HVAC - Removal & Installation: Other Volvo S60 I

Climate control unit, replacing

Special tools

1158957

The illustrations in this service information are used for different model years and / or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Preparations

Note. Read off data from the control module before replacing the control module. This is carried out via VIDA communication. After replacing the control module, the relevant parameters must be programmed into the new control module.

Read the safety precautions for handling refrigerant. See Refrigerant, safety regulations .

Read the instructions covering slow and fast leaks. See Oil air conditioning (A/C) system, filling .

Note. Always plug pipes and connectors when working on the climate control system.

Drain the refrigerant from the air conditioning (A/C) system. See REFRIGERANT, DRAINING .

Remove the battery lead. See Battery, disconnecting .

Scheme 676

Clamp the heating hoses. Use lock grip pliers 1158957 .

Detach the heating hoses from the heat exchanger by pressing in the hose coupling and twisting it out to the side. Then pull the hose out.

Plug the pipes for the heat exchanger.

Remove

1. the cover plate and the rubber seal for the lead-in
2. the windshield wiper arm. See «WIPER MECHANISM, WINDSHIELD, REPLACING»(ref-445663-S05917259242012010600000)

Scheme 677

1. the 2 screws.

Scheme 678

Remove

1. the heat shield on the firewall above the expansion valve
2. the striker plate for the refrigerant pipes
3. the refrigerant pipes from the expansion valve.

Scheme 679

Remove the dashboard and the center console. See Dashboard, replacing .

Protect the floor and sills.

Remove

1. the 4 screws to the left and right of the A-post
2. the 2 screws between the door and the A-post. Tighten the screws a little so that they protrude from the member
3. the 4 screws to the left and right of the center console.

Detach the steering column / steering shaft but leave it hanging in place. See Steering column, replacing .

Scheme 680

1. the air ducts from the heater assembly to the floor
2. the floor drainage channels on the left and right-hand sides.

Pull the member and the climate control unit backwards a little.

Remove

1. the tie straps for the cable harness on the driver's side
2. the cable duct above the climate control unit on both sides.

Scheme 681

1. the 2 screws from the member / climate control unit on the passenger side
2. the 4 screws securing the climate control unit at the member on the left and right-hand sides
3. the switch for the blower fan motor.

Scheme 682

1. the cable duct behind / above the member mounting on the passenger side
2. the cable duct above / behind the mounting for the member
3. the T shaped member from the climate control unit.

Hold up the member and the cable duct on the passenger side. Remove the climate control unit on the passenger side.

Note. Two people are required for this job.

Scheme 683

Check and replace the floor seals if necessary.

Install the front seal for the refrigerant pipe.

Check and replace the O-rings.

Scheme 684

Work in the passenger compartment

Install

1. the climate control unit in the car
2. the member on the climate control unit.

Note. Two people are required for this job.

Install

1. the screws and the bracket on the member / climate control unit
2. the cable duct and secure it.

Position the wiring for the radio and the climate control unit in the cable duct.

Locate the cable for the sensor on the dashboard and the cable for the light switch.

Position the member for the climate control unit against the firewall. Check the location in relation to the openings for the coolant and heat exchange pipes.

Press the member / climate control unit into position on the A-post against the firewall.

Secure the member / climate control unit loosely on the A-post using the screws.

Secure the member / climate control unit and console loosely using the screws.

Install the member on the A-post.

Tighten the screws on the center console.

Install

1. the air ducts
2. the gutter
3. the cable ducts and the tie straps
4. the connector for the blower fan motor
5. the 2 screws for the member / climate control unit on the passenger side
6. the steering column. See «Steering column, replacing»(ref-445664-S11841501472012010600000)
7. the dashboard and the center console. See «Dashboard, replacing»(ref-445638-S22256600762012010600000) .

