Air Intake Unit Electrical Components and Connecting Elements
Air Intake Unit Electrical Components and Connecting Elements
• On removal, mark the various control motors and the associated connecting elements between door and motor to prevent mix-ups with connecting elements of other control motors.
• When removing, mark the various connectors to the control motors (risk of interchange with connectors and control motors of identical construction).
• Various connectors of identical construction are present on wiring harness of heating & A/C unit, apply identifying marks on connectors before disconnecting (risk of interchange).
• If connecting elements are interchanged, actuators with incorrect connecting elements do not reach their specified end position, and fault "upper or lower limit exceeded" may be displayed in DTC memory after basic setting.
• The control motor housings are currently identical (except the Control Motor for the Rear Vent (V112)), but the shaft of each motor is different due to the different connecting elements so if they are switched, it may not be possible to install the connecting element.
• Various control motors are installed on the A/C unit and in the air intake unit. They have different electrical values (e.g. potentiometer with an adjustment range of 120° or 150°) and are different in the part number index (at start of production, without index, with index "A" or "B"). For this reason, mark the control motors prior to removing them (risk of interchange).
• Apply a small amount of Grease (G 000 150) to the connecting element guides, as well as the pins and toothed segments on the door levers.
1 Air Distribution Housing
• Do not disassemble further
• Versions vary for vehicles with the Climatronic Control Module (J255) A/C control head in the "Comfort" or "Basic" version.
• In model year 2008, there is a rolling change in the threading at the screw points of the air distributor housing to the central tube of the instrument panel (the cast metal inserts have been eliminated, the screws go directly into the plastic), ensure the proper screw version during installation.
2 Connecting Element (Shaft/Control Motor)
• Mark before removing (risk of interchange)
• Removing and installing => [ Connecting Elements to A/C Unit Doors ] Connecting Elements to A/C Unit Doors
3 Defroster Door Motor (V107)
• With Defroster Door Motor Position Sensor (G135)
• Removing and installing => [ Defroster Door Motor ] Defroster Door Motor
4 Screw
5 Connecting Element (to Control Motor)
• Mark before removing (risk of interchange)
• Removing and installing => [ Front Upper Body Outlet Motors ] Front Upper Body Outlet Motors
6 Right Chest Vent Control Motor (V238) (Comfort Version) or Left Chest Vent Control Motor (V237) (Basic Version)
• The name for this control motor depends on the version of the Climatronic Control Module (J255) A/C control head, it is different in the guided troubleshooting and the wiring diagram of the "Comfort" version and "Basic" version.
• The Right Chest Vent Potentiometer (G388) is installed in the Right Front Chest Vent Control Motor (V238).
• The Left Chest Vent Potentiometer (G387) is installed in the Left Front Chest Vent Control Motor (V237).
- In vehicles with the "Basic" version of the Climatronic Control Module (J255) A/C control head, left and right chest vent doors are operated by the Left Chest Vent Door Motor (V237) (both left and right doors are connected to each other via a shaft) => [ Connection between Left and Right Upper Body Outlet Door, Basic A/C Unit ] Connection between Left and Right Upper Body Outlet Door, Basic A/C Unit.
• Removing and installing => [ Front Upper Body Outlet Motors ] Front Upper Body Outlet Motors.
7 Connecting Element (to Shaft)
• Mark before removing (risk of interchange)
• Removing and installing => [ Connecting Elements to A/C Unit Doors ] Connecting Elements to A/C Unit Doors
8 Right Vent Temperature Sensor (G151)
• Removing and installing => [ Right Vent Temperature Sensor ] Right Vent Temperature Sensor
9 Auxiliary Heater Heating Element (Z35)
• Not for North American market.
10 Rubber bushing
11 Screw
12 Front Cold Air Door Motor (V197)
• With Front Cold Air Door Control Motor Potentiometer (G315)
• Removing and installing => [ Front Cold Air Door Motor ] Front Cold Air Door Motor
13 Connecting Element (to Control Motor)
• Mark before removing (risk of interchange)
• Removing and installing => [ Front Cold Air Door Motor ] Front Cold Air Door Motor
14 Connecting Element (to Shaft)
• Mark before removing (risk of interchange)
• Removing and installing => [ Connecting Elements to A/C Unit Doors ] Connecting Elements to A/C Unit Doors
15 Rear Vent Control Motor (V112)
• With Potentiometer in the Rear Vent Control Motor (G141)
• Removing and installing => [ Rear Footwell Vent Motor ] Rear Footwell Vent Motor
16 Connecting Element (Shaft/Control Motor)
• Mark before removing (risk of interchange)
• Removing and installing => [ Rear Footwell Vent Motor ] Rear Footwell Vent Motor
17 Right Footwell Door Control Motor (V109) (Comfort Version) or Left Footwell Door Control Motor (V108) (Basic Version)
• The name for this control motor depends on the version of the Climatronic Control Module (J255) A/C control head, it is different in the guided troubleshooting and the wiring diagram of the "Comfort" version and "Basic" version.
• Right Footwell Door Motor Position Sensor (G140) is installed in Right Footwell Door Motor (V109).
• Left Footwell Door Motor Position Sensor (G139) is installed in Left Footwell Door Motor (V108).
