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VW Id4 Heating Air Conditioning System Eng
VW Id4 Heating Air Conditioning System Eng
Workshop Manual
ID.4 2021 ➤
Heating, air conditioning system
Edition 09.2021
Repair Group
00 - Technical data
87 - Air conditioning system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness
and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as
a matter of course, be observed.
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Type plates, R1234yf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Type plates, R744 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Refrigerant capacities, R1234yf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Refrigerant capacities, R744 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Refrigerant oil capacities, R1234yf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.4 Refrigerant oil capacities, R744 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.5 Oil distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Access to diagnoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Contents i
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
ii Contents
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
7.18 Removing and installing high voltage heater (PTC) [ZX17] . . . . . . . . . . . . . . . . . . . . . . . . 152
8 Air duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
8.1 Assembly overview – air duct and air distribution in passenger compartment . . . . . . . . . . 159
8.2 Removing and installing driver side footwell vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
8.3 Removing and installing front passenger side footwell vents . . . . . . . . . . . . . . . . . . . . . . . . 163
8.4 Removing and installing rear footwell vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
8.5 Removing and installing fresh air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
8.6 Removing and installing air duct for defroster vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
8.7 Removing and installing air duct for centre dash panel vent . . . . . . . . . . . . . . . . . . . . . . . . 165
8.8 Removing and installing air duct for vent in centre console (rear) . . . . . . . . . . . . . . . . . . . . 166
8.9 Removing and installing front air duct for dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
9 Coolant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
9.1 Assembly overview – high-voltage heater (PTC), rear-wheel drive . . . . . . . . . . . . . . . . . . 168
9.2 Assembly overview – high-voltage heater (PTC), all-wheel drive . . . . . . . . . . . . . . . . . . . . 168
9.3 Removing and installing PTC heater element 3 [Z132], rear-wheel drive . . . . . . . . . . . . . . 169
9.4 Removing and installing PTC heater element 3 [Z132], all-wheel drive . . . . . . . . . . . . . . . . 172
10 Operating and display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
10.1 Overview of fitting locations – operating and display unit . . . . . . . . . . . . . . . . . . . . . . . . . . 174
10.2 Removing and installing display unit for front information display and operating unit control
unit [J685] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
10.3 Removing and installing operating and display unit for rear air conditioning system [E265] . .174
11 Other controlling and regulating components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
11.1 Removing and installing external air quality and air humidity sensor G935 . . . . . . . . . . . . 175
11.2 Removing and installing ambient temperature sensor G17 . . . . . . . . . . . . . . . . . . . . . . . . 175
11.3 Removing and installing humidity sender for air conditioning system [G260] . . . . . . . . . . 176
11.4 Removing and installing left vent temperature sender [G150[ . . . . . . . . . . . . . . . . . . . . . . 176
11.5 Removing and installing right vent temperature sender [G151] . . . . . . . . . . . . . . . . . . . . . . 177
11.6 Removing and installing left footwell vent temperature sender [G261] . . . . . . . . . . . . . . . . 178
11.7 Removing and installing right footwell vent temperature sender [G262] . . . . . . . . . . . . . . 179
11.8 Removing and installing sensor for interior carbon dioxide concentration [G929] . . . . . . . . 180
11.9 Removing and installing heater and air conditioning system control unit J979 . . . . . . . . . . 180
11.10 Removing and installing vehicle interior temperature sensor [G1090] . . . . . . . . . . . . . . . . 181
11.11 Removing and installing rear vent temperature sender [G174] . . . . . . . . . . . . . . . . . . . . . . 182
Contents iii
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
iv Contents
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
00 – Technical data
1 General information
10004JNX6027.006.1 - 09.2021
1. General information 1
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
2 Technical data
2. Technical data 3
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
3 Electrical components
3. Electrical components 5
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
1 - Gas cooler
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing gas
cooler
2 - Refrigerant pressure and
temperature sender 5 -G829-
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing re‐
frigerant pressure and
temperature sender 5
[G829]
3 - Dryer
