pin 24 (K32) on the ACC control module, when pin 24 is ground the relay makes and the heating circuit is activated.

Scheme 451

Wiring diagram, Back and seat heating pad

Scheme 452

Wiring diagram, Heating pad temperature sensor.

Scheme 453

Temperature sensor circuit

The sensor (254) is ground internally in the ACC unit via pin 31 (K32) and the sensor is fed from pin 21 (K32) with 5V via an integrated 10 kOhm resistor in the ACC unit. The NTC resistor characteristics mean the at the resistance drops as the temperature rises. This means that the voltage measured across the resistor will at the same time drop with a rising temperature.

The voltage level from the A/D sensor is converted and is then available in digital form. The digital voltage level is then converted to a temperature value which is stored in the ACC unit operating memory. Voltage levels near 0 V or 5 V are determined as circuit faults.

If the heating pad is connected to the MCC

Heating element

Relay 511FL is fed with +15 from fuse 16 in the rear electrical center. The circuit continues through the seat and backrest cushion and is ground at grounding point G34P.

The relay is connected to pin 3 on the MCC control module, when pin 3 is ground the relay makes and the heating circuit is activated.

Temperature sensor circuit

The sensor (254) is ground internally in the MCC unit via pin 9 and the sensor is fed from pin 15 with 5V via an integrated 10 kOhm resistor in the ACC unit. The NTC resistor characteristics mean the at the resistance drops as the temperature rises. This means that the voltage measured across the resistor will at the same time drop with a rising temperature.

The voltage level from the A/D sensor is converted and is then available in digital form. The digital voltage level is then converted to a temperature value which is stored in the ACC unit operating memory. Voltage levels near 0 V or 5 V are determined as circuit faults.

To quickly electrically heat the seat when starting in cold temperatures.

The heating pad consists of two circuits, one circuit is the heating element and the other circuit provides information about the temperature in question. The temperature sensor consists of a NTC resistor whose resistance varies with the temperature of the heating pad.

If the heating pad is connected to the ACC unit

Heating element

Relay 511FL is fed with +15 from fuse 15 in the rear electrical center. The circuit continues through the seat and backrest cushion and is ground at grounding point G33P.

Wiring diagram, Back and seat heating pad

Scheme 454

Scheme 455

Wiring diagram, Heating pad temperature sensor.

Scheme 456

The relay is connected to pin 8 (K32) on the ACC control module, when pin 8 is ground the relay makes and the heating circuit is activated.

Temperature sensor circuit

The sensor (254) is ground internally in the ACC unit via pin 31 (K32) and the sensor is fed from pin 23 (K32) with 5V via an integrated 10 kOhm resistor in the ACC unit. The NTC resistor characteristics mean the at the resistance drops as the temperature rises. This means that the voltage measured across the resistor will at the same time drop with a rising temperature.

The voltage level from the A/D sensor is converted and is then available in digital form. The digital voltage level is then converted to a temperature value which is stored in the ACC unit operating memory. Voltage levels near 0 V or 5 V are determined as circuit faults.

If the heating pad is connected to the MCC

Heating element

Relay 511FL is fed with +15 from fuse 15 in the rear electrical center. The circuit continues through the seat and backrest cushion and is ground at grounding point G33P.

The relay is connected to pin 2 on the MCC control module, when pin 2 is ground the relay makes and the heating circuit is activated.

Temperature sensor circuit

The sensor (254) is grounded internally in the MCC unit via pin 9 and the sensor is fed from pin 21 with 5V via a 10 kOhm resistor integrated in the MCC unit. The NTC resistor characteristics mean the that the resistance drops as the temperature rises. This means that the voltage measured across the resistor will at the same time drop with a rising temperature.

The voltage level from the A/D sensor is converted and is then available in digital form. The digital voltage level is then converted to a temperature value which is stored in the ACC unit operating memory. Voltage levels near 0 V or 5 V are determined as circuit faults.

The control unit controls ventilation fan motor speed with input from the MCC unit.

Scheme 457

The control unit contains electronics which receive and process the MCC unit's control signal regarding fan speed. The control unit grounds the ventilation fan motor and controls fan speed by increasing or decreasing the power supply.

Scheme 458

The control unit has one connector which is connected to the MCC unit and two separate outputs for ventilation fan motor power supply and ground.

Four pin connector.

Control unit B+ feed to pin 1 from fuse 23 (fuse board 22) and ground connection through pin 3 on grounding point G41.

From MCC unit pin 27, fan speed is controlled by control unit pin 2 with 0-5 volts.

The ventilation fan motor is connected with 2 separate inputs from the control unit.

The fan motor is connected to ground on pin 2 through the fan motor control unit on grounding point G41.