- In vehicles with the "Basic" version of the Climatronic Control Module (J255) A/C control head, left and right footwell vent doors are operated by the Left Footwell Vent Door Motor (V108) (both left and right doors are connected to each other via a coupling rod).=> [ Connection between Left and Right Footwell Door, Basic A/C Unit ] Connection between Left and Right Footwell Door, Basic A/C Unit
• Removing and installing => [ Footwell Door Motors ] Footwell Door Motors
18 Connecting Element (Shaft/Control Motor)
• Mark before removing (risk of interchange)
• Removing and installing => [ Connecting Elements to A/C Unit Doors ] Connecting Elements to A/C Unit Doors.
19 Connecting Element (Shaft/Control Motor)
• Mark before removing (risk of interchange)
• Removing and installing => [ Connecting Elements to A/C Unit Doors ] Connecting Elements to A/C Unit Doors
20 Left Footwell Door Motor (V108)
• With Potentiometer in the Left Footwell Door Control Motor (G139)
• In vehicles with the "Basic" version of the Climatronic Control Module (J255) A/C control head, there is no control motor at this location. The Left Footwell Door Control Motor (V108) in these vehicles is installed at the A/C unit to the right (the two doors are connected via a coupling rod) => [ Connection between Left and Right Footwell Door, Basic A/C Unit ] Connection between Left and Right Footwell Door, Basic A/C Unit.
• This control motor is only installed in vehicles with the "Comfort" version of the Climatronic Control Module (J255) A/C control head.
- In vehicles with the "Basic" version of the Climatronic Control Module (J255)A/C control head, both footwell doors are operated by the Left Footwell Door Control Motor (V108) (installed at the A/C unit to the right).
• Removing and installing => [ Left Footwell Door Motor ] Left Footwell Door Motor
21 Center Outlet Temperature Sensor (G191)
• Removing and installing => [ Center Vent Temperature Sensor ] Center Vent Temperature Sensor
• The Center Outlet Temperature Sensor (G191) is being gradually discontinued as of model year 2006, therefore pay attention to correct assignment of the Climatronic Control Module (J255) A/C control head (different versions)
22 Air Duct To Center Instrument Panel Vents
• The installed grille provides improved swirling and mixing of the flowing air.
• This air duct is available as a replacement part with and without opening for mounting of the Center Outlet Temperature Sensor (G191). Close mounting opening or open mounting opening by breaking out the plastic at the locations marked, depending on the vehicle equipment
23 Connecting Element (Shaft/Control Motor)
• Mark before removing (risk of interchange)
• Removing and installing => [ Connecting Elements to A/C Unit Doors ] Connecting Elements to A/C Unit Doors
24 Center Vent Adjustment Motor (V102)
• With Potentiometer in the Central Vent Control Motor (G138)
• Removing and installing => [ Center Vent Adjustment Motor ] Center Vent Adjustment Motor
25 Connecting Element (Control Motor/Coupling Rod)
• Removing and installing => [ Indirect Ventilation Flap Motor ] Indirect Ventilation Flap Motor
• Only installed in vehicles with the "Comfort" version of the Climatronic Control Module (J255) A/C control head.
26 Coupling Rod
• Removing and installing => [ Indirect Ventilation Flap Motor ] Indirect Ventilation Flap Motor
• Only installed in vehicles with the "Comfort" version of the Climatronic Control Module (J255) A/C control head.
27 Connecting Element (Shaft/Coupling Rod)
• Removing and installing => [ Indirect Ventilation Flap Motor ] Indirect Ventilation Flap Motor
• Only installed in vehicles with the "Comfort" version of the Climatronic Control Module (J255) A/C control head.
28 Indirect Ventilation Door Motor (V213)
• With the Potentiometer for the Indirect Ventilation Door Control Motor (G330)
- This control motor is only installed in vehicles with the "Comfort" version of the Climatronic Control Module (J255) A/C control head. This control motor is not available in vehicles with the "Basic" version of the Climatronic Control Module (J255) A/C control head (the opening in the air distribution housing is sealed and the door is not installed).
• Removing and installing => [ Indirect Ventilation Flap Motor ] Indirect Ventilation Flap Motor
29 Left Vent Temperature Sensor (G150)
• Removing and installing => [ Left Vent Temperature Sensor ] Left Vent Temperature Sensor.
30 Connecting Element (to Shaft)
• Mark before removing (risk of interchange)
• Removing and installing => [ Connecting Elements to A/C Unit Doors ] Connecting Elements to A/C Unit Doors
31 Connecting Element (to Control Motor)
• Mark before removing (risk of interchange)
• Removing and installing => [ Left Front Upper Body Outlet Motor, Comfort ] Left Front Upper Body Outlet Motor, Comfort
• Only installed in vehicles with the "Comfort" version of the Climatronic Control Module (J255) A/C control head.
32 Left Front Chest Vent Control Motor (V237)
• In vehicles with the "Basic" version of the Climatronic Control Module (J255) A/C control head, there is no control motor at this location. The Control Motor for the Front Left Chest Vent (V237) in these vehicles is installed at the A/C unit to the right (the two doors are connected via a shaft) => [ Connection between Left and Right Upper Body Outlet Door, Basic A/C Unit ] Connection between Left and Right Upper Body Outlet Door, Basic A/C Unit.
• This control motor is only installed in vehicles with the "Comfort" version of the Climatronic Control Module (J255) A/C control head.
- In vehicles with the "Basic" version of the Climatronic Control Module (J255) A/C control head, both chest vent doors are operated by the Left Chest Vent Door Control Motor (V237) (installed to the right at the A/C unit).
• Removing and installing => [ Left Front Upper Body Outlet Motor, Comfort ] Left Front Upper Body Outlet Motor, Comfort