Work in the engine compartment

Install

1. the striker plate for the refrigerant pipes
2. the refrigerant pipes on the expansion valve
3. the heat shield over the expansion valve
4. the cover plate and the rubber seal for the lead-in for the heating hoses
5. the heating hoses which will click when connected
6. the 2 screws for the member for the dashboard
7. the windshield wiper arm. See «WIPER MECHANISM, WINDSHIELD, REPLACING»(ref-445663-S05917259242012010600000)

Finishing

Install the battery lead. See Battery, disconnecting .

Vacuum pump the air conditioning (A/C) system. See Vacuum pumping .

Fill the air conditioning (A/C) system with refrigerant. See Refrigerant, filling .

Leak trace the air conditioning (A/C) system. See Leak tracing, fluorescent tracing agent / UV lamp or Leak tracing, electronic leak tracer .

Condenser, replacing

Note. The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Scheme 685

Note. First read the instructions covering slow and fast leaks. See: Oil air conditioning (A/C) system, filling .

Note. Always plug the pipes and connections when working on the climate control system.

Drain the refrigerant from the system. See Refrigerant, draining .

Raise the vehicle.

Remove

1. the air baffle under the radiator unit with the 2 screws (1), and the 2 catches (2).
2. the bumper cover, see: «Bumper front, replacing»(ref-445630-S30137572602012010600000) .

Scheme 686

Scheme 687

Remove

1. right-hand pipe connection for A/C with the screw, x 1
2. the connector to the pressure sensor
3. the pressure sensor
4. right-hand lower mounting with the screw, x 1.

Scheme 688

Detach the left-hand A/C pipe from the clip.

Remove the left-hand lower mounting with the screw, x 1.

Scheme 689

Detach the left-hand headlight slightly but allow the cables to remain, see: Headlamp/bulb, replacing .

Remove the left-hand A/C pipe with the screw, x 1.

Scheme 690

Remove the upper mountings on the condenser with the screws, x 2.

The condenser is held in place by the left-hand A/C pipe.

Raise the vehicle.

Remove the condenser straight down. Press aside the A/C pipe slightly on the left-hand side while pulling the condenser down.

Note. For tightening torques, see: Tightening torque .

Installing the condenser

Fill oil in the condenser, see: Oil air conditioning (A/C) system, filling .

Note. Always use new O-rings lubricated with compressor oil.

Install the condenser with the 2 x M6 lower mounting screws. Tighten.

Guide the left-hand A/C pipe into place to the condenser connection and secure with the clip

Install

1. the right-hand A/C pipe with the screw, 1 x M6, and tighten
2. the pressure sensor and tighten
3. the connector.

Raise the vehicle.

Install

1. the condenser's upper mountings, 2 x M6, and tighten
2. the left-hand A/C pipe, 1 x M8, and tighten
3. left-hand headlight, see: «Headlamp/bulb, replacing»(ref-445658-S02030193702012010600000) .

Filling refrigerant and detecting leaks

Vacuum pump the air conditioning (A/C) system. See: Vacuum pumping .

Fill the system, see: Refrigerant, filling .

Leak trace the system. See: Leak tracing, fluorescent tracing agent / UV lamp or: Leak tracing, electronic leak tracer .

Installing the bumper cover and air baffle

Install

1. the bumper cover, see: «Bumper front, replacing»(ref-445630-S30137572602012010600000)
2. the air baffle under the radiator unit with the 2 catches and the 2 screws.

Damper motor module (DMM) air distribution, replacing

The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Note. The damper motor module (DMM) for air distribution is only on the right-hand side of the car.

Scheme 691

Remove

1. the glove compartment. See «Glove compartment, replacing»(ref-445638-S30771532232012010600000)
2. the switch HINT: Use a small electrician's screwdriver to pry up the switch by the lock. Depress the switch at the rear edge. Pull straight out.
3. the 2 x screws
4. the control module.

Installing the damper motor module (DMM) for air distribution

Install

1. the control module in position. Adjust the shaft journal so that it goes in
2. the 2 screws. Tighten alternately
3. the switch. Ensure that it is correctly positioned
4. the glove compartment. See «Glove compartment, replacing»(ref-445638-S30771532232012010600000) .

