Service
Workshop Manual
ID.4 2021 ➤
Heating, air conditioning system
Edition 09.2021
Service Department. Technical Information
Service
List of Workshop Manual Repair Groups
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
1.1
1.2
2
2.1
2.2
2.3
2.4
2.5
3
3.1
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type plates, R1234yf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type plates, R744 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant capacities, R1234yf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant capacities, R744 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant oil capacities, R1234yf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant oil capacities, R744 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Access to diagnoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1.1
1.2
2
2.1
2.2
2.3
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
3.19
3.20
3.21
3.22
3.23
3.24
3.25
3.26
Safety information and repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview of fitting locations – air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview of fitting locations – components not located in passenger compartment, with
heat pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview of fitting locations – components not located in passenger compartment, without
heat pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview of fitting locations - components located in front section of passenger
compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System overview – refrigerant circuit, without heat pump . . . . . . . . . . . . . . . . . . . . . . . . . .
System overview – refrigerant circuit, with heat pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview – refrigerant lines, R1234yf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview – refrigerant lines, R744 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview – heat exchanger for high-voltage battery, R1234yf . . . . . . . . . . . . . .
Assembly overview – condenser, R1234yf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing refrigerant pressure and temperature sender [G395], R1234yf . .
Removing and installing refrigerant pressure and temperature sender [G395], R744 . . . .
Removing and installing pressure sender for refrigerant circuit [G805], R1234yf . . . . . . . .
Removing and installing expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing/installing refrigerant line from/to expansion valve, R1234yf . . . . . . . . . . . . . . . .
Removing and installing condenser/gas cooler, R1234yf . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing condenser/gas cooler, R744 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing desiccant bag/dryer, R1234yf . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing desiccant bag/dryer, R744 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing evacuating and charging valves on low and high-pressure side,
R1234yf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing evacuating and charging valves on low and high-pressure side,
R744 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing refrigerant pressure and temperature sender 2 [G826] . . . . . . . .
Removing and installing refrigerant pressure and temperature sender 3 [G827] . . . . . . . .
Removing and installing refrigerant pressure and temperature sender 4 [G828] . . . . . . . .
Removing and installing refrigerant pressure and temperature sender 5 [G829] . . . . . . . .
Removing and installing pressure relief valve, R744 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing heat exchanger for high-voltage battery, R1234yf . . . . . . . . . . . .
Removing and installing heat exchanger for high-voltage battery, R744 . . . . . . . . . . . . . .
Removing and installing heat condenser, R744 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing refrigerant shut-off valve for heater and air conditioner unit [N541]
........................................................................
Contents
1
1
1
1
2
2
2
2
2
2
4
4
6
6
6
6
7
7
10
12
15
15
17
19
21
23
24
25
27
28
29
30
31
32
32
34
36
37
38
40
42
43
45
46
48
50
50
i
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
3.27
3.28
3.29
3.30
3.31
3.32
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
5
5.1
5.2
5.3
5.4
5.5
5.6
6
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
7
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
7.12
7.13
7.14
7.15
7.16
7.17
ii Contents
Removing and installing refrigerant line, R1234yf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54
Removing and installing refrigerant line, R744 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
61
Disconnecting/connecting refrigerant lines from/to condenser/gas cooler, R1234yf . . . . . . 72
Disconnecting/connecting refrigerant lines from/to condenser/gas cooler, R744 . . . . . . . .
74
Cleaning refrigerant circuit, refrigerant R744 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Cleaning refrigerant circuit, refrigerant R1234yf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Valve unit of heat pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Exploded view - heat pump valve unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
81
Removing and installing valve unit of heat pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
85
Removing and installing refrigerant expansion valve 1 [N636] . . . . . . . . . . . . . . . . . . . . . .
89
Removing and installing refrigerant expansion valve 2 N637 . . . . . . . . . . . . . . . . . . . . . .
90
Removing and installing refrigerant expansion valve 3 N638 . . . . . . . . . . . . . . . . . . . . . .
91
Removing and installing refrigerant shut-off valve 1 N696 . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Removing and installing refrigerant shut-off valve 2 N640 . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Removing and installing refrigerant shut-off valve 3 N641 . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Removing and installing refrigerant shut-off valve 4 N642 . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Removing and installing refrigerant shut-off valve 5 N643 . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Exploded view - air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
96
Removing refrigerant lines from and installing to air conditioner compressor, R1234yf . .
97
Detaching/attaching refrigerant lines from/to air conditioner compressor, R744 . . . . . . . .
98
Removing and installing air conditioner compressor [VX81], R1234yf . . . . . . . . . . . . . . . .
99
Removing and installing air conditioner compressor [VX81], R744 . . . . . . . . . . . . . . . . . . 103
Detaching and attaching air conditioner compressor at bracket . . . . . . . . . . . . . . . . . . . .
105
Control motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
107
Overview of fitting locations - control motors (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Assembly overview – control motors, PR numbers KC0, KH4 . . . . . . . . . . . . . . . . . . . . . . 109
Assembly overview – control motors, PR number KH7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Removing and installing control motor for front left temperature flap [VX34] . . . . . . . . . . . . 114
Removing and installing control motor for front right temperature flap [VX35] . . . . . . . . . . 117
Removing and installing control motor for defroster flap [VX47] . . . . . . . . . . . . . . . . . . . .
119
Removing and installing control motor for front left air distribution flap [VX93] . . . . . . . . . . 120
Removing and installing control motor for front right air distribution flap [VX94] . . . . . . . . 123
Removing and installing control motor for rear temperature flap [VX95] . . . . . . . . . . . . . . 125
Removing and installing control motor for fresh air and air recirculation flap [VX96] . . . . . . 126
Removing and installing left air distribution flap actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Removing and installing right air distribution flap actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Front heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Exploded view - heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
130
Assembly overview – evaporator housing, R1234yf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Assembly overview – evaporator housing, R744 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Exploded view - air intake box of heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . 132
Removing and installing heater and air conditioning unit, R1234yf . . . . . . . . . . . . . . . . . . 134
Removing and installing heater and air conditioning unit, R744 . . . . . . . . . . . . . . . . . . . .
137
Removing and installing evaporator, R1234yf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Removing and installing evaporator, R744 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
142
Dismantling and assembling heater and air conditioning unit, R1234yf . . . . . . . . . . . . . . . . 142
Dismantling and assembling heater and air conditioning unit, R744 . . . . . . . . . . . . . . . . . . 143
Removing and installing dust and pollen filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
143
Removing and installing fresh air blower control unit J126 . . . . . . . . . . . . . . . . . . . . . . . .
144
Removing and installing evaporator temperature sensor [G308] . . . . . . . . . . . . . . . . . . . . 145
Removing and installing condensation drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Checking condensation drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Removing and installing air intake unit of heater and air conditioning unit . . . . . . . . . . . . . . 147
Removing and installing air intake cowling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
7.18
8
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
9
9.1
9.2
9.3
9.4
10
10.1
10.2
Removing and installing high voltage heater (PTC) [ZX17] . . . . . . . . . . . . . . . . . . . . . . . . 152
Air duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Assembly overview – air duct and air distribution in passenger compartment . . . . . . . . . . 159
Removing and installing driver side footwell vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Removing and installing front passenger side footwell vents . . . . . . . . . . . . . . . . . . . . . . . . 163
Removing and installing rear footwell vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Removing and installing fresh air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Removing and installing air duct for defroster vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
165
Removing and installing air duct for centre dash panel vent . . . . . . . . . . . . . . . . . . . . . . . . 165
Removing and installing air duct for vent in centre console (rear) . . . . . . . . . . . . . . . . . . . . 166
Removing and installing front air duct for dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . . .
166
Coolant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Assembly overview – high-voltage heater (PTC), rear-wheel drive . . . . . . . . . . . . . . . . . . 168
Assembly overview – high-voltage heater (PTC), all-wheel drive . . . . . . . . . . . . . . . . . . . . 168
Removing and installing PTC heater element 3 [Z132], rear-wheel drive . . . . . . . . . . . . . . 169
Removing and installing PTC heater element 3 [Z132], all-wheel drive . . . . . . . . . . . . . . . . 172
Operating and display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Overview of fitting locations – operating and display unit . . . . . . . . . . . . . . . . . . . . . . . . . . 174
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
Volkswagen Technical Site: https://vwts.ru
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
1.1
Type plates, R1234yf
1.1.1
Type plates
Type plate with capacities in kg for refrigerant R1234yf and
refrigerant oil
1-
Designation of refrigerant oil
2-
Designation of refrigerant
3-
Refrigerant capacity in kg
1.2
Type plates, R744
1.2.1
Type plates
Type plate with capacities in kg for refrigerant R744 and refrig‐
erant oil
1-
Designation of refrigerant oil
2-
Designation of refrigerant
3-
Refrigerant capacity in kg
1. General information
1
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
2
Technical data
2.1
Refrigerant capacities, R1234yf
2.1.1
Refrigerant capacity
Refrigerant
Total capacity
R1234yf
0.460 kg ± 0.015 kg
2.2
Refrigerant capacities, R744
2.2.1
Refrigerant capacity
Refrigerant
Total capacity
R744 according to AHRI 700
specification (H2O <=10ppm
CO2 >=99.9%)
0.420 kg ± 0.015 kg
2.3
Refrigerant oil capacities, R1234yf
2.3.1
Refrigerant oil capacities
Refrigerant oil is extremely hygroscopic. Thus, open containers
must be immediately re-sealed after use to prevent the ingress
of moisture.
Required refrigerant oil
Total amount of oil in refriger‐
ant circuit *)
⇒ Electronic parts catalogue
(ETKA)
120 ml
*)1)
1) Volume of refrigerant oil contained in the replacement air conditioner com‐
pressor -VX81- and corresponding to the total capacity.
2.4
Refrigerant oil capacities, R744
2.4.1
Refrigerant oil capacities
Refrigerant oil is extremely hygroscopic. Thus, open containers
must be immediately re-sealed after use to prevent the ingress
of moisture.
Required refrigerant oil
Total amount of oil in refriger‐
ant circuit *)
⇒ Electronic parts catalogue
(ETKA)
200 ml ± 10 ml
*)2)
2) Volume of refrigerant oil contained in the replacement air conditioner com‐
pressor -VX81- and corresponding to the total capacity.
2.5
Oil distribution
♦ During operation of the air conditioning system, the refriger‐
ant oil contained in the air conditioner compressor -VX81-
2 Rep. gr.00 - Technical data
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
prior to initial operation of the air conditioning system, is
distributed throughout the refrigerant circuit.
♦ Distribution of the refrigerant oil in the refrigerant circuit de‐
pends on the last operating mode of the air conditioner when
it was switched off, the ambient temperatures and so on.
♦ Consequently, it is not possible to make a general statement
about how the refrigerant oil is distributed within the refriger‐
ant circuit.
♦ Observe notes on replacing refrigerant circuit components
⇒ Air conditioning systems with refrigerant R744 – Gener‐
al notes; Rep. gr. 87; Refrigerant circuit; Renewing compo‐
nents or ⇒ Air conditioning systems with refrigerant R1234yf
– General notes; Rep. gr. 87; Refrigerant circuit; Renewing
components.