The fan motor receives current on pin 1 and the speed is controlled by the control unit through an increase or decrease of the power supply.

Wiring diagram, control signal.

Scheme 459

Wiring diagram, power supply.

Scheme 460

The motor is connected by linkage and controls the floor, panel and defroster distribution damper.

The DC motor has a fixed position sensor (potentiometer) which provides information regarding damper position.

Scheme 461

DC motor

The motor is connected to MCC unit pins 29 and 31. The output polarity is reversed in order to change the motor rotation direction.

Scheme 462

Scheme 463

Potentiometer

The position sensor consists of a potentiometer with a 5 V power supply from MCC pin 28 to potentiometer pin 3 and which is connected to ground via pin 1 from MCC unit pin 8. Potentiometer pin 2 supplies a voltage for MCC pin 20 between 0-5 volts which represents the motor position.

The motor is connected by linkage which controls the air mixing damper.

The DC motor has a fixed position sensor (potentiometer) which provides information regarding damper position.

Scheme 464

DC motor

The motor is connected to MCC unit pins 13 and 16. The output polarity is reversed in order to change the motor rotation direction.

Scheme 465

Scheme 466

Potentiometer

The position sensor consists of a potentiometer with a 5 V feed from MCC pin 12 to potentiometer pin 1 and which is connected to ground via pin 3 from MCC unit pin 7.

Potentiometer pin 2 supplies a voltage for MCC pin 6 between 0-5 volts which represents the motor position.

The control panel processor receives information from the heating/air distribution knob potentiometers, calculates and ensures that the DC motors for heating/air distribution positions correspond to the selections made by the user.

Scheme 467

Power supply, ground and bus communication

PIN DESCRIPTION TABLE

Scheme 468

Scheme 469

The electrical center for most of the operations in the compartment and dashboard.

BCM control module 707 is located in the electrical center

Electrical center with relays, maxi and micro-fuses.

The 16 pin connector from the BCM 707 control module is connected directly to the electrical center.

The electrical center is fed with +30 voltage from the engine bay electrical center 342 and is connected to the dashboard harness via a 42 pin connector.

Scheme 470

The following current circuits are distributed by the electrical center

1. Power supply +30, dashboard's electrical center
2. Power supply +15, dashboard's electrical center
3. Power supply +54, dashboard electrical center

Scheme 471

The electrical center can contain a greater number of fuses than those listed below. In such cases, these are not connected to a wiring harness. For additional fuse information, see CIRCUIT PROTECTION DEVICES and POWER DISTRIBUTION .

FUSES REFERENCE TABLE

Scheme 472

The electrical center can contain a greater number of relays than those listed below. In such cases, these are not connected to a wiring harness. For additional relay information, see BUZZERS, RELAYS & TIMERS .

RELAYS REFERENCE CHART Location No. Description Graphic Diagram R1 21 Relay, +54 - R2 757C Relay, +15, IPEC - R3 - - - - R4 - - - - R5 - - - - R6 756 Relay, accessories - - R7 - - - - Soldered circuit board 717 Interior lighting relay INTERIOR LIGHTING AND READING LAMPS, 4D/5D INTERIOR LIGHTING AND READING LAMPS CV

Scheme 473

Scheme 474

Scheme 475

Scheme 476

LIST OF COMPONENTS

Scheme 477

LIST OF COMPONENTS

Scheme 478

LIST OF COMPONENTS

Scheme 479

LIST OF COMPONENTS

Motor, ventilation fan (36)

Location: on the underside of the fan housing

Scheme 480

Motor, air recirculation flap (38)

Location: on the outer fan housing end plate

Scheme 481

Motor, air distribution damper (221)

Location: on the RH side of the heating and ventilation unit

Scheme 482

Motor, air mixing damper, MCC (222)

Location: on the LH side of the heating and ventilation unit

Scheme 483

Scheme 484

Location: in the center of the panel

Location: in the dashboard electrical distribution unit

Location: in the center console by the dashboard left-hand support.

LIST OF COMPONENTS

LIST OF COMPONENTS

LIST OF COMPONENTS

Scheme 485

Location: In the instrument space to the right of the knee member

CONNECTED COMPONENTS REFERENCE

Scheme 486

VENTILATION FAN MOTOR SPECIFICATION

AIR RECIRCULATION FLAP MOTOR SPECIFICATION

Ventilation fan control (220)

VENTILATION FAN CONTROL SPECIFICATION

Scheme 487

AIR DISTRIBUTION DAMPER MOTOR SPECIFICATION

Potentiometer in engine

POTENTIOMETER IN ENGINE

AIR MIXING DAMPER MOTOR SPECIFICATION

Potentiometer in engine

POTENTIOMETER IN ENGINE

Scheme 488

CONTROL PANEL, MANUAL CLIMATE CONTROL SPECIFICATION

General

The demands on the car's functionality have developed strongly during the last years. Development has primarily affected the car's electrical system. From Saab 900 1994 when the instrument bus with 4 control modules via Saab 9-5 and 9-3 with the Infotainment bus and the Power train bus and 13 control modules on to the Saab 9-3 Sport Saloon with at most 30 control modules.