Note. Identify the damper motor module (DMM) for air distribution using VIDA.

Damper motor module (DMM) defroster, replacing

The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Note. The damper motor module (DMM) for the defroster is only used in cars with electronic climate control (ECC). It is positioned on the right-hand side of the car.

Scheme 692

Remove

1. the soundproofing panel. See «SOUNDPROOFING PANEL, REPLACING»(ref-445665-S24616757552012010600000)
2. the glove compartment. See «Glove compartment, replacing»(ref-445638-S30771532232012010600000)
3. the switch HINT: Use a small electrician's screwdriver to pry up the switch by the lock. Depress the switch at the rear edge. Pull straight out.
4. the 2 x screws
5. the control module.

Installing the damper motor module (DMM) for the defroster

Install

1. the control module in position. Adjust the shaft journal so that it goes in
2. the 2 screws. Tighten alternately
3. the switch. Ensure that it is correctly positioned
4. the glove compartment. See «Glove compartment, replacing»(ref-445638-S30771532232012010600000)
5. the soundproofing panel. See «SOUNDPROOFING PANEL, REPLACING»(ref-445665-S24616757552012010600000) .

Note. Identify the damper motor module (DMM) for the defroster using VIDA.

Damper motor module (DMM) recirculation, replacing

The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Scheme 693

Remove

1. the glove compartment. See «Glove compartment, replacing»(ref-445638-S30771532232012010600000)
2. the switch HINT: Use a small electrician's screwdriver to pry up the switch by the lock. Depress the switch at the rear edge. Pull straight out.
3. the 2 x screws
4. the control module.

Check the functionality of the control module mechanism (1). Check that the arms for the dampers (2) are secure.

Installing the damper motor module (DMM) for recirculation

Install

1. the control module in position. Adjust the shaft journal in relation to the mechanism (1) so that it goes in
2. the 2 screws. Tighten alternately
3. the switch. Ensure that it is correctly positioned
4. the glove compartment. See «Glove compartment, replacing»(ref-445638-S30771532232012010600000) .

Note. Identify the damper motor module (DMM) for recirculation using VIDA.

Damper motor module (DMM) temperature, replacing

The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Note. The are 2 damper motor modules (DMM) for temperature, one on the right (white arm) and one on the left-hand side (black arm).

Scheme 694

Remove

1. the glove compartment. See «Glove compartment, replacing»(ref-445638-S30771532232012010600000)
2. the switch HINT: Use a small electrician's screwdriver to pry up the switch by the lock. Depress the switch at the rear edge. Pull straight out.
3. the 2 x screws
4. the control module.

Installing the damper motor module (DMM) for temperature on the passenger side

Install

1. the control module in position. Adjust the shaft journal so that it goes in
2. the 2 screws. Tighten alternately
3. the switch. Ensure that it is correctly positioned
4. the glove compartment. See «Glove compartment, replacing»(ref-445638-S30771532232012010600000) .

Note. Identify the damper motor module (DMM) for temperature using VIDA.

Removing the damper motor module (DMM) for temperature on the driver's side

Remove

1. the soundproofing panel. See «SOUNDPROOFING PANEL, REPLACING»(ref-445665-S24616757552012010600000)
2. the connector from the control module HINT: Use a small electrician's screwdriver to pry up the switch by the lock. Depress the switch at the rear edge. Pull straight out. HINT: Pull the control module out slightly. Position the point of the electrician's screwdriver between the arms on the control for the lever. Pry the arms away from the ball on the motor lever.
3. the 2 x screws
4. the control module.