2. Technical data
3
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
3
Electrical components
3.1
Access to diagnoses
♦ 1) Open electrically actuated valves to drain, evacuate,
charge or flush refrigerant circuit
♦ 2) Air conditioner compressor run-in
♦ 3) Adapt air conditioner compressor
♦ 4) Addressing routine for refrigerant valves
♦ 5) Renew heater and air conditioning system control unit
-J979♦ 6) Adapt flap limit stops of control motors
1) Open electrically actuated valves to drain, evacuate, charge
or flush refrigerant circuit
♦ Diagnosis-compatible systems
♦ 0008 – Air conditioning/heating system electronics [J979]
♦ 0008 – Air conditioning/heating system electronics, functions
♦ 0008 – Charge/evacuate/flush refrigerant circuit
2) Air conditioner compressor run-in
♦ Diagnosis-compatible systems
♦ 0008 – Air conditioning/heating system electronics [J979]
♦ 0008 – Air conditioning/heating system electronics, functions
♦ 0008 – Air conditioner compressor run-in
3) Adapt air conditioner compressor
♦ Diagnosis-compatible systems
♦ 0008 – Air conditioning/heating system electronics [J979]
♦ 0008 – Air conditioning/heating system electronics, functions
♦ 0008 – Adapt air conditioner compressor
4) Addressing routine for refrigerant valves
♦ Diagnosis-compatible systems
♦ 0008 – Air conditioning/heating system electronics [J979]
♦ 0008 – Air conditioning/heating system electronics, functions
♦ 0008 – Automatic addressing routine
5) Renew heater and air conditioning system control unit -J979♦ Diagnosis-compatible systems
♦ 0008 – Air conditioning/heating system electronics [J979]
♦ 0008 – Air conditioning/heating system electronics, functions
♦ 00080008 – Renew control unit
6) Adapt flap limit stops of control motors
♦ Diagnosis-compatible systems
♦ 0008 – Air conditioning/heating system electronics [J979]
♦ 0008 – Air conditioning/heating system electronics, functions
4 Rep. gr.00 - Technical data
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
♦ 0008 – Basic setting
3. Electrical components
5
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
87 –
Air conditioning system
1
Safety information and repair notes
1.1
Safety information
⇒ Safety information and repair notes; Rep. gr. 00; Safety infor‐
mation
1.2
Repair notes
⇒ Safety information and repair notes; Rep. gr. 00; Repair notes
6 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
2
Overview of fitting locations – air
conditioning system
2.1
Overview of fitting locations – compo‐
nents not located in passenger com‐
partment, with heat pump
2.1.1
Overview of fitting locations - components not located in passenger com‐
partment
2. Overview of fitting locations – air conditioning system
7
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 highvoltage 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]
8 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
13 - Evacuating and charging valve
❑ High-pressure side
❑ ⇒ Rep. gr. 87; Removing and installing evacuating and charging valves on low and high-pressure side
14 - Evacuating and charging valve
❑ Low-pressure side
❑ ⇒ Rep. gr. 87; Removing and installing evacuating and charging valves on low and high-pressure side
15 - 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
16 - External air quality and air humidity sensor -G935❑ ⇒ Rep. gr. 87; Removing and installing external air quality and humidity sensor [G935]
17 - Fresh air intake
❑ ⇒ Rep. gr. 87; Removing and installing fresh air intake
18 - Fresh air blower control unit -J126❑ ⇒ Rep. gr. 87; Assembly overview – air intake unit of heater and air conditioning unit
❑ ⇒ Rep. gr. 87; Removing and installing fresh air blower control unit [J126]
19 - Control motor for fresh air and air recirculation flap -VX96❑ ⇒ Rep. gr. 87; Assembly overview – air intake unit of heater and air conditioning unit
❑ ⇒ Rep. gr. 87; Removing and installing control motor for fresh air and air recirculation flap [VX96]
20 - Refrigerant shut-off valve 3 -N641❑ ⇒ Rep. gr. 87; Assembly overview – valve unit of heat pump
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant shut-off valve 3 [N641]
21 - Refrigerant shut-off valve 2 -N640❑ ⇒ Rep. gr. 87; Assembly overview – valve unit of heat pump
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant shut-off valve 2 [N640]
22 - PTC heater element 3 -Z132❑ ⇒ Rep. gr. 87; Assembly overview – high-voltage heater (PTC)
❑ ⇒ Rep. gr. 87; Removing and installing PTC heater element 3 [Z132]
23 - Refrigerant pressure and temperature sender -G395❑ ⇒ Rep. gr. 87; Removing and installing refrigerant pressure and temperature sender [G395]
24 - Air conditioner compressor -VX81❑ With control unit for air conditioner compressor -J842❑ With electrical air conditioner compressor -V470❑ ⇒ Rep. gr. 87; Assembly overview – air conditioner compressor
❑ ⇒ Rep. gr. 87; Removing and installing air conditioner compressor [VX81]
25 - Refrigerant pressure and temperature sender 3 -G827❑ ⇒ Rep. gr. 87; Removing and installing refrigerant pressure and temperature sender 3 [G827]
26 - Ambient temperature sensor -G17❑ ⇒ Rep. gr. 87; Removing and installing ambient temperature sensor [G17]
2. Overview of fitting locations – air conditioning system
9
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
2.2
Overview of fitting locations – compo‐
nents not located in passenger com‐
partment, without heat pump
2.2.1
Overview of fitting locations – components located outside of passenger
compartment
10 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
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
2. Overview of fitting locations – air conditioning system
11
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
❑ ⇒ Rep. gr. 87; Removing and installing fresh air intake
12 - Fresh air blower control unit -J126❑ ⇒ Rep. gr. 87; Assembly overview – air intake unit of heater and air conditioning unit
❑ ⇒ Rep. gr. 87; Removing and installing fresh air blower control unit [J126]
13 - Control motor for fresh air and air recirculation flap -VX96❑ ⇒ Rep. gr. 87; Assembly overview – air intake unit of heater and air conditioning unit
❑ ⇒ Rep. gr. 87; Removing and installing control motor for fresh air and air recirculation flap [VX96]
14 - PTC heater element 3 -Z132❑ ⇒ Rep. gr. 87; Assembly overview – high-voltage heater (PTC)
❑ ⇒ Rep. gr. 87; Removing and installing PTC heater element 3 [Z132]
❑
15 - Desiccant bag
❑ ⇒ Rep. gr. 87; Assembly overview – condenser
❑ ⇒ Rep. gr. 87; Removing and installing desiccant bag/dryer
16 - Ambient temperature sensor -G17❑ ⇒ Rep. gr. 87; Removing and installing ambient temperature sensor [G17]
2.3
Overview of fitting locations - components located in front section of pas‐
senger compartment
The overview shows a left-hand drive vehicle as an example:
12 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
1 - Left vent temperature
sender -G150❑ ⇒ Rep. gr. 87; Remov‐
ing and installing left
vent temperature send‐
er [G150[
2 - Rain and light sensor G397❑ With humidity sender
for air conditioning sys‐
tem -G260❑ With sunlight pene‐
tration photosensor G107❑ ⇒ Electrical system;
Rep. gr. 92; Wind‐
screen wiper system;
Removing and instal‐
ling rain and light sen‐
sor [G397]
3 - Control motor
❑ Shown as an example
for all control motors
❑ ⇒ Rep. gr. 87; Over‐
view of fitting locations
– control motors at front
4 - Heat condenser
❑ Depending on equip‐
ment/version
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing heat
condenser
5 - Evaporator
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing evap‐
orator
6 - Evaporator temperature sensor -G308❑ ⇒ Rep. gr. 87; Removing and installing evaporator temperature sensor [G308]
7 - Heater and air conditioning system control unit -J979❑ ⇒ Rep. gr. 87; Removing and installing heater and air conditioning system control unit [J979]
8 - Condensation drain hose
❑ ⇒ Rep. gr. 87; Checking condensation drain
❑ ⇒ Rep. gr. 87; Removing and installing condensation drain
9 - Right vent temperature sender -G151❑ ⇒ Rep. gr. 87; Removing and installing right vent temperature sender [G151]
10 - Right footwell vent temperature sender -G262❑ ⇒ Rep. gr. 87; Removing and installing right footwell vent temperature sender [G262]
11 - Sensor for interior carbon dioxide concentration -G929❑ Depending on equipment/version
❑ ⇒ Rep. gr. 87; Removing and installing sensor for interior carbon dioxide concentration [G929]
12 - High-voltage heater (PTC) -ZX17❑ With high-voltage heater (PTC) control unit -J848❑ With high-voltage heater (PTC) -Z1152. Overview of fitting locations – air conditioning system
13
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
❑ ⇒ Rep. gr. 87; Removing and installing high voltage heater (PTC) [ZX17]
13 - Vehicle interior temperature sensor -G1090❑ ⇒ Rep. gr. 87; Removing and installing vehicle interior temperature sensor [G1090]
14 - Display unit for front information display and operating unit control unit -J685❑ ⇒ Rep. gr. 87; Removing and installing display unit for front information display and operating unit
control unit [J685]
15 - Left footwell vent temperature sender -G261❑ ⇒ Rep. gr. 87; Removing and installing left footwell vent temperature sender [G261]
16 - Rear vent temperature sender -G174❑ Depending on equipment/version
❑ ⇒ Rep. gr. 87; Removing and installing rear vent temperature sender [G174]
17 - Operating and display unit for rear air conditioning system -E265❑ Depending on equipment/version
❑ ⇒ Rep. gr. 87; Removing and installing operating and display unit for rear air conditioning system
[E265]
14 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
3
Refrigerant circuit
3.1
System overview – refrigerant circuit,
without heat pump
3.1.1
System overview - refrigerant circuit
3. Refrigerant circuit
15
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
1 - Air conditioner compressor
-VX81❑ ⇒ Rep. gr. 87; Remov‐
ing and installing air
conditioner compressor
[VX81]
2 - Refrigerant pressure and
temperature sender -G395❑ ⇒ Rep. gr. 87; Remov‐
ing and installing re‐
frigerant pressure and
temperature sender
[G395]
3 - Service connection, lowpressure side
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing evac‐
uating and charging
valves on low and highpressure side
4 - Evaporator
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing evap‐
orator
5 - Expansion valve
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing ex‐
pansion valve
6 - Refrigerant shut-off valve
for heater and air conditioner
unit -N541❑ ⇒ Rep. gr. 87; Remov‐
ing and installing refrig‐
erant shut-off valve for
heater and air condi‐
tioner unit [N541]
7 - Service connection, high-pressure side
❑ ⇒ Rep. gr. 87; Removing and installing evacuating and charging valves on low and high-pressure side
8 - Refrigerant expansion valve 1 -N636❑ Currently not available as a separate part
❑ ⇒ Rep. gr. 87; Removing and installing heat exchanger for high-voltage battery
9 - Incorporation in high-voltage battery coolant circuit
❑ ⇒ Electric drive motor; Rep. gr. 19; Cooling system/coolant; Connection diagram – coolant hoses
10 - Heat exchanger for high-voltage battery
❑ ⇒ Rep. gr. 87; Removing and installing heat exchanger for high-voltage battery
11 - Pressure sender for refrigerant circuit -G805❑ ⇒ Rep. gr. 87; Removing and installing pressure sender for refrigerant circuit [G805]
12 - Dryer with receiver
❑ ⇒ Rep. gr. 87; Removing and installing desiccant bag
13 - Condenser
❑ ⇒ Rep. gr. 87; Removing and installing condenser
16 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
3.2
System overview – refrigerant circuit,
with heat pump
3.2.1
System overview - refrigerant circuit
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 (lowpressure side)
❑ ⇒ Rep. gr. 87; Re‐
moving and installing
evacuating and charg‐
ing valve (low-pres‐
sure and high-pressure
sides)
6 - Service connection (highpressure 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
18 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
15 - Refrigerant shut-off valve 3 -N641❑ ⇒ Rep. gr. 87; Removing and installing refrigerant shut-off valve 3 N641
16 - Dryer with internal heat exchanger
❑ ⇒ Rep. gr. 87; Removing and installing dryer
17 - Refrigerant pressure and temperature sender 5 -G829❑ ⇒ Rep. gr. 87; Removing and installing refrigerant pressure and temperature sender 5 G829
18 - Air conditioner compressor -VX81❑ ⇒ Rep. gr. 87; Removing and installing air conditioner compressor VX81
19 - Refrigerant pressure and temperature sender -G395❑ ⇒ Rep. gr. 87; Removing and installing refrigerant pressure and temperature sender G395
20 - Refrigerant shut-off valve 2 -N640❑ ⇒ Rep. gr. 87; Removing and installing refrigerant shut-off valve 2 N640
21 - Refrigerant shut-off valve 5 -N643❑ ⇒ Rep. gr. 87; Removing and installing refrigerant shut-off valve 5 N643
22 - Refrigerant pressure and temperature sender 3 -G827❑ ⇒ Rep. gr. 87; Removing and installing refrigerant pressure and temperature sender 3 G827
3.3
Assembly overview – refrigerant lines,
R1234yf
3.3.1
Exploded view - refrigerant lines
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
20 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
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
3.4
Assembly overview – refrigerant lines,
R744
3.4.1
Exploded view - refrigerant lines
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
22 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant line between expansion valve N638/N637 and
evaporator
13 - Refrigerant pressure and temperature sender 4 -G828❑ ⇒ Rep. gr. 87; Removing and installing refrigerant pressure and temperature sender 4 G828
❑ 40 Nm
14 - Refrigerant line
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant line between heat pump valve unit and evaporator
15 - Refrigerant line
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant line between expansion valve N636/N696 and heat
condenser
16 - Refrigerant pressure and temperature sender -G395❑ ⇒ Rep. gr. 87; Removing and installing refrigerant pressure and temperature sender G395
❑ 40 Nm
17 - Refrigerant line
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant line between air conditioner compressor VX81 and
valve block N641/N640
18 - Air conditioner compressor -VX81❑ ⇒ Rep. gr. 87; Exploded view - air conditioner compressor
❑ ⇒ Rep. gr. 87; Removing and installing air conditioner compressor VX81
19 - Refrigerant line
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant line between gas cooler and refrigerant shut-off
valve 2 N640
20 - Refrigerant pressure and temperature sender 3 -G827❑ ⇒ Rep. gr. 87; Removing and installing refrigerant pressure and temperature sender 3 G827
❑ 40 Nm
21 - Gas cooler
❑ ⇒ Rep. gr. 87; Removing and installing gas cooler
22 - Refrigerant line
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant line between dryer and gas cooler
23 - Refrigerant line
❑ ⇒ Rep. gr. 87; Removing and installing refrigerant line between air conditioner compressor VX81 and
dryer
24 - Refrigerant pressure and temperature sender 5 -G829❑ ⇒ Rep. gr. 87; Removing and installing refrigerant pressure and temperature sender 5 G829
❑ 40 Nm
3.5
Assembly overview – heat exchanger
for high-voltage battery, R1234yf
3.5.1
Assembly overview - heat exchanger for high-voltage battery
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 highvoltage 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
3.6
Assembly overview – condenser,
R1234yf
3.6.1
Exploded view - condenser
24 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
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
3.7
Removing and installing refrigerant
pressure and temperature sender
[G395], R1234yf
3.7.1
Removing and installing refrigerant
pressure and temperature sender
G395
Special tools and workshop equipment required
♦ engine bung set -VAS 6122♦ socket -T40284-
3. Refrigerant circuit
25
ID.4 2021 ➤
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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-.
– Check refrigerant line connection -4- and refrigerant pres‐
sure and temperature sender -G395- -2- for dirt and clean if
necessary.
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 nonreturn valve.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Unscrew sender -2- using socket -T40284-; at the same time
counterhold at refrigerant line -4- using open-end spanner.
Installing
Installation is carried out in reverse order; note the following:
– Check that refrigerant line is seated correctly and screw
in and tighten refrigerant pressure and temperature sender
-G395-.
Tightening torques
♦ ⇒ Rep. gr. 87; Exploded view - refrigerant lines
26 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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3.8
Removing and installing refrigerant
pressure and temperature sender
[G395], R744
3.8.1
Removing and installing refrigerant
pressure and temperature sender
G395
Special tools and workshop equipment required
♦ engine bung set -VAS 6122♦ socket -T40284Removing
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.
– Unclip coolant hoses -1- and push them to side.
– Mark electrical connector -5- to avoid interchange and un‐
plug it.
– Check refrigerant line connection -1- and refrigerant pres‐
sure and temperature sender -G395- -4- for dirt and clean if
necessary.
3. Refrigerant circuit
27
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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.
– Unscrew sender -4- using socket -T40284-; at the same time
counterhold at refrigerant line -1- using open-end spanner.
Installing
Installation is carried out in reverse order; note the following:
– Install seals, making sure they are free of oil.
– Check that refrigerant lines are seated correctly and tighten
refrigerant pressure and temperature sender -G395-; coun‐
terhold using open-end spanner while doing so.
– 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
3.9
Removing and installing pressure
sender for refrigerant circuit [G805],
R1234yf
3.9.1
Removing and installing pressure
sender for refrigerant circuit G805
Special tools and workshop equipment required
♦ engine bung set -VAS 6122♦ socket -T40284Removing
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-.