In addition to the I-bus and the P-bus, an Optical bus was introduced on the Saab 9-3 Sport Saloon, which interconnects the car's infotainment system. Furthermore, an electrically controlled steering column lock was introduced. Initially it will be possible to SPS program 8 of the car's control modules. Most of the car's control modules have a flash memory and will be successively included in SPS.

Bus

Bus configuration can be read and reset as before. An addition is that, besides "Missing" and "OK", "Added" is also shown if a unit has been fitted without resetting the bus list. Furthermore, "Not fitted" is shown for control modules that are not mounted and should not be mounted in the car. The bus list is divided into four pages, two for the I-bus, one for the P-bus and one for the O-bus.

With an "Add/Remove" of a control module updating of the list takes place automatically. In connection with the trouble code reading a check is made on the buses in accordance with the previous concept. Further tools have been introduced for fault diagnosis of the buses. A fault counter in each control module can be read and reset using the diagnostic tool. The counter's value increases with short term breaks to the control module in question.

Scheme 489

Ignition ON.

No Diagnostic Trouble Codes Stored

For additional information, see ELECTRICAL COMPONENT LOCATOR .

LIST OF COMPONENTS No. Name location Graphic - Components - 22 Electrical center, dashboard, on short end of dashboard by LH door 4 18 21 23 36 Motor, ventilation fan on the underside of the fan housing 38 Motor, air recirculation flap, on the outer fan housing end plate 220a Control unit, ventilation fan, MCC, component: inside the fan housing on the underside connector: in the center of the floor duct 221 Motor, air distribution damper, on the RH side of the heating and ventilation unit 222 Motor, air mixing damper, MCC, on the LH side of the heating and ventilation unit 409a Relay, parking heater, in center console on dashboard support 504 Control panel for manual climate control center of the panel 707 Body control module, BCM, in the dashboard's main fuse box - 27 pin connector - H27-1 In the center console by the dashboard left-hand support - Crimps - J71 LHD: Approx. 100 mm from branching point column integration module to grounding point G41 RHD: Approximately 50 mm from grounding point G43 branching point towards the radio - J76 LHD: Approximately 40 mm from cigarette lighter branching point towards grounding point G41 RHD: Approximately 130 mm from grounding point G43 branching point towards the radio - J79 LHD: Approximately 100 mm from the cigarette lighter branching point towards the cigarette lighter RHD: Approximately 110 mm from the BCM - - Grounding points - G41 In the instrument space to the right of the knee member

Scheme 490

Scheme 491

Scheme 492

Scheme 493

Scheme 494

Scheme 495

ACC unit (216)

Carry out measures before dismantling the control module.

Scheme 496

Scheme 497

1. Remove the ACC unit by carefully pulling out the ACC unit. Use «82 93 474 REMOVAL TOOL»(ref-275884-S18487896872007122900000) to remove the unit. IMPORTANT: Take care when releasing the locking mechanism on the connector so as not to damage the connector. Pull the halves straight apart to avoid bending the pins. For further information regarding connectors, refer to «CONNECTORS, HANDLING AND INSPECTION»(ref-275884-S07002899182007122900000) .
2. Remove the ACC unit's connector.
3. Lift out the ACC unit.

Scheme 498

Scheme 499

1. Connect the ACC unit's connector.
2. Lift the ACC unit into position and fit it. Carry out measures after replacing the control module.

Scheme 500

Scheme 501

Scheme 502

1. Remove «GLOVE BOX»(ref-275837-S35412718882007122900000) .
2. Dismantle the floor console's front side panel on the passenger side.
3. Dismantle «SOUND INSULATION PANEL, PASSENGER»(ref-275837-S08591073902007122900000) .
4. Dismantle the air duct for the floor vent and lift out the air duct through the hole for the glove box. The stepping motor for the right hand mixed air is the lower stepping motor.
5. Dismantle the stepping motor's connector by pressing in the lock and pulling out the connector.
6. Remove the screws from the stepping motor.
7. Dismantle the stepping motor by carefully pulling out the motor from the guide pins. Move the motor backwards and downwards.
8. Dismantle the stepping motor from the heating and ventilation unit's link arm.

