Note: All electrical cable ties must be installed in their original positions. The wiring harness is removed together with the climate system housing.
1. On some engines, it may be necessary to remove the engine top cover to gain access to the expansion valve (see chapter 2), turbocharger inlet hose, particulate filter cover and air cleaner inlet hose (see chapter 4).
2. Drain the coolant.
3. Disconnect the negative cable from the battery.
4. Remove the center console and instrument panel (see chapter 11).
5. Remove the lower trim of the right pillar A (see chapter 11).
6. Clamp the coolant hoses (1 in illustration 13.2) heater radiator, mark them, pull out the clamps and disconnect the hoses from the radiator, collecting the flowing coolant. If the radiator is to be replaced, the coolant must also be replaced, so in this case it can be drained (see section 2).
7. Connect the compressor to the upper fitting of the heater radiator (1 in illustration 13.3) and blow out the radiator (3) coolant residues in a pre-prepared container (2).
8. Turn out bolts (1 per resist. illustrations) refrigerant line fittings (2) and disconnect them from the expansion valve (3). Seal the connections to prevent dirt from entering the refrigerant circuit.
15.8 Bolts (1) refrigerant line fittings (2)
9. Cover the floor covering under the heater core with waterproof material and absorbent paper.
10. Remove the beam (7 on resist. illustrations) dashboard (see chapter 11), pull out and remove the wiring harness from the climate system housing. Remove the wiring harness from the holder (4).
15.10 Fastening parts of the climate system housing
1 Bolt, 4.5 Nm
2 Wiring holder
3 Climate system housing
4 Right bracket
5 Nuts, 8 Nm
6 Bolts, 8 Nm
7 Instrument panel beam
8 Bolt, 2 Nm
9 Support
10 Left bracket
11. Remove diagnostic interface J533 (see chapter 12).
12. Slightly tilt the climate system housing and remove it from the rear air duct upwards. Remove the climate system housing from the vehicle by gently prying the wiring harness out of the right holder.
13. If it is necessary to disassemble the housing, refer to Ref. illustrations.
15.13a Assembly parts of the climate system housing "Climatic"
1 Temperature damper actuator V68
2 Bracket
3 Lid
4 Activator V113 circulation damper
5 Air intake, with circulation damper
6/7 Upper/lower part of the evaporator casing
8 Evaporator
9 Glove box cooling hose, no longer installed from week 46 2010
10 Assembly of N24 fan resistors 11
11 Fan V2
12 Diesel particulate filter
13 Filter cover 12
14 Heater radiator
15 Radiator cap 14
16 Auxiliary heating element Z35, on some diesel models
17 Distribution box
18 Actuator V145 front distribution flap
15.13b Climate system housing assembly parts "Climatronic"
1 Actuator V426 front distribution flap
2 Actuator V158 left temperature flap
3 Actuator V107 defroster damper
4 Bracket
5 Actuator V425 circulation damper
6 Air intake, with circulation damper
7/8 Upper/lower part of the evaporator casing
9 Evaporator
10 Glove box cooling hose
11 Fan V2 with control unit J126
12 Diesel particulate filter
13 Filter cover 12
14 Heater radiator
15 Radiator cap 14
16 Auxiliary heating element "Z35", on some diesel models
17 Actuator V159 right temperature flap
18 Distribution box
14. Installation is carried out in the reverse order. When installing, ask an assistant to direct both coolant pipes from the side of the engine compartment. Use new expansion valve o-rings.