28 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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– Check connection of refrigerant line and pressure sender for
refrigerant circuit -G805- -2- for dirt and clean if necessary.
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 nonreturn valve.
– Extract/drain refrigerant and then immediately open up re‐
frigerant circuit.
– Unscrew sender -2- using socket -T40284-.
Installing
Installation is carried out in reverse order; note the following:
– Check that refrigerant line is seated correctly and tighten
pressure sender for refrigerant circuit -G805-.
Tightening torques
♦ ⇒ Rep. gr. 87; Exploded view - refrigerant lines
3.10
Removing and installing expansion
valve
3.10.1
Removing and installing expansion
valve
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
Immediately seal any open lines and connections with clean
plugs from engine bung set -VAS 6122-.
– ⇒ Air conditioning systems with refrigerant R1234yf – Gener‐
al notes; Rep. gr. 87; Working with air conditioner service
station; Draining refrigerant circuit.
– Detach refrigerant lines from expansion valve ⇒ Rep. gr. 87;
Detaching/attaching refrigerant line from/to expansion valve.
– Unscrew bolts -1- and -2-.
3. Refrigerant circuit
29
ID.4 2021 ➤
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– Remove expansion valve -3-.
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 – evaporator housing,
R1234yf
3.11
Removing/installing refrigerant line
from/to expansion valve, R1234yf
3.11.1
Removing/installing refrigerant line
from/to expansion valve
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
Immediately seal any open lines and connections with clean
plugs from engine bung set -VAS 6122-.
– ⇒ Air conditioning systems with refrigerant R1234yf – Gener‐
al notes; Rep. gr. 87; Working with air conditioner service
station; 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.
– Unscrew bolt -2-.
30 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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– Pull off refrigerant lines -1- and -3-.
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
3.12
Removing and installing condens‐
er/gas cooler, R1234yf
3.12.1
Removing and installing condenser
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
Immediately seal any open lines and connections with clean
plugs from engine bung set -VAS 6122-.
– ⇒ Air conditioning systems with refrigerant R1234yf – Gener‐
al notes; Rep. gr. 87; Working with air conditioner service
station; Draining refrigerant circuit.
– Disconnect refrigerant lines from condenser ⇒ Rep. gr. 87;
Disconnecting/connecting refrigerant lines from/to condens‐
er/gas cooler.
– Dismantle radiator module ⇒ Rep. gr. 19; Radiator/radiator
fan; Dismantling and assembling radiator module.
Installing
Install in reverse order of removal, observing the following:
If condenser is renewed:
– Carry out adaption routine for refrigerant oil capacity, and
clean refrigerant circuit, if necessary ⇒ Air conditioning sys‐
tems with refrigerant R1234yf – General notes; Rep. gr. 87;
Refrigerant circuit; Renewing components.
– ⇒ 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 – condenser
3. Refrigerant circuit
31
ID.4 2021 ➤
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♦ ⇒ Rep. gr. 19; Radiator, radiator fan; Assembly overview –
radiator, radiator fan
3.13
Removing and installing condens‐
er/gas cooler, R744
3.13.1
Removing and installing gas cooler
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
Seal off open pipes/lines and connections immediately with
clean plugs from engine bung set -VAS 6122-.
If gas cooler is renewed:
– Observe procedure for renewing components of refrigerant
circuit ⇒ Air conditioners with refrigerant R744 - General
information; Rep. gr. 87; Refrigerant circuit; Renewing com‐
ponents.
– 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.
– Disconnect refrigerant lines from gas cooler ⇒ Rep. gr. 87;
Detaching and attaching refrigerant lines at condenser/gas
cooler.
– Disassemble radiator module ⇒ Rep. gr. 19; Radiator/radia‐
tor fans; Dismantling and assembling radiator module.
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
♦ ⇒ Rep. gr. 19; Radiator/radiator fans; Exploded view - radia‐
tor/radiator fans
3.14
Removing and installing desiccant bag/
dryer, R1234yf
3.14.1
Removing and installing desiccant bag
Special tools and workshop equipment required
♦ engine bung set -VAS 6122-
32 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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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.
– Remove plug -1- from condenser -2-.
– Take desiccant bag -1- out of condenser -2-.
– Pull filter -2- out of condenser -3- using a piece of wire -1-.
3. Refrigerant circuit
33
ID.4 2021 ➤
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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
3.15
Removing and installing desiccant bag/
dryer, R744
3.15.1
Removing and installing dryer
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
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 heat pump valve unit ⇒ Rep. gr. 87; Removing and
installing heat pump valve unit.
– Unscrew bolts -1- and -2-.
34 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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– Unscrew bolts -1-, -2- and -3-.
– Pull off refrigerant lines -1- and -2-.
– Unscrew nut -2-.
– Pull dryer -1- upwards out of bracket.
3. Refrigerant circuit
35
ID.4 2021 ➤
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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
3.16
Removing and installing evacuating
and charging valves on low and highpressure side, R1234yf
3.16.1
Removing and installing evacuating
and charging valve (low-pressure and
high-pressure sides)
Special tools and workshop equipment required
♦ engine bung set -VAS 6122♦ socket -T10364/4ARemoving
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 protective cap -3-.
36 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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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.
– Remove valve core -2- using socket -T10364/4A-.
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
3.17
Removing and installing evacuating
and charging valves on low and highpressure side, R744
3.17.1
Removing and installing evacuating
and charging valve (low-pressure and
high-pressure sides)
Special tools and workshop equipment required
♦ engine bung set -VAS 6122♦ socket -T10364/5Removing
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.
– Detach protective cap -3-.
3. Refrigerant circuit
37
ID.4 2021 ➤
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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.
– Remove valve core -2- using socket -T10364/5-.
Installing
Installation is carried out in reverse order; note the following:
– 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
3.18
Removing and installing refrigerant
pressure and temperature sender 2
[G826]
3.18.1
Removing and installing refrigerant
pressure and temperature sender 2
[G826]
Special tools and workshop equipment required
♦ engine bung set -VAS 6122-
38 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
♦ socket -T40284Removing
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.
– Unscrew bolts -1-.
– Pull off and remove refrigerant line -2-.
– Mark (to avoid interchanging) and disconnect electrical con‐
nector -5-.
3. Refrigerant circuit
39
ID.4 2021 ➤
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– Check connection of refrigerant line -1- and refrigerant pres‐
sure and temperature sender 2 -G826- -4- for soiling, and
clean as necessary.
– Unscrew sender -4- using socket -T40284- while counter‐
holding at refrigerant line -1- with open-end spanner.
Installing
Install in reverse order of removal, observing the following:
– Install seals and captive fasteners free of oil.
– Make sure that refrigerant lines are seated correctly, and
tighten refrigerant pressure and temperature sender 2 G826- while counterholding with open-end spanner.
– 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 – refrigerant lines
♦ ⇒ Rep. gr. 87; Assembly overview – valve unit of heat pump
3.19
Removing and installing refrigerant
pressure and temperature sender 3
[G827]
3.19.1
Removing and installing refrigerant
pressure and temperature sender 3
G827
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
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.
40 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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– Remove underbody trim (front) ⇒ General body repairs, ex‐
terior; Rep. gr. 66; Underbody trim; Removing and installing
underbody trim (front).
– Mark electrical connector -1- to avoid interchange and un‐
plug it.
– Check connection of refrigerant line -5- and refrigerant pres‐
sure and temperature sender 3 -G827- -2- for dirt and clean
if necessary.
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.
– Unscrew refrigerant pressure and temperature sender 3 G827--2- while counterholding at refrigerant line using openend spanner.
Installing
Installation is carried out in reverse order; note the following:
– Install seals, making sure they are free of oil.
– Check that refrigerant lines are seated correctly and tight‐
en refrigerant pressure and temperature sender 3 -G827-;
counterhold using open-end spanner while doing so.
– 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
41
ID.4 2021 ➤
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3.20
Removing and installing refrigerant
pressure and temperature sender 4
[G828]
3.20.1
Removing and installing refrigerant
pressure and temperature sender 4
G828
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
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.
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.
– Unfasten coolant expansion tank and move slightly to side
⇒ Rep. gr. 19; Cooling system/coolant; Removing and instal‐
ling coolant expansion tank.
– Mark electrical connector -5- to avoid interchange and un‐
plug it.
– Check connection of refrigerant line -1- and refrigerant pres‐
sure and temperature sender 4 -G828- -4- for dirt and clean
if necessary.
42 Rep. gr.87 - Air conditioning system
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.
– Unscrew refrigerant pressure and temperature sender 4 G828--4- while counterholding at refrigerant line using openend spanner.
Installing
Installation is carried out in reverse order; note the following:
– Install seals, making sure they are free of oil.
– Check that refrigerant lines are seated correctly and tight‐
en refrigerant pressure and temperature sender 4 -G828-;
counterhold using open-end spanner while doing so.
– 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
3.21
Removing and installing refrigerant
pressure and temperature sender 5
[G829]
3.21.1
Removing and installing refrigerant
pressure and temperature sender 5
[G829]
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
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 conditioner compressor -VX81- ⇒ Rep. gr. 87;
Removing and installing air conditioner compressor [VX81].
3. Refrigerant circuit
43
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– Mark (to avoid interchanging) and disconnect electrical con‐
nector -5-.
– Check connection of refrigerant line -1- and refrigerant pres‐
sure and temperature sender 5 -G829- -4- for soiling, and
clean as necessary.
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.
– Unscrew refrigerant pressure and temperature sender 5 G829- -4- while counterholding at refrigerant line with openend spanner.
Installing
Install in reverse order of removal, observing the following:
– Install seals free of oil.
– Make sure that refrigerant lines are seated correctly, and
tighten refrigerant pressure and temperature sender 5 G829- while counterholding with open-end spanner.
– 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 – refrigerant lines
♦ ⇒ Rep. gr. 87; Assembly overview – drive unit of air condi‐
tioner compressor
44 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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3.22
Removing and installing pressure relief
valve, R744
3.22.1
Removing and installing pressure limit‐
ing valve
Special tools and workshop equipment required
♦ ESD workplace -VAS 6613Removing
– Remove heat pump valve unit ⇒ Rep. gr. 87; Removing and
installing heat pump valve unit.
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.
– Place heat pump valve unit on ESD workplace -VAS 6613-.
Remove pressure limiting valve on valve block for refrigerant
expansion valve 2 -N637- and refrigerant expansion valve 3
-N638-:
– ⇒ Rep. gr. 87; Removing and installing refrigerant expansion
valve 2 N637
Remove pressure limiting valve on valve block for refrigerant
shut-off valve 4 -N642- and refrigerant shut-off valve 5 -N643-:
– ⇒ Rep. gr. 87; Removing and installing refrigerant shut-off
valve 4 N642
– Check area around pressure limiting valve -2- for dirt and
clean it.
– Unscrew pressure limiting valve -2- from valve block -1-.
Note
The pressure limiting valve has a left-hand thread.
Installing
Installation is carried out in reverse order; note the following:
3. Refrigerant circuit
45
ID.4 2021 ➤
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Pressure limiting valves with damaged protective film must not
be fitted.
– Before installing, check protective film -3- on pressure limit‐
ing valve -2- for damage.
– Install seals and retaining elements, making sure they are
free of oil.
Tightening torques
♦ ⇒ Rep. gr. 87; Exploded view - refrigerant lines
♦ ⇒ Rep. gr. 87; Exploded view - heat pump valve unit
3.23
Removing and installing heat exchang‐
er for high-voltage battery, R1234yf
3.23.1
Removing and installing heat exchang‐
er for high-voltage battery
Special tools and workshop equipment required
♦ engine bung set -VAS 6122♦ hose clamps up to 25 mm -3094Removing
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 air intake box of heater and air conditioning unit
⇒ Rep. gr. 87; Removing and installing air intake box of
heater and air conditioning unit.
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.
– Unfasten coolant expansion tank and move slightly to side
⇒ Rep. gr. 19; Cooling system/coolant; Removing and instal‐
ling coolant expansion tank.
46 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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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-.
– Cover area beneath connections for coolant hoses at heat
exchanger -1- with absorbent paper.
– Release hose clips -5- and disconnect coolant hoses.
– Unplug electrical connector -4-.
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.
– Remove bolts -2-.
– Detach refrigerant lines from heat exchanger -1-.
– Unhook refrigerant line from bracket -6-.
– Remove bolts -3-.
– Take heat exchanger -1- out with bracket.
– Remove bolts -7-.
– Detach heat exchanger -1- from bracket.
Installing
Installation is carried out in reverse order; note the following:
3. Refrigerant circuit
47
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If heat exchanger is renewed:
– Adjust quantity of refrigerant oil ⇒ Air conditioners with refrig‐
erant R1234yf - General information; Rep. gr. 87; Refriger‐
ant circuit; Renewing components.
If coolant expansion tank was completely empty:
– ⇒ Rep. gr. 19; Cooling system/coolant; Draining coolant
– ⇒ Rep. gr. 19; Cooling system/coolant; Filling cooling system
– Fill up with coolant ⇒ Rep. gr. 19; Cooling system/coolant;
Filling cooling system.
– ⇒ Rep. gr. 19; Cooling system/coolant; Checking filling quali‐
ty
Important
•
Should there be air in the coolant circuit, it must be bled
⇒ Rep. gr. 19; Cooling system/coolant; Filling cooling system
Tightening torques
♦ ⇒ Rep. gr. 87; Exploded view - refrigerant lines
♦ ⇒ Rep. gr. 87; Exploded view - heat exchanger for high-volt‐
age battery
♦ ⇒ Rep. gr. 87; Exploded view - air intake box of heater and
air conditioning unit
3.24
Removing and installing heat exchang‐
er for high-voltage battery, R744
3.24.1
Removing and installing heat exchang‐
er for high-voltage battery
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
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.
If heat exchanger is renewed:
– 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.
– ⇒ Rep. gr. 87; Removing and installing desiccant bag.
– Before dismantling the heat pump valve unit, mark electrical
connectors and refrigerant lines accordingly.
48 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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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.
– Unscrew bolts -1-, -2-, -3- and -4-.