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing dryer
4 - Heat exchanger for high-
voltage battery
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing heat
exchanger for high-volt‐
age battery
5 - Refrigerant pressure and
temperature sender 2 -G826-
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing re‐
frigerant pressure and
temperature sender 2
[G826]
6 - Refrigerant shut-off
valve 4 -N642-
❑ ⇒ Rep. gr. 87; Assem‐
bly overview – valve
unit of heat pump
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing refrig‐
erant shut-off valve 4
[N642]
7 - Refrigerant shut-off valve 5 -N643-
❑ ⇒ Rep. gr. 87; Assembly overview – valve unit of heat pump
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant shut-off valve 5 [N643]
8 - Refrigerant expansion valve 2 -N637-
❑ ⇒ Rep. gr. 87; Assembly overview – valve unit of heat pump
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant expansion valve 2 [N637]
9 - Refrigerant expansion valve 3 -N638-
❑ ⇒ Rep. gr. 87; Assembly overview – valve unit of heat pump
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant expansion valve 3 [N638]
10 - Refrigerant shut-off valve 1 -N696-
❑ ⇒ Rep. gr. 87; Assembly overview – valve unit of heat pump
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant shut-off valve 1 [N696]
11 - Refrigerant expansion valve 1 -N636-
❑ ⇒ Rep. gr. 87; Assembly overview – valve unit of heat pump
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant expansion valve 1 [N636]
12 - Refrigerant pressure and temperature sender 4 -G828-
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant pressure and temperature sender 4 [G828]
1 - Condenser
❑ ⇒ Rep. gr. 87; As‐
sembly overview – con‐
denser
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing con‐
denser/gas cooler
2 - Air conditioner compressor
-VX81-
❑ With control unit for air
conditioner compressor
-J842-
❑ With electrical air con‐
ditioner compressor -
V470-
❑ ⇒ Rep. gr. 87; Assem‐
bly overview – air con‐
ditioner compressor
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing air
conditioner compressor
[VX81]
3 - Pressure sender for refrig‐
erant circuit -G805-
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing pres‐
sure sender for refrig‐
erant circuit [G805],
R1234yf
4 - Refrigerant pressure and
temperature sender -G395-
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing re‐
frigerant pressure and
temperature sender
[G395]
5 - Heat exchanger for high-voltage battery
❑ With refrigerant expansion valve 1 -N636-
❑ ⇒ Rep. gr. 87; Removing and installing heat exchanger for high-voltage battery
6 - Evacuating and charging valve
❑ Low-pressure side
❑ ⇒ Rep. gr. 87; Removing and installing evacuating and charging valves on low and high-pressure side
7 - Refrigerant shut-off valve for heater and air conditioner unit -N541-
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant shut-off valve for heater and air conditioner unit
[N541]
8 - Evacuating and charging valve
❑ High-pressure side
❑ ⇒ Rep. gr. 87; Removing and installing evacuating and charging valves on low and high-pressure side
9 - Air intake box of heater and air conditioning unit
❑ ⇒ Rep. gr. 87; Assembly overview – air intake unit of heater and air conditioning unit
❑ ⇒ Rep. gr. 87; Removing and installing air intake unit of heater and air conditioning unit
10 - External air quality and air humidity sensor -G935-
❑ ⇒ Rep. gr. 87; Removing and installing external air quality and humidity sensor [G935]
11 - Fresh air intake
3 Refrigerant circuit
3. Refrigerant circuit 15
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
3. Refrigerant circuit 17
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
1 - Gas cooler
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing gas
cooler
2 - Refrigerant shut-off valve
1 -N696-
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing refrig‐
erant shut-off valve 1
N696
3 - Incorporation into coolant
circuit for high-voltage battery
❑ ⇒ Electric drive mo‐
tor; Rep. gr. 19; Cool‐
ing system/coolant;
Connection diagram -
coolant hoses
4 - High-voltage battery heat
exchanger
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing heat
exchanger for high-volt‐
age battery
5 - Service connection (low-
pressure side)
❑ ⇒ Rep. gr. 87; Re‐
moving and installing
evacuating and charg‐
ing valve (low-pres‐
sure and high-pressure
sides)
6 - Service connection (high-
pressure side)
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing evac‐
uating and charging
valve (low-pressure and high-pressure sides)
7 - Refrigerant expansion valve 2 -N637-
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant expansion valve 2 N637
8 - Refrigerant expansion valve 3 -N638-
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant expansion valve 3 N638
9 - Refrigerant pressure and temperature sender 4 -G828-
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant pressure and temperature sender 4 G828
10 - Heat condenser
❑ ⇒ Rep. gr. 87; Removing and installing heat condenser
11 - Refrigerant expansion valve 1 -N636-
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant expansion valve 1 N636
12 - Evaporator
❑ ⇒ Rep. gr. 87; Removing and installing evaporator
13 - Refrigerant shut-off valve 4 -N642-
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant shut-off valve 4 N642
14 - Refrigerant pressure and temperature sender 2 -G826-
