Front Evaporator With A/C Unit Installed

Front Evaporator With A/C Unit Installed

Special tools, testers and auxiliary items required

• Pliers (T40147)

• Strong carpet knife with a point; the blade must be secure and the handle must be strong.

• The removed evaporator contains refrigerant oil that must be returned to the refrigerant circuit (with the new evaporator).

• The evaporator is currently not available as a replacement part for all versions, therefore check in advance, whether this evaporator is available as a replacement evaporator. Refer to Electronic Parts Catalog (ETKA). If the evaporator is not available as a replacement evaporator, the A/C unit must be removed. Refer to => [ Front Heating and A/C Unit ] Front Heating and A/C Unit and the evaporator housing with the series evaporator must be replaced entirely, refer to => [ Front Evaporator Housing ] Front Evaporator Housing (as well as for => [ Disassembling Front A/C Unit ] Disassembling Front A/C Unit and => [ Evaporator Housing ] Evaporator Housing).

Removing

- Move the driver and front passenger seats as far back as possible.

- Switch off the ignition.

- Drain the refrigerant circuit.

- Remove the plenum chamber front wall.

- Remove the expansion valve to the evaporator in the front A/C unit, refer to => [ Front Expansion Valve ] Front Expansion Valve.

• Seal open pipe connections.

- Remove the expansion valve mounting plate - A - from the refrigerant lines - B - and - C -.






- Remove the storage compartment under the dash panel on the driver's side.

- Remove the left footwell (driver side), refer to => [ Left Footwell Vents ] Left Footwell Vents.

- Remove the steering column and pedal assembly.

• Due to the limited space, the pedal assembly must be removed for the following steps (disconnect the refrigerant lines on the evaporator, remove them from the A/C unit, and install the new refrigerant lines). If the evaporator was already replaced once (and the refrigerant lines to the evaporator therefore do not need to be disconnected and removed), it is still helpful to remove the pedal assembly because of the space conditions.

- Release catch - B - and remove the cover for the refrigerant lines to evaporator - A - from A/C unit - C -.






• During the remaining steps, ensure that the sealing lip on A/C unit - E - is not damaged.

• Shortly after the start of production of this vehicle, the refrigerant lines to the evaporators - A - and - B - were wrapped with a Butyl matting. This wrapping serves to reduce the noise from the refrigerant lines to the evaporator.

• This illustration shows the refrigerant lines to the evaporator - A - and - B - without wrapping (status at the start of production).






• Shortly after the start of production of this vehicle, the refrigerant lines to the evaporators - A - and - B - were wrapped with a Butyl matting - C -. This wrapping serves to reduce the noise from the refrigerant lines to the evaporator. The refrigerant lines without and with wrapping are cut through in the same way.






• This illustration shows the refrigerant lines to the evaporator - A - and - B - without wrapping (status at the start of production).






• Shortly after the start of production of this vehicle, the refrigerant lines to the evaporators - A - and - B - were wrapped with a Butyl matting - C -. This wrapping serves to reduce the noise from the refrigerant lines to the evaporator. The refrigerant lines without and with wrapping are cut through in the same way.






- Remove the Butyl matting - C - as far away as necessary from the refrigerant lines to the evaporator - A - and - B -.

- Disconnect both refrigerant lines to evaporator - A - and - B - at the locations identified with - C - using the (T40147).






- Bend the part of the refrigerant line - A - (which is already on the evaporator) to the right (to the evaporator) so that it does not interfere when removing the evaporator.

- Remove the glove compartment.

- Remove the right (passenger) footwell vent. Refer to => [ Right Footwell Vent ] Right Footwell Vent.

• A/C system malfunctions in the case of interchanged control motors and/or connectors, refer to => [ A/C Control Motor Block Diagram ] A/C Control Motor Block Diagram.

• The control motors and connectors are identical. If they are installed or connected incorrectly, the corresponding doors cannot be properly adapted and/or activated.