– Pull off refrigerant lines.
– Unscrew bolts -1-.
– Disconnect electrical connectors.
– Remove heat exchanger -2-.
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.
3. Refrigerant circuit
49
ID.4 2021 ➤
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Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – valve unit of heat pump
♦ ⇒ Rep. gr. 87; Assembly overview – refrigerant lines
3.25
Removing and installing heat condens‐
er, R744
3.25.1
Removing and installing heat condens‐
er
– Heat condenser -11- is currently not available separately
⇒ Electronic parts catalogue (ETKA).
3.26
Removing and installing refrigerant
shut-off valve for heater and air condi‐
tioner unit [N541]
3.26.1
Removing and installing refrigerant
shut-off valve for heater and air condi‐
tioner unit [N541], left-hand drive vehi‐
cles
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
Immediately seal any open lines and connections with clean
plugs from engine bung set -VAS 6122-.
– 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.
– ⇒ Air conditioning systems with refrigerant R1234yf – Gener‐
al notes; Rep. gr. 87; Working with air conditioner service
station; Draining air conditioner service station.
– Disconnect electrical connector -4-.
50 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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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.
– Loosen union nuts -2-. When doing this, counterhold on
refrigerant shut-off valve for heater and air conditioner unit
-N541--3-.
– Detach refrigerant shut-off valve for heater and air condition‐
er unit -N541--3-.
Installing
Install in reverse order of removal, observing the following:
– Make sure that refrigerant lines -1- are routed free of stress.
3. Refrigerant circuit
51
ID.4 2021 ➤
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– When tightening union nuts, make sure that refrigerant lines
-1- remain free of stress.
– Screw on union nuts -2- to stop by hand.
– Tighten union nuts -2-. When doing this, counterhold on
refrigerant shut-off valve for heater and air conditioner unit
-N541--3-.
– Connect electrical connector -4-.
– ⇒ 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 – air intake unit of heater
and air conditioning unit
♦ ⇒ Rep. gr. 87; Assembly overview – refrigerant lines
3.26.2
Removing and installing refrigerant
shut-off valve for heater and air condi‐
tioner unit [N541], right-hand drive ve‐
hicles
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
Immediately seal any open lines and connections with clean
plugs from engine bung set -VAS 6122-.
– ⇒ Air conditioning systems with refrigerant R1234yf – Gener‐
al notes; Rep. gr. 87; Working with air conditioner service
station; Draining refrigerant circuit.
– Remove refrigerant line leading from condenser to expan‐
sion valve ⇒ Rep. gr. 87; Removing and installing refrigerant
line from condenser to expansion valve.
– Mark installation position between refrigerant shut-off valve
for heater and air conditioning unit -N541--3- and refrigerant
line -1- before loosening union nuts.
52 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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– Loosen union nuts -2- while counterholding at shut-off valve
-3-.
– Detach shut-off valve -3-.
Installing
Install in reverse order of removal, observing the following:
Important
•
Before installing the refrigerant line in the vehicle, the re‐
frigerant shut-off valve for heater and air conditioning unit
-N541--4- must be secured to the refrigerant line -2-.
– Screw refrigerant line -2- with union nut -3- by hand and as
far as stop onto shut-off valve -4- while observing marking of
installation position.
– Tighten union nut -3- while counterholding at shut-off valve
-4-.
– Install refrigerant line -2- with shut-off valve -4-, and make
sure it is routed free of stress ⇒ Rep. gr. 87; Removing and
installing refrigerant line from condenser to expansion valve.
3. Refrigerant circuit
53
ID.4 2021 ➤
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– Connect electrical connector -1-.
– Install refrigerant line -6- between shut-off valve -4- and ex‐
pansion valve while observing following sequence:
♦ Secure refrigerant line -6- to expansion valve ⇒ Rep. gr. 87;
Detaching/attaching refrigerant line from/to expansion valve.
♦ Tighten union nut -5- while counterholding at shut-off valve
-4-.
♦ When tightening union nut -5-, make sure that refrigerant
lines -2- and -6- remain free of stress.
– ⇒ 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
3.27
Removing and installing refrigerant
line, R1234yf
3.27.1
Removing and installing refrigerant line
from condenser to expansion valve
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
Immediately seal any open lines and connections with clean
plugs from engine bung set -VAS 6122-.
– ⇒ Air conditioning systems with refrigerant R1234yf – Gener‐
al notes; Rep. gr. 87; Working with air conditioner service
station; 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.
– 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.
– Unscrew bolt -2-.
54 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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– Pull off refrigerant line -1-.
– Disconnect electrical connector -2-.
– Unhook refrigerant line -1- from bracket -3-.
– Disconnect electrical connector -3-.
– Unscrew bolts -2-.
– Pull off refrigerant line -1-.
– Unscrew bolt -2-.
3. Refrigerant circuit
55
ID.4 2021 ➤
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– Pull off refrigerant lines -3- from expansion valve.
– Remove refrigerant lines -1-.
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
3.27.2
Removing and installing refrigerant line
from air conditioner compressor VX81
to expansion valve
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
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 air intake box of heater and air conditioning unit
⇒ Rep. gr. 87; Removing and installing air intake box of
heater and air conditioning unit.
56 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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– Unfasten coolant expansion tank and move slightly to side
⇒ 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.
– Unscrew bolt -3- securing refrigerant line from air conditioner
compressor to expansion valve.
– Remove bolts -3-.
– Detach refrigerant line -2-.
– Unplug electrical connector -5-.
– Release refrigerant line -1- from retainer -4-.
– Remove bolt -2-.
3. Refrigerant circuit
57
ID.4 2021 ➤
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– Detach refrigerant line -1-.
– Remove refrigerant line -1-.
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
3.27.3
Removing and installing refrigerant line
from condenser to air conditioner com‐
pressor [VX81]
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
Immediately seal any open lines and connections with clean
plugs from engine bung set -VAS 6122-.
– Drain refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf – general notes; Rep. gr. 87; Working with
air conditioner service station; Draining refrigerant circuit.
– Remove lock carrier ⇒ General body repairs, exterior; Rep.
gr. 50; Lock carrier; Removing and installing lock carrier.
– 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.
58 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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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.
– Unscrew bolts -2- and -3-.
– Pull off and remove refrigerant line -1-.
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 – condenser
♦ ⇒ Rep. gr. 87; Assembly overview – refrigerant lines
♦ ⇒ General body repairs, exterior; Rep. gr. 50; Lock carrier;
Assembly overview – lock carrier
3.27.4
Removing and installing refrigerant line
from heat exchanger for high-voltage
battery to high-pressure line
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
Immediately seal any open lines and connections with clean
plugs from engine bung set -VAS 6122-.
– ⇒ Air conditioning systems with refrigerant R1234yf – Gener‐
al notes; Rep. gr. 87; Working with air conditioner service
station; 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.
3. Refrigerant circuit
59
ID.4 2021 ➤
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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.
– Unscrew bolts -2-.
– Pull off and remove refrigerant line -1-.
Installing
Install in reverse order of removal, observing the following:
– Make sure that refrigerant lines are properly seated, and
tighten them.
– ⇒ 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 – air intake unit of heater
and air conditioning unit
3.27.5
Removing and installing refrigerant line
from heat exchanger for high-voltage
battery to low-pressure line
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
Immediately seal any open lines and connections with clean
plugs from engine bung set -VAS 6122-.
– ⇒ Air conditioning systems with refrigerant R1234yf – Gener‐
al notes; Rep. gr. 87; Working with air conditioner service
station; Draining refrigerant circuit.
60 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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– 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.
– Unscrew bolts -3-.
– Pull off and remove refrigerant line -2-.
Installing
Install in reverse order of removal, observing the following:
– Make sure that refrigerant lines are properly seated, and
tighten them.
– ⇒ 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 – air intake unit of heater
and air conditioning unit
3.28
Removing and installing refrigerant
line, R744
3.28.1
Removing and installing refrigerant line
between air conditioner compressor
VX81 and dryer
Special tools and workshop equipment required
♦ engine bung set -VAS 6122-
3. Refrigerant circuit
61
ID.4 2021 ➤
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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.
– Unscrew bolt -3- securing refrigerant line from air conditioner
compressor -VX81- to dryer.
– Remove bolt -3- securing refrigerant line -2-.
62 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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– Detach refrigerant line -2-.
– Mark electrical connector -5- to avoid interchange and un‐
plug it.
– Remove refrigerant line -1-.
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
3.28.2
Removing and installing refrigerant line
between air conditioner compressor
[VX81] and valve block [N641]/[N640]
Special tools and workshop equipment required
♦ engine bung set -VAS 6122-
3. Refrigerant circuit
63
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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.
– Unscrew bolts -2-.
– Pull off and remove refrigerant line -1-.
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.
64 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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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
3.28.3
Removing and installing refrigerant line
between dryer and gas cooler
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
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 front underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66; Underbody cladding; Removing and
installing front underbody cladding.
– Mark (to avoid interchanging) and disconnect electrical con‐
nector -4-.
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.
– Unscrew bolts -2-.
3. Refrigerant circuit
65
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– Pull off and remove refrigerant line -1-.
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 – refrigerant lines
♦ ⇒ Rep. gr. 87; Assembly overview – air conditioner compres‐
sor
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Underbody
cladding; Assembly overview – underbody cladding
3.28.4
Removing and installing refrigerant line
between gas cooler and refrigerant
shut-off valve 2 [N640]
Special tools and workshop equipment required
♦ counter-hold tool -T10630♦ counterhold tool -T10630♦ engine bung set -VAS 6122Removing
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 lock carrier ⇒ General body repairs, exterior; Rep.
gr. 50; Lock carrier; Removing and installing lock carrier.
– Insert counter-hold tool -T10630- -3-.
66 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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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.
– Unscrew bolts -2-.
– Pull off and remove refrigerant line -1-.
Installing
Install in reverse order of removal, observing the following:
– Install seals and captive fasteners free of oil.
– When tightening bolts -2-, use counterhold tool -T10630-.
– 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
♦ ⇒ General body repairs, exterior; Rep. gr. 50; Lock carrier;
Assembly overview – lock carrier
3.28.5
Removing and installing refrigerant line
between refrigerant shut-off valve 3
[N641] and heat condenser
Special tools and workshop equipment required
♦ engine bung set -VAS 6122-
3. Refrigerant circuit
67
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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.
– Unscrew bolts -2-.
– Pull off and remove refrigerant line -1-.
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
68 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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3.28.6
Removing and installing refrigerant
line between expansion valve [N638]/
[N637] and evaporator
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
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.
– Mark (to avoid interchanging) and disconnect electrical con‐
nector -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.
– Unscrew bolts -2-.
– Pull off and remove refrigerant line -1-.
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.
3. Refrigerant circuit
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– ⇒ 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
3.28.7
Removing and installing refrigerant line
between valve unit of heat pump and
evaporator
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
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.
– Unscrew bolts -2-.
– Pull off and remove refrigerant line -1-.
70 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
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
3.28.8
Removing and installing refrigerant
line between expansion valve [N636]/
[N696] and heat condenser
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
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.
– Unscrew bolts -2-.
3. Refrigerant circuit
71
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– Pull off and remove refrigerant line -2-.
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
3.29
Disconnecting/connecting refrigerant
lines from/to condenser/gas cooler,
R1234yf
3.29.1
Disconnecting/connecting refrigerant
lines from/to condenser
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Disconnecting
Immediately seal any open lines and connections with clean
plugs from engine bung set -VAS 6122-.
– ⇒ Air conditioning systems with refrigerant R1234yf – Gener‐
al notes; Rep. gr. 87; Working with air conditioner service
station; Draining refrigerant circuit.
– Remove lock carrier ⇒ General body repairs, exterior; Rep.
gr. 50; Lock carrier; Removing and installing lock carrier.
– Remove front underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66; Underbody cladding; Removing and
installing front underbody cladding.
72 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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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.
– Unscrew bolt -1-.
– Pull off refrigerant line -2-.
– Unscrew bolt -2-.
– Pull off refrigerant line -1-.
Connecting
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 – condenser
♦ ⇒ Rep. gr. 87; Assembly overview – refrigerant lines
♦ ⇒ General body repairs, exterior; Rep. gr. 50; Lock carrier;
Assembly overview – lock carrier
3. Refrigerant circuit
73
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♦ ⇒ General body repairs, exterior; Rep. gr. 66; Underbody
cladding; Assembly overview – underbody cladding
3.30
Disconnecting/connecting refrigerant
lines from/to condenser/gas cooler,
R744
3.30.1
Disconnecting and connecting refriger‐
ant lines on gas cooler
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Disconnecting
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.
– Remove front underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66; Underbody cladding; Removing and
installing front 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.
– Unscrew bolt -1-.
– Pull off refrigerant line -2-.
74 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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– Unscrew bolt -1-.
– Pull off refrigerant line -2-.
Connecting
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 – refrigerant lines
♦ ⇒ General body repairs, exterior; Rep. gr. 50; Lock carrier;
Removing and installing lock carrier
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Underbody
cladding; Assembly overview – underbody cladding
3.31
Cleaning refrigerant circuit, refriger‐
ant R744
3.31.1
Cleaning refrigerant circuit
Special tools and workshop equipment required
♦ Air conditioner service station
♦ air conditioner service station
♦ engine bung set -VAS 6122♦ flushing adapter -VAS 6338/77♦ flushing device
♦ The refrigerant circuit is flushed using refrigerant R1234yf
or R134a and the air conditioner service station which is
designed for this purpose.
♦ The following procedure is described for an air conditioner
service station with integrated flushing device for R1234yf
as an example. The procedure for an air conditioner service
station with integrated flushing device for R134a is similar.
♦ If the refrigerant circuit is contaminated, it is flushed in the
same direction as the normal direction of flow.
3. Refrigerant circuit
75
ID.4 2021 ➤
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♦ There must be at least 6 kg of refrigerant in the air condition‐
er service station.
♦ Observe operating instructions for air conditioner service
station ⇒ Operating instructions.
Procedure
Important
•
Seal off open pipes/lines and connections immediately with
clean plugs from engine bung set -VAS 6122-.
– Detach refrigerant lines from air conditioner compressor
⇒ Rep. gr. 87; Detaching and attaching refrigerant lines at
air conditioner compressor.