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant pressure and temperature sender 2 G826
3. Refrigerant circuit 19
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
1 - Bolt
❑ Applies for all connec‐
tions in illustration
❑ 8 Nm
2 - Seal
❑ Applies for all connec‐
tions in illustration
❑ Renew after removing
3 - Refrigerant line
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing re‐
frigerant line from con‐
denser to expansion
valve
4 - Pressure sender for refrig‐
erant circuit -G805-
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing pres‐
sure sender for refriger‐
ant circuit G805
❑ 8 Nm
5 - Seal
❑ Renew after removing
6 - Valve core
❑ 1.5 Nm
7 - Refrigerant shut-off valve
for heater and air conditioning
unit -N541-
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing refrig‐
erant shut-off valve for
heater and air condi‐
tioning unit N541
8 - Union nut
❑ 16.5 Nm
9 - Evacuating and charging valve (high-pressure side)
❑ ⇒ Rep. gr. 87; Removing and installing evacuating and charging valve (low-pressure and high-pres‐
sure sides)
❑ 1.5 Nm
10 - Valve cap (high pressure)
❑ 1 Nm
11 - Refrigerant line
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant line from heat exchanger for high-voltage battery to
high-pressure line
12 - Bracket
13 - Refrigerant line
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant line from air conditioner compressor VX81 to
expansion valve
14 - Expansion valve
❑ ⇒ Rep. gr. 87; Exploded view - evaporator housing
❑ ⇒ Rep. gr. 87; Removing and installing expansion valve
15 - Valve core
❑ 2 Nm
16 - Seal
❑ Renew after removing
17 - Refrigerant pressure and temperature sender -G395-
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant pressure and temperature sender G395
❑ 10 Nm
18 - Valve cap (low pressure)
❑ 1 Nm
19 - Evacuating and charging valve (low-pressure side)
❑ ⇒ Rep. gr. 87; Removing and installing evacuating and charging valve (low-pressure and high-pres‐
sure sides)
❑ 1.5 Nm
20 - Refrigerant line
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant line from heat exchanger for high-voltage battery to
low-pressure line
21 - Bolt
❑ 2x
❑ 20 Nm
22 - Air conditioner compressor -VX81-
❑ ⇒ Rep. gr. 87; Exploded view - air conditioner compressor
❑ ⇒ Rep. gr. 87; Removing and installing air conditioner compressor VX81
23 - Refrigerant line
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant line from condenser to air conditioner compressor
VX81
24 - Condenser
❑ ⇒ Rep. gr. 87; Exploded view - condenser
❑ ⇒ Rep. gr. 87; Removing and installing condenser
25 - High-voltage battery heat exchanger
❑ ⇒ Rep. gr. 87; Exploded view - heat exchanger for high-voltage battery
❑ ⇒ Rep. gr. 87; Removing and installing heat exchanger for high-voltage battery
3. Refrigerant circuit 21
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
1 - Bolt
❑ Applies for all connec‐
tions in illustration
❑ Renew after removing
❑ 13 Nm
2 - Seal
❑ Applies for all connec‐
tions in illustration
❑ Renew after removing
3 - Retaining element
❑ Applies for all connec‐
tions in illustration
❑ Renew after removing
4 - Seal
❑ Applies for all refriger‐
ant pressure and tem‐
perature senders in il‐
lustration
❑ Renew after removing
5 - Dust ring
❑ Applies for all refriger‐
ant pressure and tem‐
perature senders in il‐
lustration
❑ Renew after removing
6 - Refrigerant pressure and
temperature sender 2 -G826-
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing re‐
frigerant pressure and
temperature sender 2
G826
❑ 40 Nm
7 - Heat pump valve unit
❑ ⇒ Rep. gr. 87; Exploded view - heat pump valve unit
❑ ⇒ Rep. gr. 87; Removing and installing heat pump valve unit
8 - Pressure limiting valve
❑ Left-hand thread
❑ Renew after removing
❑ ⇒ a3.22.1 nd installing pressure limiting valve”, page 45
❑ 14 Nm
9 - Evacuating and charging valve
❑ ⇒ Rep. gr. 87; Removing and installing evacuating and charging valve (low-pressure and high-pres‐
sure sides)
❑ 2 Nm
10 - Valve cap
11 - Refrigerant line
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant line between refrigerant shut-off valve 3 N641 and
heat condenser
12 - Refrigerant line
3. Refrigerant circuit 23
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
1 - Bracket
2 - Bolt
❑ Qty. 2
❑ 8 Nm
3 - Bolt
❑ Qty. 2
❑ 20 Nm
4 - Clamping nut
❑ Qty. 2
5 - Heat exchanger for high-
voltage battery
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing heat
exchanger for high-volt‐
age battery
6 - Refrigerant expansion
valve 1 -N636-
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing heat
exchanger for high-volt‐
age battery
7 - Bolt
❑ 8 Nm
8 - Seal
❑ Renew after removing
1 - Plug
❑ Renew after removing
❑ 10 Nm
2 - Seal
❑ 2x
❑ Renew after removing
3 - Desiccant bag
❑ Renew after removing
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing desic‐
cant bag/dryer
4 - Filter
❑ Renew after removing
5 - Condenser
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing con‐
denser - R1234yf
6 - Bolt
❑ ⇒ Rep. gr. 87; Explo‐
ded view - refrigerant
lines
7 - Seal
❑ ⇒ Rep. gr. 87; Explo‐
ded view - refrigerant
lines
8 - Refrigerant line
❑ ⇒ Rep. gr. 87; Explo‐
ded view - refrigerant
lines
9 - Refrigerant line
❑ ⇒ Rep. gr. 87; Explo‐
ded view - refrigerant lines
3. Refrigerant circuit 25
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
Removing
Seal off open pipes/lines and connections immediately with
clean plugs from engine bung set -VAS 6122-.