Installing the damper motor module (DMM) for temperature on the driver's side

Install

1. the control module in position. Adjust the shaft journal so that it goes in
2. the lever for the mechanism on the ball for the motor lever HINT: Insert the point of the electrician's screwdriver behind the lever and round-nosed pliers or similar behind the motor lever. Press the ball onto the mechanism.
3. the 2 screws. Tighten alternately
4. the switch. Ensure that it is correctly positioned
5. the soundproofing panel. See «SOUNDPROOFING PANEL, REPLACING»(ref-445665-S24616757552012010600000) .

Note. Identify the damper motor module (DMM) for temperature using VIDA.

Note. Read off data from the control module before replacing the control module. This is carried out via VIDA vehicle communication. After replacing the control module, the relevant parameters must be programmed into the new control module.

Scheme 695

Ignition off.

Remove the key.

Note. The key must be removed to ensure that the ignition is not switched on by mistake.

Note. After the key has been removed: Wait 3minutes before starting work.

Scheme 696

Note. The gear selector must be in the rearmost position before the dashboard environment panel can be removed.

Scheme 697

Remove

1. the two screws (2) on the lower edge of the panel.
2. the panel (3). NOTE: The radio component and the dashboard environment panel are complementary and are mounted at the join with hooked mountings.

Scheme 698

HINT: To facilitate removal: Angle the dashboard environment panel outwards so that it is possible to insert a couple of fingers between the center console and the dashboard environment panel.

HINT: Pull the dashboard environment panel downwards at the same angle.

HINT: The dashboard environment panel is correctly secured. Force is required to remove it.

1. connectors.

Lift out the panel.

Install

In reverse order.

Scheme 699

Note. If any of the outer hooks break off, this must be "rectified". Tape the 3.5mm thick component measuring 20 X 20mm to the reverse of the dashboard environment panel. Use double-sided adhesive tape. Fix the other side of the piece with double-sided adhesive tape so that there is a solid anchorage when reinstalling against the center console.

Scheme 700

Removal

1. Remove the dashboard environment panel. See «Replacing dashboard environment panel»(ref-445648-S13798195582012010600000) .
2. Remove the panel for the switches. See «Replacing climate control unit switches»(ref-415321-S41429179482011081500000) .
3. Remove the rear cover.

Front panel

1. Release the catches. Pull off the front panel. NOTE: Be careful if the front panel is to be reused. The panel has double-sided adhesive tape on the reverse.

Installation

1. When reusing the front panel, check that the tape is intact and secures correctly. Replace the tape if necessary.
2. For a new front panel, remove the masking tape from the double-sided adhesive tape and press the front panel into place.

Install in reverse order.

Ordering software

Order the software. See 9438292 .

After replacing the control module, the following must be carried out.

1. Reprogram the customer programmed data.
2. Carry out self-adjustment of the damper motor end positions.
3. Test drive the car. Check that the function of the climate control system is OK.
4. Then check that no diagnostic trouble codes have been stored during the replacement.

Information about programming the control module, damper motor self-adjustment and reading off diagnostic trouble codes can be found under VIDA vehicle communication.

Scheme 701

Remove

1. the switches. See «Replacing climate control unit switches»(ref-415321-S41429179482011081500000)

Install

In reverse order.

Regulations

Filling and leak tracing the climate control system with tracing agent and an UV lamp from Bright Solutions Inc.

Note. The coloring agent may discolor the car paintwork. Therefore extreme caution must be taken when handling the tracing agent.

Note. Carefully follow the manufacturers instructions when handling the UV lamp and the tracing agent.

Note. After filling with the tracing agent, the decal supplied by the manufacturer / supplier must be applied at the point indicated.

Filling with fluorescent tracing agent

When replacing components in the climate control system, the component (for example the drier) can be filled with tracing agent.

Filling an empty climate control system with tracing agent when a leak cannot be localized

1. Fill with 225g of refrigerant with fluorescent tracing agent according to the manufacturers instructions for leak tracing.