– Unplug electrical connector -1- on refrigerant pressure and
temperature sender -G395- -2-.
– Connect low-pressure hose -1- of air conditioner service sta‐
tion to flushing device -3- of air conditioner service station
with quick-release coupling -2-.
– Screw refrigerant line (high-pressure side) -4- to flushing
adapter -VAS 6338/77- -3-.
76 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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– Screw refrigerant line (low-pressure side) -5- to flushing
adapter -VAS 6338/78- -6-.
– Screw refrigerant hose -7- of flushing device to flushing
adapter -VAS 6338/78- -6-.
– Connect refrigerant hose -2- of air conditioner service station
to flushing adapter -VAS 6338/77- -3-.
– Perform function “Opening electrically actuated valves in
refrigerant circuit for extracting, evacuating, charging and
flushing” with ⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00;
Starting diagnosis.
– Start flushing procedure via menu of air conditioner service
station ⇒ Operating instructions.
Important
•
Air conditioner service station displays when flushing proce‐
dure has been completed.
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.
– Check pressure in flushing circuit; only detach refrigerant
hoses and adapters if pressure is below or equal to ambient
pressure.
– Disconnect air conditioner service station and detach adapt‐
er.
– After charging refrigerant circuit and re-energising high-volt‐
age system, perform “Compressor activation” with ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00; Starting diagnosis.
3. Refrigerant circuit
77
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Tightening torques
♦ ⇒ Rep. gr. 87; Exploded view - refrigerant lines
3.32
Cleaning refrigerant circuit, refriger‐
ant R1234yf
3.32.1
Cleaning refrigerant circuit
Special tools and workshop equipment required
♦ Adapter -VAS 6338/3♦ Air conditioner service station
♦ MQB adapter -VAS 6338/38♦ adapter -VAS 6338/12♦ air conditioner service station
♦ engine bung set -VAS 6122♦ The following procedure is described for an air conditioner
service station with integrated flushing device for R1234yf as
an example.
♦ If the refrigerant circuit is contaminated, it is flushed against
the normal direction of flow.
♦ There must be at least 6 kg of refrigerant in the air condition‐
er service station.
♦ Observe operating instructions for air conditioner service
station ⇒ Operating instructions.
Procedure
Important
•
Seal off open pipes/lines and connections immediately with
clean plugs from engine bung set -VAS 6122-.
– Remove air conditioner compressor ⇒ Rep. gr. 87; Remov‐
ing and installing air conditioner compressor VX81.
– Fit adapter -VAS 6338/12- and adapter -VAS 6338/3- on
refrigerant lines.
– Remove expansion valve and fit MQB adapter -VAS
6338/38- in its place ⇒ Rep. gr. 87; Removing and installing
expansion valve.
– Remove desiccant bag and re-seal receiver ⇒ Rep. gr. 87;
Removing and installing desiccant bag.
– Screw caps with seals onto both service connections of re‐
frigerant circuit.
Note
The refrigerant circuit cannot be evacuated properly if caps are
not fitted, as air will enter when the vacuum in the refrigerant
circuit causes the valves in the service connections to open.
– Connect air conditioner service station -1- to refrigerant cir‐
cuit for flushing.
78 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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♦ 1. Air conditioner service station
♦ 2. Refrigerant hose of air conditioner service station (low
pressure side)
♦ 3. Flushing device
♦ 4. Refrigerant hose
♦ 5. Adapter -VAS 6338/3♦ 6. Vehicle refrigerant line with connection to air conditioner
compressor (high-pressure side)
♦ 7. Vehicle refrigerant line with connection to air conditioner
compressor (low-pressure side)
♦ 8. Adapter -VAS 6338/12♦ 9. Refrigerant hose of air conditioner service station (highpressure side)
– Perform function “Opening electrically actuated valves in
refrigerant circuit for extracting, evacuating, charging and
flushing” with ⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00;
Starting diagnosis.
– Start flushing procedure via menu of air conditioner service
station ⇒ Operating instructions.
Important
•
Air conditioner service station displays when flushing proce‐
dure has been completed.
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 ➤
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– Check pressure in flushing circuit; only detach refrigerant
hoses and adapters if pressure is below or equal to ambient
pressure.
– Renew desiccant bag ⇒ Rep. gr. 87; Removing and instal‐
ling desiccant bag.
– Remove rinsing adapters and assemble refrigerant circuit.
– After charging refrigerant circuit and re-energising high-volt‐
age system, perform “Compressor activation” with ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00; Starting diagnosis.
Tightening torques
♦ ⇒ Rep. gr. 87; Exploded view - refrigerant lines
♦ ⇒ Rep. gr. 87; Exploded view - evaporator housing
80 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
4
Valve unit of heat pump
4.1
Exploded view - heat pump valve unit
Exploded view - heat pump valve unit, components
4. Valve unit of heat pump
81
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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 -G82811 - 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 -G82617 - Electrical wiring for refrigerant pressure and temperature sender 5 -G82918 - 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
82 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
20 - Bracket
21 - Flexible joint
❑ 3 Nm
22 - Nut
❑ 15 Nm
Exploded view - refrigerant lines inside heat pump valve unit
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
Exploded view - refrigerant lines at heat pump valve unit
4. Valve unit of heat pump
83
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
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
84 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
4.2
Removing and installing valve unit of
heat pump
Special tools and workshop equipment required
♦ ESD workplace -VAS 6613♦ engine bung set -VAS 6122Removing
Immediately seal any open lines and connections with clean
plugs from engine bung set -VAS 6122-.
When renewing several components of heat pump valve unit at
the same time:
– 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; Draining refrigerant circuit.
– ⇒ Rep. gr. 19; Cooling system/coolant; Draining coolant.
– 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.
– Detach coolant expansion tank, and lay it slightly aside
⇒ Rep. gr. 19; Cooling system/coolant; Removing and instal‐
ling coolant expansion tank.
– Remove front underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66; Underbody cladding; Removing and
installing front underbody cladding.
– Separate coolant hose -1- and lay to one side.
4. Valve unit of heat pump
85
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.
– Unscrew bolt -2-.
– Pull off refrigerant line -3-.
– Mark (to avoid interchanging) and disconnect electrical con‐
nector -3-.
– Unscrew bolt -2-.
– Pull off refrigerant line -1-.
– Unscrew bolts -3-.
– Pull off refrigerant line -1- and -2-.
– Loosen clamps -3-.
86 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
– Pull off coolant hoses -1- and -2-.
– Mark (to avoid interchanging) and disconnect electrical con‐
nectors -1- and -2-.
– Unscrew bolts -1-, -2-, -3- and -4-.
– Pull off refrigerant lines.
– Unscrew bolts -2-, -3- and -4- from bracket of heat pump
valve unit -1-.
4. Valve unit of heat pump
87
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
– Remove valve unit of heat pump -1- upwards.
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.
– Place heat pump valve unit onto ESD workplace -VAS
6613-.
Installing
Install in reverse order of removal, observing the following:
– Install seals and captive fasteners free of oil.
After renewal of several components of heat pump valve unit at
the same time:
– Carry out adaption routine for refrigerant oil capacity in re‐
frigerant circuit ⇒ Air conditioning systems with refrigerant
R744 – General notes; Rep. gr. 87; Refrigerant circuit; Re‐
newing components.
– 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.
– ⇒ Rep. gr. 19; Cooling system/coolant; Filling cooling system
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – valve unit of heat pump
♦ ⇒ Rep. gr. 87; Assembly overview – refrigerant lines
88 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
♦ ⇒ Rep. gr. 87; Assembly overview – air intake unit of heater
and air conditioning unit
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Underbody
cladding; Assembly overview – underbody cladding
4.3
Removing and installing refrigerant ex‐
pansion valve 1 [N636]
Special tools and workshop equipment required
♦ ESD workplace -VAS 6613Removing
Refrigerant expansion valve 1 -N636- and refrigerant shut-off
valve 1 -N696- cannot be renewed individually.
– Remove heat pump valve unit ⇒ Rep. gr. 87; Removing and
installing heat pump valve unit.
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.
– Place heat pump valve unit onto ESD workplace -VAS
6613-.
– Unscrew bolts -1-, -2- and -3-.
– Mark (to avoid interchanging) and disconnect electrical con‐
nectors -2-.
– Unscrew bolts -3-.
– Remove refrigerant expansion valve 1 -N636- and refriger‐
ant shut-off valve 1 -N696--1-.
4. Valve unit of heat pump
89
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
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
4.4
Removing and installing refrigerant ex‐
pansion valve 2 N637
Special tools and workshop equipment required
♦ ESD workplace -VAS 6613Removing
Refrigerant expansion valve 2 -N637- and refrigerant expansion
valve 3 -N638- cannot be renewed separately.
– Remove heat pump valve unit ⇒ Rep. gr. 87; Removing and
installing heat pump valve unit.
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.
– Place heat pump valve unit on ESD workplace -VAS 6613-.
– Remove bolts -1-, -2- and -3-.
– Mark electrical connectors -2- to avoid interchange and un‐
plug them.
90 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
– Remove bolts -3-.
– Detach refrigerant expansion valve 2 -N637- and refrigerant
expansion valve 3 -N638- -1-.
Installing
Installation is carried out in reverse order; note the following:
– Install seals and retaining elements, making sure they are
free of oil.
If expansion valves have been renewed:
– Perform function “Addressing refrigerant valves” using ⇒ Ve‐
hicle diagnostic tester ⇒ Rep. gr. 00; Starting diagnosis.
Tightening torques
♦ ⇒ Rep. gr. 87; Exploded view - heat pump valve unit
4.5
Removing and installing refrigerant ex‐
pansion valve 3 N638
Removing and installing
Refrigerant expansion valve 3 -N638- is removed together with
refrigerant expansion valve 2 -N637- and cannot be renewed
separately ⇒ Rep. gr. 87; Removing and installing refrigerant
expansion valve 2 N637.
4.6
Removing and installing refrigerant
shut-off valve 1 N696
Removing and installing
Refrigerant shut-off valve 1 -N696- is removed together with
refrigerant expansion valve 1 -N636- and cannot be renewed
separately ⇒ Rep. gr. 87; Removing and installing refrigerant
expansion valve 1 N636.
4.7
Removing and installing refrigerant
shut-off valve 2 N640
Special tools and workshop equipment required
♦ ESD workplace -VAS 6613♦ counterhold tool -T10630Removing
Refrigerant shut-off valve 2 -N640- and refrigerant shut-off valve
3 -N641- cannot be renewed separately.
– Remove heat pump valve unit ⇒ Rep. gr. 87; Removing and
installing heat pump valve unit.
4. Valve unit of heat pump
91
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
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.
– Place heat pump valve unit on ESD workplace -VAS 6613-.
– Use counterhold tool -T10630--4-.
– Remove bolts -1-, -2-, -3- and -5-.
– Detach refrigerant lines.
– Mark electrical connectors -2- to avoid interchange and un‐
plug them.
– Remove bolts -3-.
– Detach refrigerant shut-off valve 2 -N640- and refrigerant
shut-off valve 3 -N641- -1-.
Installing
Installation is carried out in reverse order; note the following:
– Install seals and retaining elements, making sure they are
free of oil.
– Use counterhold tool -T10630- when tightening bolts -3-.
92 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
If shut-off valves have been renewed:
– Perform function “Addressing refrigerant valves” using ⇒ Ve‐
hicle diagnostic tester ⇒ Rep. gr. 00; Starting diagnosis.
Tightening torques
♦ ⇒ Rep. gr. 87; Exploded view - heat pump valve unit
4.8
Removing and installing refrigerant
shut-off valve 3 N641
Removing and installing
Refrigerant shut-off valve 3 -N641- is removed together with re‐
frigerant shut-off valve 2 -N640- and cannot be renewed sepa‐
rately ⇒ Rep. gr. 87; Removing and installing refrigerant shut-off
valve 2 N640.
4.9
Removing and installing refrigerant
shut-off valve 4 N642
Special tools and workshop equipment required
♦ ESD workplace -VAS 6613Removing
Refrigerant shut-off valve 4 -N642- and refrigerant shut-off valve
5 -N643- -1- cannot be renewed separately.
– Remove heat pump valve unit ⇒ Rep. gr. 87; Removing and
installing heat pump valve unit.
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.
– Place heat pump valve unit on ESD workplace -VAS 6613-.
– Remove bolts -2-, -3- and -4-.
4. Valve unit of heat pump
93
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
– Detach refrigerant line -1-.
– Remove bolts -1- and -2-.
– Mark electrical connectors -2- to avoid interchange and un‐
plug them.
– Remove bolts -3-.
– Detach refrigerant shut-off valve 4 -N642- and refrigerant
shut-off valve 5 -N643- -1-.
Installing
Installation is carried out in reverse order; note the following:
– Install seals and retaining elements, making sure they are
free of oil.
If shut-off valves have been renewed:
– Perform function “Addressing refrigerant valves” using ⇒ Ve‐
hicle diagnostic tester ⇒ Rep. gr. 00; Starting diagnosis.
Tightening torques
♦ ⇒ Rep. gr. 87; Exploded view - heat pump valve unit
94 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
4.10
Removing and installing refrigerant
shut-off valve 5 N643
Removing and installing
Refrigerant shut-off valve 5 -N643- is removed together with re‐
frigerant shut-off valve 4 -N642- and cannot be renewed sepa‐
rately ⇒ Rep. gr. 87; Removing and installing refrigerant shut-off
valve 4 N642.