– Unfasten coolant expansion tank and move slightly to side
⇒ Rep. gr. 19; Cooling system/coolant; Removing and instal‐
ling coolant expansion tank.
– Unplug electrical connector -1-.
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– If refrigerant escapes from the refrigerant line for more
than 1 second when the pressure sender is unfastened,
tighten the pressure sender and renew the defective non-
return valve.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
3. Refrigerant circuit 27
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– If refrigerant escapes from the refrigerant line for more
than 1 second when the pressure sender is unfastened,
tighten the pressure sender and renew the defective non-
return valve.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
3. Refrigerant circuit 29
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
3. Refrigerant circuit 31
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
Removing
Seal off open pipes/lines and connections immediately with
clean plugs from engine bung set -VAS 6122-.
– ⇒ Air conditioners with refrigerant R1234yf - General infor‐
mation; Rep. gr. 87; Working with the air conditioner service
station; Discharging refrigerant circuit
– Remove condenser ⇒ Rep. gr. 87; Removing and installing
condenser/gas cooler.
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
– Pull filter -2- out of condenser -3- using a piece of wire -1-.
3. Refrigerant circuit 33
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
Installing
Installation is carried out in reverse order; note the following:
– Check that threads and sealing surfaces of condenser are
not dirty or damaged.
– ⇒ Air conditioners with refrigerant R1234yf - General infor‐
mation; Rep. gr. 87; Working with the air conditioner service
station; Charging refrigerant circuit
Tightening torques
♦ ⇒ Rep. gr. 87; Exploded view - condenser
3. Refrigerant circuit 35
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
Installing
Install in reverse order of removal, observing the following:
After renewing dryer:
– Observe procedure for renewal of refrigerant circuit compo‐
nents ⇒ Air conditioning system with refrigerant R744 – Gen‐
eral notes; Rep. gr. 87; Refrigerant circuit; Renewing compo‐
nents.
– Carry out function “Open electrically actuated valves to
drain, evacuate or charge refrigerant circuit” using ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00; Access to diagnoses.
– ⇒ Air conditioning systems with refrigerant R744 – General
notes; Rep. gr. 87; Working with air conditioner service sta‐
tion; Charging refrigerant circuit.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – valve unit of heat pump
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
3. Refrigerant circuit 37
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
♦ socket -T40284-
Removing
Immediately seal any open lines and connections with clean
plugs from engine bung set -VAS 6122-.
– Carry out function “Open electrically actuated valves to
drain, evacuate or charge refrigerant circuit” using ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00; Access to diagnoses.
– ⇒ Air conditioning systems with refrigerant R744 – General
notes; Rep. gr. 87; Working with air conditioner service sta‐
tion; Draining refrigerant circuit.
– Remove lock carrier ⇒ General body repairs, exterior; Rep.
gr. 50; Lock carrier; Removing and installing lock carrier.
– Detach coolant expansion tank, and lay it slightly aside
⇒ Rep. gr. 19; Cooling system/coolant; Removing and instal‐
ling coolant expansion tank.
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
3. Refrigerant circuit 39
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
3. Refrigerant circuit 41
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
CAUTION
The cooling system may be under pressure. Risk of scalding
due to hot steam and hot coolant
Danger of scalding skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Cover filler cap on expansion tank with a suitable cloth and
open carefully to release pressure.
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
3. Refrigerant circuit 43
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
NOTICE
Risk of damage to electrical components.
Electrostatic discharge can cause damage to electrical com‐
ponents.
– Work on electrical components must always be performed
on an ESD workplace.
3. Refrigerant circuit 45
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
CAUTION
The cooling system may be under pressure. Risk of scalding
due to hot steam and hot coolant
Danger of scalding skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Cover filler cap on expansion tank with a suitable cloth and
open carefully to release pressure.
Note
If so much coolant is lost while removing the heat exchanger
that the coolant expansion tank is emptied completely, the en‐
tire coolant must be drained and the cooling system must be
re-filled.
– Clamp off coolant hoses behind hose clips -5- using hose
clamps up to 25 mm -3094-.
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
3. Refrigerant circuit 47
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
3. Refrigerant circuit 49
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – valve unit of heat pump
♦ ⇒ Rep. gr. 87; Assembly overview – refrigerant lines
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
3. Refrigerant circuit 51
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
3. Refrigerant circuit 53
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
3. Refrigerant circuit 55
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
Installing
Install in reverse order of removal, observing the following:
– ⇒ Air conditioning systems with refrigerant R1234yf – Gener‐
al notes; Rep. gr. 87; Working with air conditioner service
station; Charging refrigerant circuit.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – refrigerant lines
♦ ⇒ Rep. gr. 87; Assembly overview – condenser
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Underbody
cladding; Assembly overview – underbody cladding
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
3. Refrigerant circuit 57
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
Installing
Installation is carried out in reverse order; note the following:
– ⇒ Air conditioners with refrigerant R1234yf - General infor‐
mation; Rep. gr. 87; Working with the air conditioner service
station; Charging refrigerant circuit
Tightening torques
♦ ⇒ Rep. gr. 87; Exploded view - refrigerant lines
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
3. Refrigerant circuit 59
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
3. Refrigerant circuit 61
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
Removing
Seal off open pipes/lines and connections immediately with
clean plugs from engine bung set -VAS 6122-.