Scheme 702

If the climate control system is filled

1. Drain off 225 g of refrigerant, see «Refrigerant, draining»(ref-445662-S38931960722012010600000)
2. Fill the climate control system with refrigerant with tracing agent according to the manufacturers instructions
3. Leak trace according to «Leak tracing, fluorescent tracing agent / UV lamp»(ref-415247-S41745310232011081500000) .

If the amount of refrigerant in the climate control unit cannot be determined

1. Drain the climate control system according to «Refrigerant, draining»(ref-445662-S38931960722012010600000)
2. Fill the climate control system with refrigerant with tracing agent according to the manufacturers instructions
3. Leak trace according to «Leak tracing, fluorescent tracing agent / UV lamp»(ref-415247-S41745310232011081500000) .

Important information about filling with refrigerant

Note. Refrigerant must only be filled via the service valve (TXV system) on the high pressure (HP) side.

HINT: A specification decal in the engine compartment lists the refrigerant capacity of the air conditioning (A/C) system.

Scheme 703

Note. The most common cause of failed filling on the high pressure side is incorrect vacuum pumping or because the pressure in the filling unit is not high enough, or a combination of these two.

Note. The filling unit should preferably have a heating unit for refrigerant. This is so that the pressure in the filling unit is higher than in the system that is to be filled.

Note. When filling with refrigerant, compensate for the volume in the filling hoses before closing the filler valve.

Leak tracing, electronic leak tracer

Special tools

9511207

Leak tracing with an electronic leak tracer using refrigerant as a tracing agent

When fault tracing using refrigerant as a tracing agent, we recommend that leak tracer 9511207 is used.

Note. The engine must always be switched off when leak tracing.

An electronic leak tracer can be used if there is still refrigerant in the climate control system.

If the climate control system is empty and a visual or physical test has not identified the leak.

Leak tracing

1. Fill the climate control system with 200 grams of refrigerant
2. There must not be any strong smells or fumes in the engine compartment. These can affect the leak tracing
3. Leak-trace using a leak tracer.

If no leakage is found

1. Fill with the remaining amount of refrigerant
2. Add fluorescent tracing agent according to «Filling with fluorescent tracing agent with the refrigerant»(ref-445648-S17437214132012010600000)
3. If leakage is suspected, ask the customer to drive the car and then return for new leak tracing / repairs.

If leakage is detected

1. Remedy the cause of the leak
2. Vacuum pump according to «Vacuum pumping»(ref-445662-S33106600472012010600000)
3. Add fluorescent tracing agent with the refrigerant according to «Filling with fluorescent tracing agent with the refrigerant»(ref-445648-S17437214132012010600000) .

Or

1. Fill with refrigerant according to «Refrigerant, filling»(ref-415247-S31108879012011081500000)
2. Leak trace according to «Leak tracing with an electronic leak tracer using refrigerant as a tracing agent»(ref-445648-S28306172312012010600000) .

Or

1. Leak trace according to «Leak tracing, fluorescent tracing agent / UV lamp»(ref-415247-S41745310232011081500000) .

Oil in the A/C system

Special tools

9511204

Replacing the receiver

Replace the receiver in the following case

1. When replacing the compressor (compressor breakdown for example).
2. For coolant leaks in which nearly 100% has leaked out of the system. (System not under pressure).
3. When replacing an A/C component after the warranty period.

Filling the A/C system with oil

Note. Fill with oil before vacuum pumping.

Filling with PAG oil

When replacing pipes or hoses the oil can be filled through the service valve.

When filling with PAG oil (part number 8708581-7) in the vehicle, do the following

1. Remove the needle valve in the service valve using valve tool «9511204»(ref-403953-S29886163752011061000000)

Scheme 704

Use the filler sprayer (without plastic hose) which is supplied with the station. The sprayer may need to be cleaned so that different oils are not mixed.

1. Check according to the table above and measure how much oil should be filled. After filling with oil, re-install the needle valve.

Note. Use only your thumb and index finger when tightening the service valve using valve needle tool 9511204 . This is to prevent damage to the seal on the valve.