Scheme 503

Scheme 504

1. Fit the stepping motor to the heating and ventilation unit's link arm.
2. Fit the stepping motor to the heating and ventilation unit.
3. Connect the stepping motor's connector. Make sure the connector locks correctly.
4. Fit the air duct for the floor vent.
5. Fit «SOUND INSULATION PANEL, PASSENGER»(ref-275837-S08591073902007122900000) .
6. Fit the floor console's front side panel.
7. Fit «GLOVE BOX»(ref-275837-S35412718882007122900000) .

Scheme 505

Scheme 506

Scheme 507

1. Remove «GLOVE BOX»(ref-275837-S35412718882007122900000) . The floor air distribution flap stepping motor is the middle stepping motor.
2. Dismantle the stepping motor's connector by pressing in the lock and pulling out the connector.
3. Dismantle the stepping motor screws and carefully pull out the stepping motor. Now move the motor forwards and downwards.
4. Dismantle the stepping motor from the heating and ventilation unit's link arm.

Scheme 508

Scheme 509

1. Fit the stepping motor to the heating and ventilation unit's link arm.
2. Fit the stepping motor to the heating and ventilation unit.
3. Connect the stepping motor's connector. Make sure the connector locks correctly.
4. Fit «GLOVE BOX»(ref-275837-S35412718882007122900000) .

Scheme 510

Scheme 511

1. Dismantle «GLOVE BOX»(ref-275837-S35412718882007122900000) . The right panel vent, air distribution flap stepping motor is the uppermost stepping motor.
2. Dismantle the stepping motor's connector by pressing in the lock and pulling out the connector.
3. Dismantle the screws holding the stepping motor and dismantle the stepping motor.

Scheme 512

1. Fit the stepping motor.
2. Connect the stepping motor's connector. Make sure the connector locks correctly.
3. Fit «GLOVE BOX»(ref-275837-S35412718882007122900000) .

Scheme 513

Scheme 514

1. Dismantle «SOUND INSULATION PANEL, DRIVER»(ref-275837-S20291105042007122900000) .
2. Dismantle the air duct for the floor vent. The defrost air distribution flap stepping motor is located at the top front on the heating and ventilation unit's left hand side.
3. Remove the screws from the stepping motor.
4. Carefully lift out the stepping motor a little. Turn the stepping motor so that it releases from the link arm.
5. Dismantle the stepping motor's connector by pressing in the lock and pulling out the connector.

Scheme 515

1. Connect the connector to the stepping motor. Make sure the connector locks correctly.
2. Fit the stepping motor to the link arm and align the steeping motor on the guide pin.
3. Fit the stepping motor.
4. Fit the air duct for the floor vent.
5. Fit «SOUND INSULATION PANEL, DRIVER»(ref-275837-S20291105042007122900000) .

1. Fit the air recirculation flap's stepping motor.
2. Connect the stepping motor's connector. Make sure the connector locks correctly.
3. Refit «GLOVE BOX»(ref-275837-S35412718882007122900000) .

Scheme 516

Scheme 517

1. Dismantle the rear cover from the headlining's lamp console.
2. Dismantle the center cover from the headlining's lamp console.
3. Dismantle the front cover from the headlining's lamp console.
4. Dismantle the compartment temperature sensor by pressing out the hooks that hold the compartment temperature sensor at the same time as the sensor is lifted upwards.
5. Pull out the compartment temperature sensor from the lamp console and dismantle the connector from the compartment temperature sensor.

Scheme 518

Scheme 519

1. Connect the compartment temperature sensor's connector to the sensor.
2. Insert the compartment temperature sensor into position.
3. Fit the compartment temperature sensor by carefully pressing it into the lamp console so that the hooks lock into position.
4. Fit the front cover on the headlining's lamp console.
5. Fit the center cover on the headlining's lamp console.
6. Fit the rear cover on the headlining's lamp console.

Scheme 520

1. Put the seat in its rearmost position.
2. Remove «GLOVE BOX»(ref-275837-S35412718882007122900000) .
3. Remove «SOUND INSULATION PANEL, PASSENGER»(ref-275837-S08591073902007122900000)
4. Dismantle the connector from the ventilation fan control.
5. Dismantle the ventilation fan control's securing screws.
6. Dismantle the ventilation fan control by pulling it outwards and back.

Scheme 521

1. Fit the ventilation fan control.
2. Connect the ventilation fan control's connector.
3. Fit «SOUND INSULATION PANEL, PASSENGER»(ref-275837-S08591073902007122900000) .
4. Refit «GLOVE BOX»(ref-275837-S35412718882007122900000) .

Scheme 522

Scheme 523

1. Remove the speaker grille.
2. Remove the screws.
3. Lift out the SID unit and unplug the connector.
4. Remove the solar sensor from the cover.