– Perform function “Opening electrically actuated valves in re‐
frigerant circuit for extracting, evacuating and charging” with
⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00; Starting diagnosis.
– ⇒ Air conditioners with refrigerant R744 - General informa‐
tion; Rep. gr. 87; Working with the air conditioner service
station; Discharging refrigerant circuit.
– Remove air intake box of heater and air conditioning unit
⇒ Rep. gr. 87; Removing and installing air intake box of
heater and air conditioning unit.
– Remove underbody trim (front) ⇒ General body repairs, ex‐
terior; Rep. gr. 66; Underbody trim; Removing and installing
underbody trim (front).
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
Installing
Installation is carried out in reverse order; note the following:
– Install seals and retaining elements, making sure they are
free of oil.
– Perform function “Opening electrically actuated valves in re‐
frigerant circuit for extracting, evacuating and charging” with
⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00; Starting diagnosis.
– ⇒ Air conditioners with refrigerant R744 - General informa‐
tion; Rep. gr. 87; Working with the air conditioner service
station; Charging refrigerant circuit
Tightening torques
♦ ⇒ Rep. gr. 87; Exploded view - refrigerant lines
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Underbody
trim; Exploded view - underbody trim
3. Refrigerant circuit 63
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
Removing
Immediately seal any open lines and connections with clean
plugs from engine bung set -VAS 6122-.
– Carry out function “Open electrically actuated valves to
drain, evacuate or charge refrigerant circuit” using ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00; Access to diagnoses.
– ⇒ Air conditioning systems with refrigerant R744 – General
notes; Rep. gr. 87; Working with air conditioner service sta‐
tion; Draining refrigerant circuit.
– Remove air intake unit of heater and air conditioning unit
⇒ Rep. gr. 87; Removing and installing air intake unit of
heater and air conditioning unit.
– Remove front underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66; Underbody cladding; Removing and
installing front underbody cladding.
– Disconnect electrical connector -3-.
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – air intake unit of heater
and air conditioning unit
♦ ⇒ Rep. gr. 87; Assembly overview – refrigerant lines
♦ ⇒ Rep. gr. 87; Assembly overview – air conditioner compres‐
sor
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Underbody
cladding; Assembly overview – underbody cladding
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
3. Refrigerant circuit 65
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
3. Refrigerant circuit 67
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
Removing
Immediately seal any open lines and connections with clean
plugs from engine bung set -VAS 6122-.
– Carry out function “Open electrically actuated valves to
drain, evacuate or charge refrigerant circuit” using ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00; Access to diagnoses.
– ⇒ Air conditioning systems with refrigerant R744 – General
notes; Rep. gr. 87; Working with air conditioner service sta‐
tion; Draining refrigerant circuit.
– Remove air intake unit of heater and air conditioning unit
⇒ Rep. gr. 87; Removing and installing air intake unit of
heater and air conditioning unit.
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
3. Refrigerant circuit 69
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
Installing
Install in reverse order of removal, observing the following:
– Install seals and captive fasteners free of oil.
– Carry out function “Open electrically actuated valves to
drain, evacuate or charge refrigerant circuit” using ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00; Access to diagnoses.