4. Valve unit of heat pump
95
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
5
Air conditioner compressor
5.1
Exploded view - air conditioner compressor
1 - Air conditioner compressor
-VX81❑ ⇒ Rep. gr. 87; Remov‐
ing and installing air
conditioner compressor
VX81
2 - Electrical connector for
high-voltage system
❑ ⇒ Electric drive motor;
Rep. gr. 93; High-volt‐
age wires; Overview of
fitting locations - highvoltage wires
3 - Electrical connector
4 - Bolt
❑ 8 Nm
5 - Potential equalisation line
❑ ⇒ Electric drive mo‐
tor; Rep. gr. 93; Poten‐
tial equalisation lines;
Overview of fitting loca‐
tions - potential equali‐
sation lines
6 - Bolt
❑ 3x
❑ 20 Nm
7 - Bracket
❑ ⇒ Rep. gr. 87; Detach‐
ing and attaching air
conditioner compressor
at bracket
8 - Bolt
❑ 4x
❑ 8 Nm
9 - Bolt
❑ 3x
❑ 20 Nm
10 - Bracket
❑ ⇒ Rep. gr. 87; Detaching and attaching air conditioner compressor at bracket
96 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
5.2
Removing refrigerant lines from and in‐
stalling to air conditioner compressor,
R1234yf
5.2.1
Detaching and attaching refrigerant
lines at air conditioner compressor
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
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 air intake box of heater and air conditioning unit
⇒ Rep. gr. 87; Removing and installing air intake box 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.
– Remove bolts -3- and detach refrigerant lines -2-.
Installing
Installation is carried out in reverse order; note the following:
– Connect refrigerant lines -2- and tighten bolts -3-.
5. Air conditioner compressor
97
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
– ⇒ 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
5.3
Detaching/attaching refrigerant lines
from/to air conditioner compressor,
R744
5.3.1
Detaching and attaching refrigerant
lines at air conditioner compressor
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
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.
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.
– Remove bolts -3- and detach refrigerant lines -2-.
98 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
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-.
– 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
5.4
Removing and installing air conditioner
compressor [VX81], R1234yf
5.4.1
Removing and installing air conditioner
compressor [VX81]
Special tools and workshop equipment required
♦ engine bung set -VAS 6122-
5. Air conditioner compressor
99
ID.4 2021 ➤
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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.
– ⇒ Rep. gr. 93; De-energise high-voltage system.
– ⇒ Air conditioning systems with refrigerant R1234yf – Gener‐
al notes; Rep. gr. 87; Working with air conditioner service
station; Draining refrigerant circuit.
– Remove air intake box of heater and air conditioning unit
⇒ Rep. gr. 87; Removing and installing air intake unit of
heater and air conditioning unit.
– Disconnect electrical connectors -2-, and unclip lines ⇒ Elec‐
tric drive motor; Rep. gr. 93; High-voltage cables; Discon‐
necting high-voltage connectors.
– Unscrew bolts -3-.
– Unscrew bolt -4-.
100 Rep. gr.87 - Air conditioning system
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.
– Unscrew bolts -3-, and pull off refrigerant lines.
– Remove air conditioner compressor -VX81- -1-.
Detaching air conditioner compressor from bracket (if necessa‐
ry):
– ⇒ Rep. gr. 87; Detaching/attaching air conditioner compres‐
sor from/to bracket.
Installing
Install in reverse order of removal, observing the following:
When renewing air conditioner compressor:
Important
•
The air conditioner compressor must not be flushed individu‐
ally.
NOTICE
Risk of damage to components due to soiling.
– Keep the measuring beaker clean.
– Drain oil from removed air conditioner compressor into a
measuring beaker -1- via the two connections to determine
the amount of oil. Move the air conditioner compressor in a
circular motion to ensure the best possible drainage.
Important
•
If the oil shows signs of contamination (by turning dark-grey
to black and cloudy), the entire refrigerant circuit must be
flushed ⇒ Air conditioning systems with refrigerant R1234yf
– General notes; Rep. gr. 87; Refrigerant circuit; Cleaning
refrigerant circuit.
– After removing protective caps on suction and pressure
sides, drain oil from new air conditioner compressor into
measuring beaker -2-. Move the air conditioner compressor
in a circular motion to ensure the best possible drainage.
– The (drained) new air conditioner compressor must be fil‐
led with exact the same amount of refrigerant oil that has
been determined in the removed air conditioner compressor
(measuring beaker -2-). This is done via the suction pipe.
Important
•
The air conditioner compressor must not be flushed individu‐
ally.
5. Air conditioner compressor
101
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
NOTICE
Risk of damage to components due to soiling.
– Keep the measuring beaker clean.
– Drain oil from removed air conditioner compressor into a
measuring beaker -1- via the two connections to determine
the amount of oil. Move the air conditioner compressor in a
circular motion to ensure the best possible drainage.
Important
•
If the oil shows signs of contamination (by turning dark-grey
to black and cloudy), the entire refrigerant circuit must be
flushed ⇒ r3.32.1 efrigerant circuit”, page 78 .
– After removing protective caps on suction and pressure
sides, drain oil from new air conditioner compressor into
measuring beaker -2-. Move the air conditioner compressor
in a circular motion to ensure the best possible drainage.
– The (drained) new air conditioner compressor must be fil‐
led with exact the same amount of refrigerant oil that has
been determined in the removed air conditioner compressor
(measuring beaker -2-). This is done via the suction pipe.
– Fit refrigerant lines -2-, and tighten bolts -3-.
– 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 bolt -4-.
– ⇒ Air conditioning systems with refrigerant R1234yf – Gener‐
al notes; Rep. gr. 87; Working with air conditioner service
station; 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.
– ⇒ Rep. gr. 93; Re-energising high-voltage system.
102 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
Heating, air conditioning system - Edition 09.2021
After renewal of air conditioner compressor:
– Carry out function “Air conditioner compressor run-in” using
⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00; Access to diagno‐
ses.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – air conditioner compres‐
sor
♦ ⇒ Rep. gr. 87; Assembly overview - refrigerant lines
5.5
Removing and installing air conditioner
compressor [VX81], R744
5.5.1
Removing and installing air conditioner
compressor [VX81]
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
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.
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.
– ⇒ Rep. gr. 93; De-energise high-voltage system.
– 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.
– Disconnect electrical connectors -3-, and unclip lines ⇒ Elec‐
tric drive motor; Rep. gr. 93; High-voltage cables; Discon‐
necting high-voltage connectors.
5. Air conditioner compressor
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– Unclip cable retainer -4-.
– Unscrew bolts -2-.
– Unscrew bolt -4-.
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.
– Unscrew bolts -3-, and pull off refrigerant lines.
– Remove air conditioner compressor -VX81--1-.
Detaching air conditioner compressor from bracket (if necessa‐
ry):
– ⇒ Rep. gr. 87; Detaching/attaching air conditioning compres‐
sor from/to bracket.
Installing
Install in reverse order of removal, observing the following:
When renewing air conditioner compressor:
– Carry out adaption routine for refrigerant oil capacity, and
clean refrigerant circuit, if necessary ⇒ Air conditioning sys‐
tems with refrigerant R744 – General notes; Rep. gr. 87;
Refrigerant circuit; Renewing components.
– Install seals and captive fasteners free of oil.
– Check screw connections of potential equalisation line, and
clean them if necessary ⇒ Electrical system; Rep. gr. 97;
Cleaning contact surfaces; Cleaning contact surfaces.
104 Rep. gr.87 - Air conditioning system
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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.
– ⇒ Rep. gr. 93; Re-energising high-voltage system.
After renewal of air conditioner compressor:
– After charging refrigerant circuit and re-energising high-volt‐
age system, carry out functions “Adapt air conditioning com‐
pressor” and “Compressor run-in” using ⇒ Vehicle diagnostic
tester ⇒ Rep. gr. 00; Access to diagnoses.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – air conditioner compres‐
sor
♦ ⇒ Rep. gr. 87; Assembly overview – refrigerant lines
5.6
Detaching and attaching air conditioner
compressor at bracket
Removing
– Remove air conditioner compressor -VX81- ⇒ Rep. gr. 87;
Removing and installing air conditioner compressor VX81.
– Remove bolts -2-.
5. Air conditioner compressor
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– Detach air conditioner compressor -3- from bracket -1-.
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ Rep. gr. 87; Exploded view - air conditioner compressor
106 Rep. gr.87 - Air conditioning system
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6
Control motors
6.1
Overview of fitting locations - control motors (front)
6. Control motors
107
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1 - Control motor for fresh
air and air recirculation flap VX96❑ With fresh air/air recir‐
culation, air flow flap
control motor -V425❑ With potentiometer for
fresh air/air recircula‐
tion, air flow flap control
motor -G644❑ ⇒ Rep. gr. 87; Remov‐
ing and installing con‐
trol motor for fresh
air and air recirculation
flap VX96
2 - Control motor for front left
temperature flap -VX34❑ With left temperature
flap control motor V158❑ With potentiometer for
left temperature flap
control motor -G220❑ ⇒ Rep. gr. 87; Remov‐
ing and installing front
left temperature flap
VX34
3 - Control motor for front left
air distribution flap -VX93❑ With front left air distri‐
bution flap control mo‐
tor -V706❑ With potentiometer for
front left air distribu‐
tion flap control motor
-G1105❑ ⇒ Rep. gr. 87; Removing and installing front left air distribution flap control motor VX93
4 - Control motor for rear temperature flap -VX95❑ Depending on equipment/vehicle version
❑ With rear temperature flap control motor -V137❑ With potentiometer for rear temperature flap motor -G479❑ ⇒ Rep. gr. 87; Removing and installing control motor for rear temperature flap VX95
5 - Control motor for front right air distribution flap -VX94❑ With front right air distribution flap control motor -V707❑ With potentiometer for front right air distribution flap control motor -G1106❑ ⇒ Rep. gr. 87; Removing and installing control motor for front right air distribution flap VX94
6 - Control motor for front right temperature flap -VX35❑ With right temperature flap control motor -V159❑ With potentiometer for right temperature flap control motor -G221❑ ⇒ Rep. gr. 87; Removing and installing control motor for front right temperature flap VX35
7 - Control motor for defroster flap -VX47❑ With defroster flap control motor -V107❑ With potentiometer for defroster flap control motor -G135❑ ⇒ Rep. gr. 87; Removing and installing control motor for defroster flap VX47
108 Rep. gr.87 - Air conditioning system
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6.2
Assembly overview – control motors,
PR numbers KC0, KH4
6.2.1
Exploded view - control motors (front)
Exploded view - control motors (front left)
1 - Control motor for front left
temperature flap -VX34❑ ⇒ Rep. gr. 87; Remov‐
ing and installing con‐
trol motor for front left
temperature flap VX34
2 - Bolt
❑ 1.5 Nm
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
Exploded view - control motors (front right)
6. Control motors
109
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1 - Heater and air conditioning
unit
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing heater
and air conditioning unit
2 - Bolt
❑ 1.5 Nm
3 - Control motor for defroster
flap -VX47❑ ⇒ Rep. gr. 87; Remov‐
ing and installing con‐
trol motor for defroster
flap VX47
4 - Actuator
5 - Control motor for front
right air distribution flap VX94❑ ⇒ Rep. gr. 87; Re‐
moving and installing
control motor for front
right air distribution flap
VX94
6 - Control motor for front
right temperature flap -VX35❑ ⇒ Rep. gr. 87; Remov‐
ing and installing con‐
trol motor for front right
temperature flap VX35
Exploded view - control motors (front), air intake box of heater
and air conditioning unit
110 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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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
6.3
Assembly overview – control motors,
PR number KH7
6.3.1
Exploded view - control motors (front)
Exploded view - control motors (front left)
6. Control motors
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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
Exploded view - control motors (front right)
112 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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1 - Heater and air conditioning
unit
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing heater
and air conditioning unit
2 - Bolt
❑ 1.5 Nm
3 - Control motor for defroster
flap -VX47❑ ⇒ Rep. gr. 87; Remov‐
ing and installing con‐
trol motor for defroster
flap VX47
4 - Actuator
5 - Control motor for front
right air distribution flap VX94❑ ⇒ Rep. gr. 87; Re‐
moving and installing
control motor for front
right air distribution flap
VX94
6 - Control motor for front
right temperature flap -VX35❑ ⇒ Rep. gr. 87; Remov‐
ing and installing con‐
trol motor for front right
temperature flap VX35
Exploded view - control motors (front), air intake box of heater
and air conditioning unit
6. Control motors
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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
6.4
Removing and installing control motor
for front left temperature flap [VX34]
6.4.1
Removing and installing control motor
for front left temperature flap [VX34],
LHD vehicles
Removing
The front left temperature flap -VX34- with left temperature flap
control motor -V158- and potentiometer for left temperature flap
control motor -G220- will henceforth be referred to as control
motor.
Mark position of control motors and connectors prior to removal
to avoid interchanging control motors at reinstallation.
– Deactivate function “Stationary air conditioning” ⇒ Owner’s
manual.
– Release mounting bracket ⇒ Brake system; Rep. gr. 46;
Brake pedal; Removing and installing mounting bracket.
– Disconnect electrical connector -3-.
114 Rep. gr.87 - Air conditioning system
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– Unscrew bolts -2- and -4-.
– Remove control motor -1-.
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.
– Route electrical wire so that it cannot come into contact with
any moving parts (e.g. actuating arm on control motor).
If control motor has been renewed or installed at different posi‐
tion:
– Carry out function “Adapt flap limit stops of control mo‐
tors”⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00; Access to
diagnoses.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – front control motors
♦ ⇒ Brake system; Rep. gr. 46; Brake pedal; Assembly over‐
view – brake pedal
6.4.2
Removing and installing control motor
for front left temperature flap [VX34],
right-hand drive vehicles
Removing
The front left temperature flap -VX34- with left temperature flap
control motor -V158- and potentiometer for left temperature flap
control motor -G220- will henceforth be referred to as control
motor.
6. Control motors
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Mark position of control motors and connectors prior to removal
to avoid interchanging control motors at reinstallation.
– Deactivate function “Stationary air conditioning” ⇒ Owner’s
manual.
– Remove footwell vent on front passenger side ⇒ Rep. gr. 87;
Removing and installing footwell vent on front passenger
side.
– Remove Fan for control unit -V274- ⇒ Electrical system;
Rep. gr. 97; Control units; Removing and installing fan for
control unit [V274].
– Disconnect electrical connector -3-.
– Unscrew bolts -2-.
– Remove control motor -1-.
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.
– Route electrical wire so that it cannot come into contact with
any moving parts (e.g. actuating arm on control motor).