Scheme 524

Scheme 525

1. Fit the solar sensor to the cover.
2. Plug in the connector.
3. Fit the SID unit.
4. Fit the speaker grille.

Scheme 526

1. Automatic Climate Control (216)
2. Temperature sensor, cabin air (218)
3. Solar sensor (223)
4. Mixed air temperature sensor, right, floor (217RH)
5. Mixed air temperature sensor, right, panel (712RH)
6. Mixed air temperature sensor, left, floor (217LH)
7. Mixed air temperature sensor, left, panel (712LH)
8. Ventilation fan control (220)
9. Motor, ventilation fan (36)
10. Motor, air recirculation flap (38)
11. Motor, air distribution, defrost (714)
12. Motor, air distribution, floor (715)
13. Motor, air distribution, vent, right (716RH)
14. Motor, air mixing damper, right (222RH)
15. Motor, air-mixing damper, left (222LH)
16. ECM
17. Pressure sensor A/C (620)
18. A/C relay (156)
19. Compressor, A/C (170)
20. REC (701)
21. Rear window electric heater relay (113)
22. BCM (707)
23. Unit, steering column assembly, CIM (703)

Engine not running

If the engine is not running, no cooling water circulates through the heat exchanger, the A/C compressor does not operate and the alternator does not charge. This implies that the system cannot regulate the climate nor can the system use an abundant amount of current and present a misfire risk for one of the stepping motors due to the low battery voltage if the starter motor should be engaged. For these reasons, the control module selects electrically heated rear window off, fan current 0 A, recirculation off and switches off all stepping motors.

Scheme 527

Engine is running

As soon as the engine has started, the control module guides all functions automatically if no manual settings have been selected or if customer SID (Saab Information Display) settings have been made.

Scheme 528

Ignition off

When the ignition is switched off, the display is no longer lit and no buttons function. All stepping motors are stopped and recirculation is shut off. If the car is locked, the panel and defrost dampers will close and the floor damper will open completely after 9 minutes.

Scheme 529

The control module continues to make calculations for an additional two hours. The bus is alerted at thirty minute intervals and the outdoor temperature is checked. If the ignition is switched on within this two-hour period, the control module maintains the manual selections made during the earlier driving cycle. If the two hour period has passed, the control module starts in the AUTO setting or customer selected setting (if made with SID).

Temperature, separate for passenger and driver

The control module adjusts cabin temperature with one stepping motor for the driver zone and one stepping motor for the passenger zone. The stepping motors are connected to dampers which mix warm and cool air.

Scheme 530

The current temperature at head height is calculated for the front seat passenger and the driver. The following is used as input values for this calculation

1. outdoor temperature
2. time since the engine was last run
3. time since start
4. car speed
5. mixed air temperature
6. fan speed
7. intensity of the sun

The cabin temperature sensor value is read when the ignition is switched on if the ignition has been switched off for more than two hours. The value is then no longer used during the driving cycle.

The calculated head height temperatures are then compared with those which have been set on the ACC unit display by the driver and passenger. The set temperatures are adjusted somewhat when the outdoor temperature is taken into consideration since the experienced temperature should be the same as the set temperature. The difference between the experienced and actual temperature depends on the effect from air entering the cabin and heat from body parts as well as the interior and windows.

Scheme 531

As soon as a difference in the requested and actual temperature has been detected in the zone, the mixed air temperature must be raised or lowered. The control module rotates the air mixing damper until the desired air mixture temperature is achieved.

The control module reads the current mixed air temperature from two temperature zone sensors which are mounted in the floor and panel outlets on the heating and ventilation unit. The value from the corresponding sensor on either side are weighed equally depending on the extent to which each corresponding damper has been opened.

The heating and ventilation unit contains separate dampers for air distribution to the defroster, floor and panel vents. There is one damper for either side of the panel. Each damper is rotated by a stepping motor with a feed from the control module.

Scheme 532

When the driver zone requires warmth, defrost+floor is selected; when cooling is required, the panel damper is also opened. If rapid cooling is required, the air distributed to the defroster is reduced, and if necessary also the air to the floor vents, increasing the flow of air through the panel vents. When the car is started in cold weather, defrost only is selected initially. Once the coolant has reached a temperature of 35°C, the floor damper will start to open. At 45°C, the floor damper opens more rapidly and the defroster damper is closed slightly to distribute more air to the foot wells.

Scheme 533

The control module controls a fan control unit which feeds the fan motor. Fan current is lowest when neither zone requires heating or cooling. During cold weather starts, the value is determined by the coolant temperature and the outdoor temperature. The fan is switched off when the engine is not running.

Scheme 534

The control module feeds a direct current motor which rotates the recirculation damper. The motor reverses polarity in order to run in the opposite direction.