– ⇒ Air conditioning systems with refrigerant R744 – General
notes; Rep. gr. 87; Working with air conditioner service sta‐
tion; Charging refrigerant circuit.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – air intake unit of heater
and air conditioning unit
♦ ⇒ Rep. gr. 87; Assembly overview – refrigerant lines
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
3. Refrigerant circuit 71
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
3. Refrigerant circuit 73
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
3. Refrigerant circuit 75
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
3. Refrigerant circuit 77
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
Tightening torques
♦ ⇒ Rep. gr. 87; Exploded view - refrigerant lines
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
3. Refrigerant circuit 79
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
1 - Guide sleeves
2 - Rubber bush
3 - Bolt
❑ Applies for all un‐
marked bolts in illustra‐
tion
❑ 8 Nm
4 - Bracket
5 - Bolt
❑ 3x
❑ 20 Nm
6 - Refrigerant expansion
valve 1 -N636-
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing refrig‐
erant expansion valve 1
N636
7 - Refrigerant shut-off valve
1 -N696-
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing refrig‐
erant shut-off valve 1
N696
8 - Refrigerant expansion
valve 3 -N638-
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing refrig‐
erant expansion valve 3
N638
9 - Refrigerant expansion
valve 2 -N637-
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing refrig‐
erant expansion valve 2 N637
10 - Electrical wiring for refrigerant pressure and temperature sender 4 -G828-
11 - Refrigerant shut-off valve 5 -N643-
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant shut-off valve 5 N643
12 - Refrigerant shut-off valve 4 -N642-
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant shut-off valve 4 N642
13 - Electrical wiring for heat pump valve unit
14 - Refrigerant shut-off valve 2 -N640-
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant shut-off valve 2 N640
15 - Refrigerant shut-off valve 3 -N641-
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant shut-off valve 3 N641
16 - Electrical wiring for refrigerant pressure and temperature sender 2 -G826-
17 - Electrical wiring for refrigerant pressure and temperature sender 5 -G829-
18 - High-voltage battery heat exchanger
❑ ⇒ Rep. gr. 87; Removing and installing heat exchanger for high-voltage battery
19 - Dryer
❑ ⇒ Rep. gr. 87; Removing and installing dryer
20 - Bracket
21 - Flexible joint
❑ 3 Nm
22 - Nut
❑ 15 Nm
1 - Refrigerant line
2 - Bolt
❑ Applies for all connec‐
tions in illustration
❑ Renew after removing
❑ 13 Nm
3 - Seal
❑ Applies for all connec‐
tions in illustration
❑ Renew after removing
4 - Retaining element
❑ Applies for all connec‐
tions in illustration
❑ Renew after removing
5 - Refrigerant line
6 - Dryer
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing dryer
7 - Refrigerant line
8 - Refrigerant line
9 - Refrigerant line
10 - Heat pump valve unit
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing heat
pump valve unit
11 - High-voltage battery heat
exchanger
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing heat
exchanger for high-volt‐
age battery
12 - Refrigerant line
1 - Refrigerant line
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing re‐
frigerant line between
expansion valve N636/
N696 and heat con‐
denser
2 - Refrigerant line
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing re‐
frigerant line between
expansion valve N638/
N637 and evaporator
3 - Refrigerant line
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing re‐
frigerant line between
condenser/gas cooler
and refrigerant shut-off
valve 2 N640
4 - High-voltage battery heat
exchanger
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing heat
exchanger for high-volt‐
age battery
5 - Refrigerant line
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing refrig‐
erant line between re‐
frigerant shut-off valve
3 N641 and heat con‐
denser
6 - Refrigerant line
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing refrig‐
erant line between air conditioner compressor VX81 and valve block N641/N640
7 - Retaining element
❑ Applies for all connections in illustration
❑ Renew after removing
8 - Seal
❑ Applies for all connections in illustration
❑ Renew after removing
9 - Bolt
❑ Applies for all connections in illustration
❑ Renew after removing
❑ 13 Nm
10 - Heat pump valve unit
❑ ⇒ Rep. gr. 87; Removing and installing heat pump valve unit
11 - Refrigerant line
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant line between heat pump valve unit and evaporator
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
NOTICE
Risk of damage to electrical components.
Electrostatic charge may damage electrical components.
– Work on electrical components must always be carried out
at an ESD workplace.
NOTICE
Risk of damage to electrical components.
Electrostatic charge may damage electrical components.
– Work on electrical components must always be carried out
at an ESD workplace.
Installing
Install in reverse order of removal, observing the following:
– Install seals and captive fasteners free of oil.
When renewing expansion valve/shut-off valve:
– Carry out function “Addressing routine for refrigerant valves”
using ⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00; Access to
diagnoses.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – valve unit of heat pump
NOTICE
Risk of damage to electrical components.
Electrostatic discharge can cause damage to electrical com‐
ponents.
– Work on electrical components must always be performed
on an ESD workplace.
NOTICE
Risk of damage to electrical components.
Electrostatic discharge can cause damage to electrical com‐
ponents.
– Work on electrical components must always be performed
on an ESD workplace.
NOTICE
Risk of damage to electrical components.
Electrostatic discharge can cause damage to electrical com‐
ponents.
– Work on electrical components must always be performed
on an ESD workplace.
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
Installing
Installation is carried out in reverse order; note the following:
– Connect refrigerant lines -2- and tighten bolts -3-.
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
Installing
Installation is carried out in reverse order; note the following:
– Install seals and retaining elements, making sure they are
free of oil.
– Connect refrigerant lines -2- and tighten bolts -3-.
Removing
Immediately seal any open lines and connections with clean
plugs from engine bung set -VAS 6122-.
DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) de-energise the high-voltage system.
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
NOTICE
Risk of damage to components due to soiling.
– Keep the measuring beaker clean.
NOTICE
Risk of damage to components due to soiling.
– Keep the measuring beaker clean.
WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) re-energise the high-voltage system.
DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) de-energise the high-voltage system.
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
Important
• Contact surfaces must be free of dirt, rust and grease.