• Clearly label control motors and connectors prior to removal to prevent incorrect installation.

- Remove the air intake housing, refer to => [ Air Intake Housing Of Front A/C Unit ] Air Intake Housing Of Front A/C Unit.

- Cut housing wall - A - (on the right side of the A/C unit) using a sharp knife (for example, a strong carpet knife with a point; the blade must be secure and the handle must be strong) along marked cutting line - B - from the A/C unit.






• During the further steps, ensure that the sealing lip on A/C unit - C - is not damaged when cutting out housing wall - A -.

• If the connection between housing wall - A - and the A/C unit cannot be disconnected with a carpet knife because the material at cutting line - B - is too thick, the connection at cutting line - B - can be carefully disconnected for example with a window cutter (V.A.G 1561A) and a blade, offset (V.A.G 1561/4) or a saw blade, 63mm (2.5 in.) (V.A.G 1561/25). Do not damage the sealing lip on A/C unit - C -.

• If the evaporator was already replaced earlier (separator wall glued in instead of housing wall - A -), cut out this separator wall at the adhesive line (marked cutting line - B -) with the window cutter (V.A.G 1561A). After removal of the evaporator, carefully remove adhesive residue.

- Remove evaporator - B - in the direction of the arrow - arrow - from A/C unit - A -.






- Attach a thin string - F - to each disconnected refrigerant lines - B - and - C -.






• String - F - serves as an insertion aid for the new refrigerant lines to be installed.

- Coat both disconnected refrigerant lines - B - and - C - and both pass-throughs - D - and - E - of grommet - A - with lubricant.

When removing an installing refrigerant lines - B - and - C -, do not damage grommet - A -.

• A damaged grommet - A - can only be replaced with the A/C unit removed.

• Coat grommet - A - and refrigerant lines - B - and - C - with lubricant for removal and installation of refrigerant lines - B - and - C - and work carefully.

- Ask a colleague for help detaching refrigerant lines - B - and - C - from grommet - F -.

- Turn disconnected refrigerant line - B - in the direction of the arrow, detach from the grommet, and remove from A/C unit - A -.






- Turn disconnected refrigerant line - C - in the direction of the arrow, detach from the grommet, and remove from A/C unit - A -.

Installing

Prior to installing the evaporator, (Replace the refrigerant circuit components).

• The removed evaporator contains refrigerant oil that must be returned to the refrigerant circuit (with the new evaporator) => Refrigerant R134a Servicing.

• New refrigerant lines - C - and - D - are provided with protective caps to prevent the connection from being damaged during installation and to prevent the penetration of dirt.






• Refrigerant lines - C - and - D - are installed with protective caps - A - and - B - through the A/C unit into the grommet to the plenum chamber.

• Refrigerant lines - C - and - D - are wrapped with the Butyl matting - G - and - H - to reduce the noise. Make certain that the Butyl matting is not damaged or pinched in the bracket during installation.

Installation is carried out in the reverse order while observing the following.

- Coat both protective caps - A - and - B - and new refrigerant lines - C - and - D - with lubricant in the area of the protective caps.

- Secure the new refrigerant lines at the string - F - threaded during removal of disconnected refrigerant lines - C - and - D -.






• Ensure that the strings - F - are not twisted in the installation shaft of the A/C unit.

- Coat both pass-throughs - D - and - E - of grommet - A - with lubricant.

When removing an installing refrigerant lines - B - and - C -, do not damage grommet - A -.

• A damaged grommet - A - can only be replaced with the A/C unit removed.

• Coat grommet - A - and refrigerant lines - B - and - C - with lubricant for removal and installation of refrigerant lines - B - and - C - and work carefully.

- Ask a colleague for help installing refrigerant lines - B - and - C - in grommet - A -.

• New refrigerant lines - C - and - D - are provided with protective caps to prevent the connection from being damaged during installation and to prevent the penetration of dirt.