If the ignition has been switched off, recirculation is selected after a minimum of 15 seconds after engine start and only if the outdoor temperature exceeds 25°C and both zones require excessive cooling after start.

Subsequently, recirculation is selected in the following cases

Scheme 535

1. at outdoor temperatures over 38°C if the sun intensity exceeds 700 W/m 2
2. at outdoor temperatures over 45°C (extremely hot)
3. at outdoor temperatures over 30°C and speeds under 15 km/h during an interval of 30 seconds. Fresh air is re-connected when speed exceeds 30 km/h during an interval of at least 45 seconds.
4. at outdoor temperatures over 25°C if desired mixed air temperature cannot be achieved.
5. at outdoor temperatures over 25°C if the coolant temperature exceeds 118°C (diesel 115°C). Fresh air is re-connected when the coolant temperature is reduced to 115°C (diesel 112°C)
6. with activation of the windscreen washing to avoid that the odor from the washer fluid enters the compartment when driving.

Recirculation can be selected manually on the panel. A symbol on the display indicates when air is recirculating.

During ignition, fresh air is selected immediately.

The control module requests that the A/C compressor should start if the outdoor temperature exceeds 0°C and A/C OFF is not selected.

Scheme 536

The parking heater is activated from the ICM via SID and SIDC. When the ignition is switched off, the following setting will result

Scheme 537

1. air mixing damper automatically adjusts according to temperature setting
2. defrost damper open followed by the floor damper as a function of the coolant temperature
3. recirculation damper in recirculation setting when the temperature is below -10°C, otherwise fresh air is selected
4. fan current 0A to coolant reaches 20°C and thereafter increases to approx. 5A
5. display shows temperature setting
6. manual selections can be made with all buttons except for heated seats, A/C or the electrically heated rear window. Fan speed can only be reduced.

The control module returns to normal function as soon as the parking heater is switched off or the engine is started.

Auto

All functions are adjusted automatically and the selected temperature and AUTO are displayed. AC, electrically heated rear window and temperature increase or decrease can be selected without leaving the AUTO setting.

Scheme 538

Temperature increase or decrease

Interior variable temperature selection for driver and passenger zone if 1°C between 15°C and 27°C or 2°F between 58°F and 82°F. Selected temperature is displayed.

Scheme 539

Note. The compartment temperature is always controlled so that the experienced temperature corresponds with the set temperature. This means that a thermometer normally shows a value that differs from the set value.

Defrost

The system is set as follows

Scheme 540

1. fan current approx. 18 A
2. A/C on
3. air distribution in defrost setting
4. normal temperature control
5. recirculation off
6. electrically heated rear window on
7. AUTO switched off

Floor/panel or combination, even with air directed at the windshield

The system is set as follows

Scheme 541

1. desired air distribution
2. button symbols displayed
3. AUTO switched off

The button varies between manual on and off recirculation settings. Press the AUTO button in order to return to automatic control.

Scheme 542

Note that AUTO is displayed during manual recirculation. The system is set during recirculation as follows

1. recirculation on
2. button symbol displayed

Electrically heated rear window

The button switches the electrically heated rear window on and off. The electrically heated rear window cannot be activated manually until the engine is started.

Scheme 543

Cut-in interval is always 12 minutes.

The system sets the electrically heated rear window as follows

1. electrically heated rear window on
2. button symbol displayed

Fan

The fan varies fan flow up or down. If the button is held, the flow changes continuously. Press AUTO to return to automatic control.

Scheme 544

Fan speed is shown with a symbol on the ACC display. AUTO is switched off during manual fan speed selection. If fan speed 0 is selected, climate control is switched off and OFF is displayed.

The button selects A/C ON or A/C OFF. Note that AUTO is displayed even while the A/C is switched to OFF. The function can be programmed by the customer as soon as a manual selection has been made.

Scheme 545

The system is set for A/C OFF as follows

1. A/C off
2. recirculation in fresh air setting
3. A/C OFF shown in the display

OFF

The function can be selected manually with fan speed 0. The display text alternates between OFF and a blank display.

Scheme 546

The system is set for OFF as follows

1. fan current 0 A
2. A/C off
3. air distribution damper continues to be positioned
4. air mixing damper achieves maximum cooling
5. recirculation off (the function can still be selected manually)
6. electrically heated rear window off
7. recirculation only, OFF and AUTO buttons functional
8. OFF shown on the display.

Scheme 547

When the soft top is folded down the ACC system changes over to manual temperature setting. There are eleven temperature stages, 0-10.

