Front Expansion Valve Refrigerant Lines, Disconnecting

Front Expansion Valve Refrigerant Lines, Disconnecting

Removing

- Switch off ignition.

- Drain the refrigerant circuit.

• Close all open lines and connections on the refrigerant line with suitable caps (avoid dirt and moisture from entering the system).

- Remove plenum chamber cover - A -.






• To prevent water from running via intake shaft - C - into the A/C unit when plenum chamber cover - A - is installed, plenum chamber cover - A - must not be damaged. Moreover, plenum chamber cover - A - must be correctly and completely engaged in frame - D - of windshield - B -.

- Detach wiring harness - A - and put aside.






- If present, remove suspension strut dome - B -.

- Detach or remove engine control module - C - and remove the corresponding bracket.

- Remove the plenum chamber front wall - A -.






• The front wall of plenum chamber - A - is secured with plastic nuts - B -, expanding rivets - C - and screws - D -.

- Remove screws - A -.






- Remove refrigerant line - B - and - C - from expansion valve - J -.

• Seal the open connections on the refrigerant line and on the expansion valve with suitable caps (to prevent dirt and moisture from entering the system).

Installing

Installation is done is reverse order, observe the following:

- Check support ring - E - for proper installation position and check the grommet in the plenum chamber rear wall for damage and proper installation.






• This figure shows the connections to the evaporator with the expansion valve removed.

- Thoroughly clean all connections in expansion valve - J - and at refrigerant lines - B - and - C - and check for damage.






- Replace the O-rings - D - and - C -. Refer to the Electronic Parts Catalog.

• Follow the instructions for installing the O-rings. Refer to => [ Refrigerant Circuit O-rings ] Refrigerant Circuit O-rings.

- Coat O-rings with refrigerant oil before installing. Refer to => [ Refrigerant Circuit O-rings ] Refrigerant Circuit O-rings.

- Make sure the O-ring seals fit properly inside the grooves in the connections of refrigerant lines - B - and - C -.

- Install screws - A - for refrigerant line - B - and - C -.

• Tightening specification for screws - A -: 10 Nm.

- Check the routing of the refrigerant lines after attachment. They must be inserted in the provided brackets in a tension-free manner and must not come in contact with other components.

- Install the plenum chamber front wall.

- Evacuate and fill the refrigerant circuit.

- Install the remaining components.

- Check the event memory of the Climatronic control module (J255) , 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 operation of the A/C system after filling.