If control motor has been renewed or installed at different posi‐
tion:
– Carry out function “Adapt flap limit stops of control mo‐
tors”⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00; Access to
diagnoses.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – front control motors
♦ ⇒ Rep. gr. 87; Assembly overview – air duct and air distribu‐
tion in passenger compartment
116 Rep. gr.87 - Air conditioning system
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6.5
Removing and installing control motor
for front right temperature flap [VX35]
6.5.1
Removing and installing control motor
for front right temperature flap [VX35],
left-hand drive vehicles
Removing
The front right temperature flap -VX35- with right temperature
flap control motor -V159- and potentiometer for right tempera‐
ture flap control motor -G221- will henceforth be referred to as
control motor.
Mark position of control motors and connectors prior to removal
to avoid interchanging control motors at reinstallation.
– Deactivate function “Stationary air conditioning” ⇒ Owner’s
manual.
– Remove footwell vent on front passenger side ⇒ Rep. gr. 87;
Removing and installing footwell vent on front passenger
side.
– Unscrew bolts -2-.
– Disconnect electrical connector -3-.
– Remove control motor -1-.
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.
6. Control motors
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– Route electrical wire so that it cannot come into contact with
any moving parts (e.g. actuating arm on control motor).
If control motor has been renewed or installed at different posi‐
tion:
– Carry out function “Adapt flap limit stops of control mo‐
tors”⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00; Access to
diagnoses.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – front control motors
♦ ⇒ Rep. gr. 87; Assembly overview – air duct and air distribu‐
tion in passenger compartment
6.5.2
Removing and installing control motor
for front right temperature flap [VX35],
right-hand drive vehicles
Removing
The front right temperature flap -VX35- with right temperature
flap control motor -V159- and potentiometer for right tempera‐
ture flap control motor -G221- will henceforth be referred to as
control motor.
Mark position of control motors and connectors prior to removal
to avoid interchanging control motors at reinstallation.
– Deactivate function “Stationary air conditioning” ⇒ Owner’s
manual.
– Remove footwell cover on driver side ⇒ General body re‐
pairs, interior; Rep. gr. 68; Compartments/covers; Removing
and installing footwell cover on driver side.
– Detach electrical wire -3-.
– Disconnect electrical connector -4-.
– Unscrew bolts -2-.
– Remove control motor -1-.
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.
118 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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– Route electrical wire so that it cannot come into contact with
any moving parts (e.g. actuating arm on control motor).
If control motor has been renewed or installed at different posi‐
tion:
– Carry out function “Adapt flap limit stops of control mo‐
tors”⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00; Access to
diagnoses.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – front control motors
♦ ⇒ General body repairs, interior; Rep. gr. 68; Compart‐
ments/covers; Assembly overview – dash panel cover on
driver side
6.6
Removing and installing control motor
for defroster flap [VX47]
Removing
The defroster flap -VX47- with defroster flap control motor V107- and potentiometer for defroster flap control motor -G135will henceforth be referred to as control motor.
Mark position of control motors and connectors prior to removal
to avoid interchanging control motors at reinstallation.
– Deactivate function “Stationary air conditioning” ⇒ Owner’s
manual.
– Remove dash panel ⇒ General body repairs, interior; Rep.
gr. 70; Dash panel; Removing and installing dash panel.
– Unscrew bolts -2-.
– Disconnect electrical connector -3-.
– Remove control motor -1-.
6. Control motors
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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.
– Route electrical wire so that it cannot come into contact with
any moving parts (e.g. actuating arm on control motor).
If control motor has been renewed or installed at different posi‐
tion:
– Carry out function “Adapt flap limit stops of control mo‐
tors”⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00; Access to
diagnoses.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – front control motors
♦ ⇒ General body repairs, interior; Rep. gr. 70; Dash panel;
Assembly overview – dash panel
6.7
Removing and installing control motor
for front left air distribution flap [VX93]
6.7.1
Removing and installing control motor
for front left air distribution flap [VX93],
left-hand drive vehicles
Removing
The front left air distribution flap -VX93- with front left air dis‐
tribution flap control motor -V706- and potentiometer for front
left air distribution flap control motor -G1105- will henceforth be
referred to as “control motor”.
Mark position of control motors and connectors prior to removal
to avoid interchanging control motors at reinstallation.
– Deactivate function “Stationary air conditioning” ⇒ Owner’s
manual.
– Remove tunnel support cover ⇒ General body repairs, interi‐
or; Rep. gr. 70; Dash panel; Removing and installing tunnel
support cover.
– Remove footwell vent on driver side ⇒ Rep. gr. 87; Remov‐
ing and installing footwell vent on driver side.
– Lift control unit for head-up display -J898--3- approx. 35 mm
far enough to gain access to control motor bolts, and sup‐
port it there ⇒ Electrical system; Rep. gr. 90; Dash panel
120 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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insert; Removing and installing control unit for head-up dis‐
play [J898].
– Unscrew bolts -2-.
– Disconnect electrical connector -4-.
– Remove control motor -1-.
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.
– Route electrical wire so that it cannot come into contact with
any moving parts (e.g. actuating arm on control motor).
If control motor has been renewed or installed at different posi‐
tion:
– Carry out function “Adapt flap limit stops of control mo‐
tors”⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00; Access to
diagnoses.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – front control motors
♦ ⇒ Electrical system; Rep. gr. 90; Dash panel insert; Assem‐
bly overview – head-up display
6.7.2
Removing and installing control motor
for front left air distribution flap [VX93],
right-hand drive vehicles
Removing
The front left air distribution flap -VX93- with front left air dis‐
tribution flap control motor -V706- and potentiometer for front
6. Control motors
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left air distribution flap control motor -G1105- will henceforth be
referred to as “control motor”.
Mark position of control motors and connectors prior to removal
to avoid interchanging control motors at reinstallation.
– Deactivate function “Stationary air conditioning” ⇒ Owner’s
manual.
– Remove bracket for control unit 1 for information electronics
[J794] ⇒ Communication; Rep. gr. 91; Components/control
units; Control unit 1 for information electronics [J794].
– Disconnect electrical connector -3-.
– Unscrew bolts -2-.
– Remove control motor -1-.
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.
– Route electrical wire so that it cannot come into contact with
any moving parts (e.g. actuating arm on control motor).
If control motor has been renewed or installed at different posi‐
tion:
– Carry out function “Adapt flap limit stops of control mo‐
tors”⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00; Access to
diagnoses.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – front control motors
122 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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6.8
Removing and installing control motor
for front right air distribution flap [VX94]
6.8.1
Removing and installing control mo‐
tor for front right air distribution flap
[VX94], left-hand drive vehicles
Removing
The front right air distribution flap -VX94- with right air distribu‐
tion flap control motor -V707- and potentiometer for front right
air distribution flap control motor -G1106- will henceforth be
referred to as control motor.
Mark position of control motors and connectors prior to removal
to avoid interchanging control motors at reinstallation.
– Deactivate function “Stationary air conditioning” ⇒ Owner’s
manual.
– Remove bracket for control unit 1 for information electronics
[J794] ⇒ Communication; Rep. gr. 91; Components/control
units; Control unit 1 for information electronics [J794].
– Disconnect electrical connector -3-.
– Unscrew bolts -2-.
– Remove control motor -1-.
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.
6. Control motors
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– Route electrical wire so that it cannot come into contact with
any moving parts (e.g. actuating arm on control motor).
If control motor has been renewed or installed at different posi‐
tion:
– Carry out function “Adapt flap limit stops of control mo‐
tors”⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00; Access to
diagnoses.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – front control motors
6.8.2
Removing and installing control mo‐
tor for front right air distribution flap
[VX94], right-hand drive vehicles
Removing
The front right air distribution flap -VX94- with right air distribu‐
tion flap control motor -V707- and potentiometer for front right
air distribution flap control motor -G1106- will henceforth be
referred to as control motor.
Mark position of control motors and connectors prior to removal
to avoid interchanging control motors at reinstallation.
– Deactivate function “Stationary air conditioning” ⇒ Owner’s
manual.
– Remove footwell vent on driver side ⇒ Rep. gr. 87; Remov‐
ing and installing footwell vent on driver side.
– Disconnect electrical connector -3-.
– Unscrew bolts -2-.
– Remove control motor -1-.
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.
124 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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– Route electrical wire so that it cannot come into contact with
any moving parts (e.g. actuating arm on control motor).
If control motor has been renewed or installed at different posi‐
tion:
– Carry out function “Adapt flap limit stops of control mo‐
tors”⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00; Access to
diagnoses.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – front control motors
♦ ⇒ Rep. gr. 87; Assembly overview – air duct and air distribu‐
tion in passenger compartment
6.9
Removing and installing control motor
for rear temperature flap [VX95]
Removing
The rear temperature flap -VX95- with rear temperature flap
control motor -V137- and potentiometer for rear temperature
flap control motor -G479- will henceforth be referred to as con‐
trol motor.
Mark position of control motors and connectors prior to removal
to avoid interchanging control motors at reinstallation.
– Deactivate function “Stationary air conditioning” ⇒ Owner’s
manual.
– Remove tunnel support cover ⇒ General body repairs, interi‐
or; Rep. gr. 70; Dash panel; Removing and installing tunnel
support cover.
– Disconnect electrical connector -4-.
– Unscrew bolts -1- and -3-.
– Remove control motor -2-.
6. Control motors
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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.
– Route electrical wire so that it cannot come into contact with
any moving parts (e.g. actuating arm on control motor).
If control motor has been renewed or installed at different posi‐
tion:
– Carry out function “Adapt flap limit stops of control mo‐
tors”⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00; Access to
diagnoses.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – front control motors
♦ ⇒ General body repairs, interior; Rep. gr. 70; Dash panel;
Assembly overview – dash panel
6.10
Removing and installing control motor
for fresh air and air recirculation flap
[VX96]
Removing
The fresh air and air recirculation flap -VX96- with fresh air/air
recirculation, air flow flap -V425- and potentiometer for fresh
air/air recirculation, air flow flap control motor -G644- will hence‐
forth be referred to as control motor.
Mark position of control motors and connectors prior to removal
to avoid interchanging control motors at reinstallation.
– Deactivate function “Stationary air conditioning” ⇒ Owner’s
manual.
– 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.
– Unscrew bolts -2-.
126 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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– Remove cover -1- in direction of -arrow-.
– Unscrew bolts -2-.
– Disconnect electrical connector -3-.
– Remove control motor -1-.
Installing
Install in reverse order of removal, observing the following:
– Route electrical wire so that it cannot come into contact with
any moving parts (e.g. actuating arm on control motor).
– Check shaft -A- and mounting -B- of control motor -C-. They
should be correctly aligned so that they can be joined to‐
gether.
If control motor has been renewed or installed at different posi‐
tion:
– Carry out function “Adapt flap limit stops of control mo‐
tors”⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00; Access to
diagnoses.
6. Control motors
127
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Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – front control motors
6.11
Removing and installing left air distri‐
bution flap actuator
Removing
Mark position of control motors and connectors prior to removal
to avoid interchanging control motors at reinstallation.
– Remove dash panel ⇒ General body repairs, interior; Rep.
gr. 70; Dash panel; Removing and installing dash panel.
– Remove control motor for front left temperature flap -VX34⇒ Rep. gr. 87; Removing and installing control motor for
front left temperature flap [VX34].
– Remove control motor for front left air distribution flap VX93- ⇒ Rep. gr. 87; Removing and installing front left air
distribution flap control motor [VX93].
– Unhook wiring harness.
– Detach operating lever -2-.
– Unscrew bolts -3-.
– Remove air distribution flap actuator -1-.
Installing
Install in reverse order of removal, observing the following:
– Route electrical wire so that it cannot come into contact with
any moving parts (e.g. actuating arm on control motor).
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – front control motors
♦ ⇒ General body repairs, interior; Rep. gr. 70; Dash panel;
Assembly overview – dash panel
6.12
Removing and installing right air distri‐
bution flap actuator
Removing
Mark position of control motors and connectors prior to removal
to avoid interchanging control motors at reinstallation.
– Remove dash panel ⇒ General body repairs, interior; Rep.
gr. 70; Dash panel; Removing and installing dash panel.
– Remove control motor for front right temperature flap -VX35⇒ Rep. gr. 87; Removing and installing control motor for
front right temperature flap [VX35].
128 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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– Remove control motor for front right air distribution flap VX94- ⇒ Rep. gr. 87; Removing and installing front right air
distribution flap control motor [VX94].
– Unhook wiring harness.
– Detach operating lever -1-.
– Unscrew bolts -3-.
– Remove air distribution flap actuator -2-.
Installing
Install in reverse order of removal, observing the following:
– Route electrical wire so that it cannot come into contact with
any moving parts (e.g. actuating arm on control motor).