The system sets as follows

1. AUTO switched off
2. heating, air distribution and fan speed are not affected, but selected air distribution and fan speed is displayed
3. recirculation and electrically heated rear window are disconnected
4. The A/C compressor is switched off (manual activation is possible with one press of the AC button).

All manual options are possible, apart from the electrically heated rear window and defroster functions.

Scheme 548

When the soft top is raised the system returns to AUTO mode and previously set temperature.

ACC uses the bus message "Soft top status" to determine when ACC status must be changed. At opening this takes place when the value of "Soft top status" moves from "Closed" to "Upper sequence". At closing this takes place when the value of "Soft top status" moves from "Open" to "Lower sequence", i.e. when the soft top cover starts the closing operation.

Note. When the soft top is folded down or all windows are lowered in a warm climate and high air humidity, then manual engagement of the air conditioning can result in condensation forming on cold surfaces, such as on air ducts.

The ventilation fan provides the cabin interior with air from outside the car or inside the cabin depending on the position selected for the air recirculation flap.

Scheme 549

Direct current motor.

The ventilation fan motor is connected to the corresponding fan control unit.

ACC

The fan control unit contains two connectors; a four-pin connector connected to the ACC unit and a two-pin connector which is directly-connected on the ventilation fan motor. Four-pin connector: control unit B+ feed to pin 4 from fuse 23 (fuse board 22) and is connected to ground through pin 1 on grounding point G41.

Scheme 550

Fan speed is controlled from ACC unit pin 5 through control unit pin 3 with a 2 kHz PWM. Fan control unit pin 2 is connected to ACC unit pin 25 with a return feed for diagnostics information. The control unit sends a 2 kHz PWM to the corresponding fan speed input. If a fault is detected, the control unit sends the indicated pulse ratio and the ACC unit generates the relevant DTC.

The motor is connected with linkage which controls the air recirculation flap. The flap regulates air flow to the fan so that the air is retrieved from outside the cabin or from inside the cabin; there is no intermediate setting.

The air recirculation flap has a DC motor. The ACC unit reverses output polarity in order to change the direction of motor rotation.

The motor is connected to ACC unit pins 25 (K42) and 4 (K42). The output polarity is reversed in order to change motor rotation direction. The ACC unit applies a B+ feed on pin 25 and grounds pin 4 in order to operate the motor for fresh air setting and conversely in order to operate the motor for cabin air retrieval.

Scheme 551

Scheme 552

Connection, motor/ACC unit for LHD car: ACC unit pin 25 towards motor pin 5 ACC unit pin 4 towards motor pin 6.

Connection, motor/ACC unit for RHD car: ACC unit pin 25 towards motor pin 6 ACC unit pin 4 towards motor pin 5.

For fast electric window heating during cold-weather starts.

4D, 5D: The circuit is also used for FM reception.

Scheme 553

The electrically-heated rear window consists of several wires which conduct electricity and are glued to the glass.

Electrically heated rear window, 4D

The heating coil receives voltage B+ from REC pin 2 (electrically-heated rear window relay) through the antenna amplifier and is connected to ground through an antenna filter which blocks the antenna ground signal.

Scheme 554

PIN DESCRIPTION TABLE

Electrically heated rear window, CV

Electrical heating coil is supplied with voltage B+ from REC pin 9(B3) (relay, electrically heated rear window).

PIN DESCRIPTION TABLE

Radio reception, 4D/5D

The antenna signal is received and fed to the antenna amplifier. In order that the antenna signal should not interfere with the heating coil power supply, the amplifier contains a filter which blocks the antenna signal. The heating coil ground side contains an antenna filter which blocks the antenna signal from ground.

Scheme 555

The control module ensures that the cabin climate always corresponds to the desired user settings.

Scheme 556

Scheme 557

PIN DESCRIPTION TABLE

Scheme 558

Scheme 559

The sensor provides information on the current temperature of the air passing the duct through the right-hand floor vent.

Scheme 560

The NTC sensor is located in a bracket.

Scheme 561

Sensor pin 1 has an internal ACC unit ground connection via pin 38 (K42) and sensor pin 3 receives a 5 V feed from pin 23 (K42) via an integrated 19.6 kOhm resistor in the ACC unit.

Scheme 562

Scheme 563

NTC resistor characteristics allow the resistance to decrease as the temperature rises. This means that the voltage fed over the resistor also decreases as the temperature rises.

The voltage level from the A/D sensor is converted and is then available in digital form. The digital voltage level is then converted to a temperature value which is stored in the ACC unit operating memory. Voltage levels near 0 V or 5 V are determined as circuit faults.

The sensor provides information on the current temperature of the air passing the duct through the left-hand floor vent.

The NTC sensor is located in a bracket.