– Connect potential equalisation line, and tighten bolt -4-.
– Carry out function “Open electrically actuated valves to
drain, evacuate or charge refrigerant circuit” using ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00; Access to diagnoses.
– ⇒ Air conditioning systems with refrigerant R744 – General
notes; Rep. gr. 87; Working with air conditioner service sta‐
tion; Charging refrigerant circuit.
WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) re-energise the high-voltage system.
6 Control motors
1 - Bolt
❑ 1.5 Nm
2 - Control motor for fresh
air and air recirculation flap -
VX96-
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing con‐
trol motor for fresh
air and air recirculation
flap VX96
3 - Actuator
4 - Heater and air conditioning
unit
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing heater
and air conditioning unit
1 - Bolt
❑ 1.5 Nm
2 - Control motor for front left
temperature flap -VX34-
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing con‐
trol motor for front left
temperature flap VX34
3 - Control motor for front left
air distribution flap -VX93-
❑ ⇒ Rep. gr. 87; Re‐
moving and installing
control motor for front
left air distribution flap
VX93 - left-hand drive
vehicles
4 - Actuator
5 - Heater and air conditioning
unit
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing heater
and air conditioning unit
6 - Control motor for rear tem‐
perature flap -VX95-
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing con‐
trol motor for rear tem‐
perature flap VX95
1 - Bolt
❑ 1.5 Nm
2 - Control motor for fresh
air and air recirculation flap -
VX96-
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing con‐
trol motor for fresh
air and air recirculation
flap VX96
3 - Actuator
4 - Heater and air conditioning
unit
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing heater
and air conditioning unit
Installing
Install in reverse order of removal, observing the following:
– Check shaft -A- and mounting -B- of control motor -C-. They
should be correctly aligned so that they can be joined to‐
gether.
Installing
Install in reverse order of removal, observing the following:
– Check shaft -A- and mounting -B- of control motor -C-. They
should be correctly aligned so that they can be joined to‐
gether.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – front control motors
7.4 Exploded view - air intake box of heater and air conditioning unit
17 - Cover
18 - Bolt
❑ Depending on equipment/vehicle version
❑ 2 Nm
19 - Noise insulation
20 - Gasket
21 - Seal
DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) de-energise the high-voltage system.
NOTICE
Risk of damage to airbag control unit. Electrical connectors
corrode when exposed to moisture.
– After unplugging connectors for control unit, cover them or
seal them off to prevent moisture from entering.
Important
• The aid of an additional person is required for the subse‐
quent work steps.
– Remove heater and air conditioning unit -1-.
Installing
– Install in reverse order of removal, observing the following:
– Check gasket between heater and air conditioning unit and
bulkhead for damage.
– Make sure that the condensation drain is properly seated
⇒ Rep. gr. 87; Removing and installing condensation drain.
– Check screw connections of potential equalisation line, and
clean them if necessary ⇒ Electrical system; Rep. gr. 97;
Cleaning contact surfaces; Cleaning contact surfaces.
Important
• Contact surfaces must be free of dirt, rust and grease.
– Connect potential equalisation line, and tighten nut -8-.
– Connect electrical connectors.
– Install air intake box of heater and air conditioning unit
⇒ Rep. gr. 87; Removing and installing air intake unit of
heater and air conditioning unit.
WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) re-energise the high-voltage system.
DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) de-energise the high-voltage system.
CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Extract/drain refrigerant again if more than 10 minutes
have passed since initial extraction and refrigerant circuit
has not been opened up. Renewed evaporation has cre‐
ated pressure in the refrigerant circuit.
NOTICE
Risk of damage to airbag control unit. Electrical connectors
corrode when exposed to moisture.
– After unplugging connectors for control unit, cover them or
seal them off to prevent moisture from entering.
Installing
Install in reverse order of removal, observing the following:
Important
• Contact surfaces must be free of dirt, rust and grease.
– Connect potential equalisation line, and tighten nut -8-.
– Connect electrical connectors.
– Install seals and captive fasteners free of oil.
– Install air intake box of heater and air conditioning unit
⇒ Rep. gr. 87; Removing and installing air intake unit of
heater and air conditioning unit.
– Carry out function “Open electrically actuated valves to
drain, evacuate or charge refrigerant circuit” using ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00; Access to diagnoses.
– ⇒ Air conditioning systems with refrigerant R744 – General
notes; Rep. gr. 87; Working with air conditioner service sta‐
tion; Charging refrigerant circuit.
WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) re-energise the high-voltage system.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview - refrigerant lines
♦ ⇒ Rep. gr. 87; Assembly overview – heater and air condition‐
ing unit
♦ ⇒ Rep. gr. 87; Assembly overview – evaporator housing
♦ ⇒ General body repairs, interior; Rep. gr. 70; Central tube for
dash panel; Assembly overview – central tube for dash panel
Removing
– Unscrew bolt -1-.