• Refrigerant lines - C - and - D - are wrapped with the Butyl matting - G - and - H - to reduce the noise. Make certain that the Butyl matting is not damaged or pinched in the bracket during installation.

• Refrigerant lines - C - and - D - are installed with protective caps - A - and - B - through the A/C unit into the grommet to the plenum chamber.

- Secure the part of string - F - pulled though the grommet with the disconnected refrigerant lines in the area of the protective cap to the new refrigerant lines. Ensure that the allocation is correct and that the strings in the A/C unit are not twisted.






- Insert refrigerant line - A - (thin pipe) in A/C unit - C - and thread it through the lower smaller opening into the grommet to the plenum chamber by turning in a counterclockwise direction.






• The refrigerant lines - A - and - B - are wrapped with a Butyl matting to reduce noise. Make sure that this wrapping is not damaged during installation.

• The colleague can facilitate insertion into the correct opening - E - of the grommet by carefully pulling on string - F -.






- Insert refrigerant line - B - (thicker pipe) in A/C unit - C - and thread it through the upper larger opening into the grommet to the plenum chamber by turning in a counterclockwise direction.






• The colleague can facilitate insertion into the correct opening - D - of the grommet by carefully pulling on string - F -.






- Arrange both refrigerant pipes - A - and - B - so that they do not interfere and are not damaged during installation of the evaporator.






- Check the A/C unit via the installation shaft for evaporator - A - for dirt and clean the A/C unit if necessary.






• Pay attention to left and right condensation water drains - B - in the A/C unit.

- Check foam strips - B - attached to replacement evaporator - A - and covers - E - for damage and proper adhesion.






- Check both connections - C - and - D - on replacement evaporator - A - for dirt and damage.

- Install cover - E - on the correct side of replacement evaporator - A -.

• Cover - E - is included in the delivery of the replacement evaporator. Refer to Electronic Parts Catalog.

- Push replacement evaporator - A - with cover - D - into the shaft of A/C unit - B - to the stop while ensuring that cover - D - and glued-on foam strips - C - do not detach from the evaporator during insertion.






• Both retaining tabs - E - of cover - D - must engage in the A/C unit.

- Remove the protective caps from both refrigerant pipes - A - and - B -.






- Check refrigerant lines - A - and - B - and the connections on evaporator - E - for damage and dirt.

• Even slight damage (a scratch) a little bit of dirt (a hair) can cause leakage at a connection.

• O-ring seals - C - and - D - are pre-installed on refrigerant lines - A - and - B - by the manufacturer.

• Refrigerant lines - A - and - B -, O-ring seals - C - and - D -, bracket - F - and bolt - G - are included in the delivery of the replacement evaporator. Refer to Electronic Parts Catalog.

- Coat both O-ring seals - C - and - D - lightly with refrigerant oil, refer to => [ Refrigerant Circuit O-rings ] Refrigerant Circuit O-rings.

- Install refrigerant lines - A - and - B - in the connections of evaporator - E - to the stop.

- Pre-install bracket - F - with bolt - G - as shown on evaporator - E -.

• Screw in bolt - G - so that both refrigerant lines - C - and - D - can still be turned without pretension.

• When installing bolt - G -, ensure that bracket - F - and the refrigerant lines are not under tension.

• The refrigerant lines - A - and - B - are wrapped with a Butyl matting to reduce noise. Make sure that this wrapping is not pinched in the bracket - F - during installation.

- Connect the expansion valve mounting plate - A - to the refrigerant lines - B - and - C -.






- To align the two refrigerant lines, install the expansion valve (pre-installation), refer to => [ Front Expansion Valve ] Front Expansion Valve.

- Check support ring - E - for proper installation position and check grommet - D - for damage.

- Tighten bolt - G - on the evaporator connector (tightening specification: 5 Nm).






- Install the expansion valve, refer to => [ Front Expansion Valve ] Front Expansion Valve.