Sensor pin 1 has an internal ACC unit ground connection via pin 38 (K42) and sensor pin 3 receives a 5 V feed from pin 1 (K42) via an integrated 19.6 kOhm resistor in the ACC unit.

Scheme 564

Scheme 565

NTC resistor characteristics allow the resistance to decrease as the temperature rises. This means that the voltage fed over the resistor also decreases as the temperature rises.

The voltage level from the A/D sensor is converted and is then available in digital form. The digital voltage level is then converted to a temperature value which is stored in the ACC unit operating memory. Voltage levels near 0 V or 5 V are determined as circuit faults.

The sensor provides information regarding the current cabin air temperature.

Scheme 566

The cabin temperature sensor is an NTC sensor encased in glass.

Scheme 567

Sensor pin 3 has an internal ACC unit ground connection via pin 31 (K32) and sensor pin 2 receives a 5 V feed from pin 6 (K32) via an integrated 19.6 Kohm resistor in the ACC unit.

Scheme 568

Scheme 569

NTC resistor characteristics allow the resistance to decrease as the temperature rises. This means that the voltage fed over the resistor also decreases as the temperature rises.

The voltage level from the A/D sensor is converted and is then available in digital form. The digital voltage level is then converted to a temperature value which is stored in the ACC unit operating memory. Voltage levels near 0 V or 5 V are determined as circuit faults.

Along with input from the ACC unit, the control unit controls the speed of the ventilation fan motor.

The control unit contains electronics which receive and process the ACC unit's control signal with regards to fan speed. The control unit grounds the ventilation fan motor and controls fan speed by increasing or decreasing the power supply. Control unit diagnostics occur on the ACC unit input and the outputs to the ventilation fan motor.

Scheme 570

The fan control unit contains two connectors; a four-pin connector connected to the ACC unit and a two-pin connector which is directly-connected to the ventilation fan motor.

Four pin connector.

B+ feed to control unit pin 4 from fuse 23 (fuse board 22) and is connected to ground through pin 1 on grounding point G41.

Fan speed is controlled from ACC unit pin 5 (K32) through control unit pin 3 with a 2 kHz PWM.

Fan control unit pin 2 is connected to ACC unit pin 25 (K32) with a return feed for diagnostics information. The control unit sends a 2 kHz PWM to the corresponding fan speed input. If a fault is detected, the control unit sends the indicated pulse ratio and the ACC unit generates the relevant DTC.

Two-pin connection to the ventilation fan motor.

The control unit is mounted in such a way that its two-pin voltage and ground connector are directly connected to the ventilation fan motor.

The fan motor is connected to ground through the fan control unit on grounding point G41. Fan motor speed is controlled by the control unit with an increase or decrease of the power supply.

Scheme 571

Wiring diagram, control signal.

Scheme 572

Wiring diagram, power supply.

Scheme 573

The stepping motor is connected by a linkage to and controls the air mixing damper for the left climate zone.

The unipolar stepping motor consists of a rotor (10 poles) and four stator windings. A gearbox transfers the power from the rotor to the lever which controls the damper.

Scheme 574

The four stepping motor windings receive a common B+ feed from ACC unit pin 20 (K42) and grounds each corresponding winding (pin 11, 31, 10 and 30 in K42) in a specific order thus operating the motor in short pulses, which explains the name stepping motor. The rotational direction can be changed.

Scheme 575

Scheme 576

When the stepping motor is stationary the two windings are continuously ground to lock the motor. The stepping motor does not need to be reconnected to the control module (position sensor), but by sending out a specific number of ground pulses the ACC unit always knows how far the air distribution flap has moved.

The stepping motor is connected by a linkage to the damper for air mixing the left climate zone.

The unipolar stepping motor consists of a rotor (10 poles) and four stator windings. A gearbox transfers the power from the rotor to the lever which controls the damper.

Scheme 577

The four stepping motor windings receive a common B+ feed from ACC unit pin 41 (K42) and grounds each corresponding winding (pin 12, 33, 13 and 32 in K42) in a specific order thus operating the motor in short pulses, which explains the name stepping motor. The rotational direction can be changed.

Scheme 578

Scheme 579

When the stepping motor is stationary, two windings are continuously grounded in order to lock the motor. The stepping motor does not need to be reconnected to the control module (position sensor). By sending a specific number of ground pulses, the ACC unit knows how far the air distribution damper has moved.

The solar sensor provides information regarding the intensity of the sun and its position.

Scheme 580

The solar sensor contains 5 solar cells: left, right, front, rear and top. The treated plastic housing allows infrared light (heat radiation) through only. The ACC control module sends a B+ pulse feed to the sensor and grounds the sensor. Voltage from the 5 sensor elements are sent in succession to the ACC unit which then calculates the sun's intensity and position.

Scheme 581