Installing
– Install in reverse order of removal, observing the following:
– Observe installation position of dust and pollen filter.
CAUTION
Danger of burns due to hot cooling surface on fresh air blower
control unit
Take care not to burn your hands.
– Put on protective gloves.
NOTICE
Risk of damage to fresh air blower if handled incorrectly.
Risk of imbalance and operating problems.
– Avoid any force or strain on fan wheel.
– Do NOT move balancing weights on fan wheel.
– Do not set fresh air blower down on fan wheel.
NOTICE
Risk of damage to airbag control unit. Electrical connectors
corrode when exposed to moisture.
– After unplugging connectors for control unit, cover them or
seal them off to prevent moisture from entering.
Tightening torques
♦ ⇒ General body repairs, interior; Rep. gr. 70; Passenger
compartment trim panels; Exploded view - foot rest and floor
covering
NOTICE
Risk of damage to airbag control unit. Electrical connectors
corrode when exposed to moisture.
– After unplugging connectors for control unit, cover them or
seal them off to prevent moisture from entering.
DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) de-energise the high-voltage system.
– Unscrew nuts -2- from air intake unit of heater and air condi‐
tioning unit -1-.
– Remove air intake unit of heater and air conditioning unit -1-.
Installing
Install in reverse order of removal, observing the following:
NOTICE
Risk of water ingress into the heater and air conditioning unit
and the vehicle interior due to damaged gaskets.
– Make sure that the gaskets are correctly installed.
– Check the gaskets for damage.
– Seals -1- and -2- must be seated properly on air intake unit.
WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) re-energise the high-voltage system.
NOTICE
Water entering into heater and air conditioning unit and interi‐
or due to damaged gaskets/seals.
– Fit gaskets/seals correctly.
– Check gaskets/seals for damage.
Tightening torques
♦ ⇒ Rep. gr. 87; Exploded view - air intake box of heater and
air conditioning unit
♦ ⇒ Rep. gr. 87; Exploded view - heater and air conditioning
unit
DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) de-energise the high-voltage system.
WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) re-energise the high-voltage system.
DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) de-energise the high-voltage system.
WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) re-energise the high-voltage system.
8 Air duct
8.1.1 Assembly overview – air duct and air distribution in passenger compart‐
ment, left-hand drive vehicle
8.1.2 Assembly overview – air duct and air distribution in passenger compart‐
ment, right-hand drive vehicles
– Lift footwell vent -3- and remove it from heater and air condi‐
tioning unit -1-.
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ General body repairs, interior; Rep. gr. 70; Passenger
compartment trim panels; Exploded view - foot rest and floor
covering.
♦ ⇒ General body repairs, interior; Rep. gr. 68; Centre con‐
sole; Exploded view - centre console.
– Unhook air duct for defroster vent -1- from fasteners -3-, and
remove it upwards.
Installing
Install in reverse order of removal, observing the following:
– Ensure seal -2- is seated correctly.
Tightening torques
♦ ⇒ General body repairs, interior; Rep. gr. 70; Dash panel;
Assembly overview – dash panel
– Unhook air duct for centre vent -1- from fasteners -3-, and
remove it upwards.
Installing
Install in reverse order of removal.
9 Coolant circuit
DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) de-energise the high-voltage system.
– Push aside coolant hoses -2- and -4-, and unscrew bolts -3-.
Important
• Contact surfaces must be free of dirt, rust and grease.
– Connect potential equalisation line -2-, and tighten nut -3-.
– Connect electrical connectors -4- and -6-.
– ⇒ Rep. gr. 19; Cooling system/coolant; Filling cooling system
WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) re-energise the high-voltage system.
DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) de-energise the high-voltage system.
Important
• Contact surfaces must be free of dirt, rust and grease.
– Connect potential equalisation line -3-, and tighten nut -2-.
– Connect electrical connectors -1- and -4-.
– ⇒ Rep. gr. 19; Cooling system/coolant; Filling cooling system
WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) re-energise the high-voltage system.
Installing
Install in reverse order of removal, observing the following:
– After renewal of the operating and display unit for the rear
air conditioning system [E265], carry out function “Renew
control unit” and “Basic setting” using ⇒ Vehicle diagnostic
tester ⇒ Rep. gr. 00; Access to diagnoses.
Tightening torques
♦ ⇒ General body repairs, interior; Rep. gr. 68; Centre con‐
sole; Assembly overview – centre console
Installing
Install in reverse order of removal.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – air duct and air distribu‐
tion in passenger compartment
Installing
– Install in reverse order of removal.
WARNING
Risk of asphyxiation from refrigerant R744
When sensor for interior carbon dioxide concentration is re‐
moved, there is a risk of asphyxiation due to carbon dioxide.
– The doors must always be left open when working in the
interior.
Tightening torques
♦ Install tunnel support cover ⇒ General body repairs, interior;
Rep. gr. 68; Compartments/covers; Overview of fitting loca‐
tions – compartments/covers.