- Connect both refrigerant lines to the expansion valve, refer to => [ Front Expansion Valve Refrigerant Lines, Disconnecting ] Front Expansion Valve Refrigerant Lines, Disconnecting.

- Check the cover - A -. The retainer - G - may (for example during removal) not be overstretched and the seal for the necessary surrounding groove and spring - F - may not be damaged.






- Remove the cover - A -, the separator - B - and the component - C - completely from the guide - D -.

• The component - E - for the guide - D - must remain and serve as an insertion aid.

• A modified cover, like one needed for the assembly at the refrigerant lines for the replacement evaporator, is not currently within the delivery scope for the replacement evaporator (introduction not yet finalized). Therefore, the cover - A -, like the one for the evaporator that is installed by the manufacturer, is reworked.

- Rework the corner - H - of the tab - J - according to the illustration (round or slope the corners).

• The corner - H - is reworked so that the cover - A - can be assembled more effectively.

• The surrounding groove and spring - F - for the cover - A - provided for the seal may not be damaged. This way there are no problems with the operation of the A/C system. Also, the retainer - G - must not be overstretched so that it catches correctly again when it is installed.

- Check the cover - A - and the A/C unit at the connection locations.






• Even the smallest leak at groove/spring connection - D - and - E - between cover - A - and the A/C unit can cause whistling noises. Coat the connecting surfaces lightly with silicone grease (part number G 000 405 A2). Refer to the Electronic Parts Catalog.

- Install the reworked cover - A - for the refrigerant lines to the evaporator.

• When installing cover - A - ensure that no foam parts are pinched and that the floor covering is not in contact with cover - A - possibly crushing it.

- Check cover - A - and catch - B - for proper seating.

• If the groove / spring connection - D - and - E - between the cover - A - and the A/C unit is not jointed correctly all the way around, then the noise of escaping air will be apparent when operating the A/C system.

- Carefully cover the floor covering under the installation shaft for the evaporator (to protect the floor covering against possible contamination with the adhesive sealant).

- Clean A/C unit - B - and cover - D - at the locations marked with - F - and - G - (and dry if necessary).






- Carefully apply silicone sealing compound (D 176 001 A3) , for example, to the areas marked with - F - and - G - (connection points between A/C unit - B - and inserted separator wall - D - and between the evaporator and separator wall - D -. Refer to Electronic Parts Catalog (seal).

• If the connection points between A/C unit - B - and the evaporator and separator wall - D - are not properly sealed, condensation water from the A/C unit could leak into the footwell when cornering, for example.

- Remove any excess adhesive (the adhesive may only in the area - D -); and remove any excess adhesive out of the groove - G -.

- Install the air intake housing, refer to=> [ Air Intake Housing Of Front A/C Unit ] Air Intake Housing Of Front A/C Unit.

- Install the remaining removed parts in the opposite order.

- Evacuate and fill the refrigerant circuit.

- Perform the basic setting and the output diagnostic test mode of the A/C system using the Vehicle Diagnostic Tester in the "Guided Fault Finding" function.

• In this vehicle, the control motors are equipped with electronics. During the basic setting, a new control motor learns its position on the A/C unit and can then be activated by the Climatronic control module (J255) (currently all control motors are identical). Check using the Vehicle Diagnostic Tester in the "Guided Fault Finding" function.

• During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform with the specification, the control motors will adapt incorrectly and the door control will be wrong, refer to => [ A/C Control Motor Block Diagram ] A/C Control Motor Block Diagram.

- Check the event memory of the Climatronic control module, and erase any displayed malfunctions using the Vehicle Diagnostic Tester in the "Guided Fault Finding" function.

- Operate the A/C system after filling the refrigerant circuit, refer to => [ A/C System Operating After Filling Refrigerant Circuit ] A/C System Operating After Filling Refrigerant Circuit.

• Note the information regarding operating the A/C system after filling.