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – front control motors
♦ ⇒ General body repairs, interior; Rep. gr. 70; Dash panel;
Assembly overview – dash panel
6. Control motors
129
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7
Front heater and air conditioning
unit
7.1
Exploded view - heater and air conditioning unit
1 - Cover for high-voltage
heater (PTC) -ZX172 - High-voltage heater (PTC)
-ZX17❑ ⇒ Rep. gr. 87; Remov‐
ing and installing highvoltage heater (PTC)
ZX17
3 - Condensation drain
❑ ⇒ Rep. gr. 87; Check‐
ing condensation drain
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing con‐
densation drain
4 - Potential equalisation line
❑ ⇒ Electric drive mo‐
tor; Rep. gr. 93; Poten‐
tial equalisation lines;
Overview of fitting loca‐
tions - potential equali‐
sation lines
5 - Nut
❑ 8 Nm
6 - Bolt
❑ 4x
❑ 3 Nm
7 - Bolt
❑ 3x
❑ 1 Nm
7.2
Assembly overview – evaporator hous‐
ing, R1234yf
7.2.1
Exploded view - evaporator housing
130 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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1 - Heater and air conditioning
unit
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing heater
and air conditioning unit
2 - Foam spacer
❑ For seal/insulation
❑ Note installation posi‐
tion
❑ Renew after removing
3 - Foam
❑ For insulation
❑ Note installation posi‐
tion
❑ Renew after removing
4 - Bolt
❑ 2x
❑ 4.5 Nm
5 - Expansion valve
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing ex‐
pansion valve
6 - Seal
❑ Depending on equip‐
ment/vehicle version
❑ 2x
❑ Renew after removing
7 - Bolt
❑ 4x
❑ 2 Nm
8 - Cover for evaporator hous‐
ing
9 - Condensation drain
❑ ⇒ Rep. gr. 87; Checking condensation drain
❑ ⇒ Rep. gr. 87; Removing and installing condensation drain
10 - Evaporator
❑ With seal
❑ ⇒ Rep. gr. 87; Removing and installing evaporator
7.3
Assembly overview – evaporator hous‐
ing, R744
7.3.1
Assembly overview – evaporator housing
7. Front heater and air conditioning unit
131
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1 - Heater and air conditioning
unit
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing heater
and air conditioning unit
2 - Foam spacer
❑ For sealing and insula‐
tion
❑ Observe installation po‐
sition
❑ Renew after removing
3 - Evaporator
❑ With gasket
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing evap‐
orator
4 - Foam
❑ For insulation
❑ Observe installation po‐
sition
❑ Renew after removing
5 - Bolt
❑ Qty. 2
❑ 2 Nm
6 - Cover of evaporator hous‐
ing
7 - Condensation drainage
❑ ⇒ Rep. gr. 87; Check‐
ing condensation drain
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing con‐
densation drain
8 - Cover of heat condenser
9 - Cover of heat condenser
10 - Bolt
❑ Qty. 2
❑ 2 Nm
11 - Heat condenser
❑ With gasket
❑ ⇒ Rep. gr. 87; Removing and installing heat condenser
7.4
Exploded view - air intake box of heater and air conditioning unit
132 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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1 - Cover for fresh air intake
2 - Fresh air intake
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing fresh
air intake
3 - Bolt
❑ 3x
❑ 8 Nm
4 - Air intake cowling
❑ Mounting on air intake
cowling for right-hand
drive vehicles ⇒ page
134
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing air in‐
take cowling
5 - Nut
❑ 7x
❑ 8 Nm
6 - Bolt
❑ 4x
❑ 2 Nm
7 - Cover
8 - Bolt
❑ 3x
❑ 2 Nm
9 - Fresh air blower control
unit -J126❑ ⇒ Rep. gr. 87; Remov‐
ing and installing fresh
air blower control unit
J126
10 - Air intake box of heater and air conditioning unit
❑ ⇒ Rep. gr. 87; Removing and installing air intake box of heater and air conditioning unit
11 - Nut
❑ 5x
❑ 4 Nm
12 - Bolt
❑ ⇒ Rep. gr. 87; Exploded view - control motors
13 - Control motor for fresh air and air recirculation flap -VX96❑ With fresh air/air recirculation, air flow flap control motor -V425❑ With potentiometer for fresh air/air recirculation, air flow flap control motor -G644❑ ⇒ Rep. gr. 87; Removing and installing control motor for fresh air and air recirculation flap VX96
14 - Noise insulation
15 - Dust and pollen filter
❑ ⇒ Rep. gr. 87; Removing and installing dust and pollen filter
16 - Dust and pollen filter
❑ Depending on equipment/vehicle version
❑ ⇒ Rep. gr. 87; Removing and installing dust and pollen filter
7. Front heater and air conditioning unit
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17 - Cover
18 - Bolt
❑ Depending on equipment/vehicle version
❑ 2 Nm
19 - Noise insulation
20 - Gasket
21 - Seal
Mounting on air intake cowling for right-hand drive vehicles
Component
Tightening torque
Bolt -3-
8 Nm
7.5
Removing and installing heater and air
conditioning unit, R1234yf
7.5.1
Removing and installing heater and air
conditioning unit
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
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.
– ⇒ Rep. gr. 93; De-energise high-voltage system.
– ⇒ Air conditioning systems with refrigerant R1234yf – Gener‐
al notes; Rep. gr. 87; Working with air conditioner service
station; Draining refrigerant circuit.
– Detach refrigerant line from expansion valve ⇒ Rep. gr. 87;
Detaching/attaching refrigerant line from/to expansion valve.
134 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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– Remove dash panel cross member ⇒ General body repairs,
interior; Rep. gr. 70; Dash panel cross member; Removing
and installing dash panel cross member.
– Remove rear footwell vent ⇒ Rep. gr. 87; Removing and
installing rear footwell vent.
– Detach air duct for rear centre console vent from heater and
air conditioning unit ⇒ Rep. gr. 87; Removing and installing
air duct for rear centre console vent.
– Disconnect electrical connectors and electrical wire from
heater and air conditioning unit.
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.
– Cover area under condensation drain with waterproof foil
and absorbent paper.
– Pull condensation drain -2- off connection of heater and air
conditioning unit -1- -arrow A-.
– Disconnect electrical connector - 7-, and loosen retaining
clip -5-.
– Unscrew nut -8-.
– Detach potential equalisation line.
7. Front heater and air conditioning unit
135
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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.
136 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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– ⇒ Air conditioning systems with refrigerant R1234yf – Gener‐
al notes; Rep. gr. 87; Working with air conditioner service
station; 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.
– ⇒ Rep. gr. 93; Re-energising 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
7.6
Removing and installing heater and air
conditioning unit, R744
7.6.1
Removing and installing heater and air
conditioning unit
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
Immediately seal any open lines and connections with clean
plugs from engine bung set -VAS 6122-.
If heater and air conditioning unit, evaporator or heat condenser
has been renewed:
– 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.
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.
– ⇒ Rep. gr. 93; De-energise high-voltage system.
– 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.
7. Front heater and air conditioning unit
137
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– Remove air intake box 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.
– Unscrew bolts -1- through -4-.
– Pull off refrigerant lines.
– Remove dash panel cross member ⇒ General body repairs,
interior; Rep. gr. 70; Dash panel cross member; Removing
and installing dash panel cross member.
– Remove rear footwell vent ⇒ Rep. gr. 87; Removing and
installing rear footwell vent.
– Detach air duct for rear centre console vent from heater and
air conditioning unit ⇒ Rep. gr. 87; Removing and installing
air duct for rear centre console vent.
– Disconnect electrical connectors and electrical wire from
heater and air conditioning unit.
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.
– Cover area under condensation drain with waterproof foil
and absorbent paper.
138 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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– Pull condensation drain -2- off connection of heater and air
conditioning unit -1- -arrow A-.
– Disconnect electrical connector - 7-, and loosen retaining
clip -5-.
– Unscrew nut -8-, and detach potential equalisation line.
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:
7. Front heater and air conditioning unit
139
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If components of refrigerant circuit have been renewed:
– Carry out adaption routine for refrigerant oil capacity in re‐
frigerant circuit ⇒ Air conditioning systems with refrigerant
R744 – General notes; Rep. gr. 87; Refrigerant circuit; Re‐
newing components.
– 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 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.
– ⇒ Rep. gr. 93; Re-energising high-voltage system.
140 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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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
7.7
Removing and installing evaporator,
R1234yf
7.7.1
Removing and installing evaporator
Special tools and workshop equipment required
♦ engine bung set -VAS 6122Removing
Immediately seal any open lines and connections with clean
plugs from engine bung set -VAS 6122-.
– ⇒ Air conditioning systems with refrigerant R1234yf – Gener‐
al notes; Rep. gr. 87; Working with air conditioner service
station; Draining refrigerant circuit.
– Remove heater and air conditioning unit ⇒ Rep. gr. 87; Re‐
moving and installing heater and air conditioning unit.
– Unscrew bolts -2-.
– Remove evaporator housing cover -1-.
– Pull evaporator -1- out of evaporator housing.
– Remove expansion valve -3- ⇒ Rep. gr. 87; Removing and
installing expansion valve.
7. Front heater and air conditioning unit
141
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– Detach foam spacer -2-.
– Remove seal -4-.
Installing
Install in reverse order of removal, observing the following:
– Before inserting, clean evaporator housing and evaporator.
– Before inserting evaporator, check and clean condensation
drain ⇒ Rep. gr. 87; Checking condensation drain.
– Check tongue-and-groove joint between upper and lower
sections of evaporator housing for damage and proper seat‐
ing.
– If evaporator was renewed, refrigerant circuit must be top‐
ped up with 10 ml of refrigerant oil.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – refrigerant lines
♦ ⇒ Rep. gr. 87; Assembly overview – heater and air condition‐
ing unit
7.8
Removing and installing evaporator,
R744
7.8.1
Removing and installing evaporator
– Evaporator -3- is currently not available separately ⇒ Elec‐
tronic parts catalogue (ETKA).
7.9
Dismantling and assembling heater
and air conditioning unit, R1234yf
7.9.1
Dismantling and assembling heater
and air conditioning unit
Individual disassembly and reassembly of heater and air con‐
ditioning unit is currently not intended ⇒ Electronic parts cata‐
logue.
142 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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7.10
Dismantling and assembling heater
and air conditioning unit, R744
7.10.1
Dismantling and assembling heater
and air conditioning unit
Individual disassembly and reassembly of heater and air con‐
ditioning unit is currently not intended ⇒ Electronic parts cata‐
logue.
7.11
Removing and installing dust and pol‐
len filter
Depending on the country, 2 dust and pollen filters -A- and -Bor 1 dust and pollen filter -B- may be installed.
Removing
– Unscrew bolt -1-.
– Release cover -2- -arrow-, and remove it.
– Remove dust and pollen filter -1-.
7. Front heater and air conditioning unit
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Installing
– Install in reverse order of removal, observing the following:
– Observe installation position of dust and pollen filter.
7.12
Removing and installing fresh air blow‐
er control unit J126
Removing
– 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 bolts -2-.
– Detach cover -1- in direction of -arrow-.
– Unplug electrical connector -3-.
– Remove bolts -2-.
144 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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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.
– Take out fresh air blower control unit -J126- -1-.
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ Rep. gr. 87; Exploded view - air intake box of heater and
air conditioning unit
7.13
Removing and installing evaporator
temperature sensor [G308]
Removing
– Remove tunnel support cover ⇒ General body repairs, interi‐
or; Rep. gr. 70; Dash panel; Removing and installing tunnel
support cover.
– Using commercially available plastic wedge, release and pull
out evaporator temperature sensor -G308--1-.
– Disconnect electrical connector -2-.
Installing
Install in reverse order of removal, observing the following:
Tightening torques
♦ ⇒ General body repairs, interior; Rep. gr. 70; Dash panel;
Assembly overview – dash panel
7. Front heater and air conditioning unit
145
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7.14
Removing and installing condensation
drain
Removing
– Remove floor covering ⇒ General body repairs, interior; Rep.
gr. 70; Passenger compartment trim panels; Removing and
installing 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.
– Protect area beneath condensation drain with waterproof
sheeting and absorbent paper.
– Carefully detach condensation drain -2- from connection of
heater and air conditioning unit -1- -arrow A-.
– Take condensation drain -2- out of body opening -3-.
Installing
Installation is carried out in reverse order; note the following:
– It must be possible to push condensation drain -2- onto
connection of heater and air conditioning unit -1- without
applying tension. Pay attention to lug -arrow A-.
– Sealing lip -4- must be fitted firmly at body opening -3-arrow B-.
– Install condensation drain -2- so that it is neither twisted nor
crushed.
– When fitting floor covering, make sure that it does not
squash condensation drain -2-.
146 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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Tightening torques
♦ ⇒ General body repairs, interior; Rep. gr. 70; Passenger
compartment trim panels; Exploded view - foot rest and floor
covering
7.15
Checking condensation drain
– Remove floor covering ⇒ General body repairs, interior; Rep.
gr. 70; Passenger compartment trim panels; Removing and
installing 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.
– Lug -arrow A- must be engaged at connection of heater and
air conditioning unit -1-.
– Sealing lip -4- must be fitted firmly at body opening -3-arrow B-.
– Condensation drain -2- must not be twisted or crushed.
– Remove condensation drain and check for constrictions
⇒ Rep. gr. 87; Removing and installing condensation drain.
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
7.16
Removing and installing air intake unit
of heater and air conditioning unit
Removing
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.
7. Front heater and air conditioning unit
147
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– ⇒ Rep. gr. 93; De-energise high-voltage system.
– Remove vibration isolation strut ⇒ General body repairs,
exterior; Rep. gr. 50; Lock carrier; Removing and installing
vibration isolation strut.
– Remove fresh air intake ⇒ Rep. gr. 87; Removing and instal‐
ling fresh air intake.
– Release locking lug -3-.
– Remove cover for high-voltage connection on vehicle front
end -2-.
– Remove cover for high-voltage connection on vehicle front
end -1- from guide.
Vehicles with all-wheel drive
– Detach gearbox breather.
All vehicles (continued)
– Disconnect electrical connectors -1-.
– Release clamps -2-.
– Unscrew fasteners -1-.
148 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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– Remove adapter plate -2-.
– Unscrew nuts -2- from air intake unit of heater and air condi‐
tioning unit -1-.
– 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.
7. Front heater and air conditioning unit
149
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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.
– ⇒ Rep. gr. 93; Re-energising high-voltage system.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – air intake unit of heater
and air conditioning unit
♦ ⇒ General body repairs, exterior; Rep. gr. 50; Lock carrier;
Assembly overview – lock carrier
7.17
Removing and installing air intake
cowling
Removing
– Remove air intake box ⇒ Rep. gr. 87; Removing and instal‐
ling air intake box of heater and air conditioning unit.
– Remove heater and air conditioning unit ⇒ Rep. gr. 87; Re‐
moving and installing heater and air conditioning unit.
– Release fasteners -6- from grommet -5-.
– Guide high-voltage wire -7- out of air intake cowling -4-.
– Unscrew bolts -1- to -3-.
– Unscrew nuts -1- to -7-.
150 Rep. gr.87 - Air conditioning system
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– Detach air intake cowling -8-.
Installing
Installation is carried out in reverse order; note the following:
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.
– Check seal -9- for damage.
– Tighten nuts in sequence -1- to -7-.
– Tighten bolts in sequence -1- to -3-.
– Guide high-voltage wire -7- through opening in air intake
cowling -4-, making sure it is routed correctly.
– Clip in fasteners -6- of grommet -5-.
7. Front heater and air conditioning unit
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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
7.18
Removing and installing high voltage
heater (PTC) [ZX17]
7.18.1
Removing and installing high voltage
heater (PTC) [ZX17], left-hand drive
vehicles
Removing
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.
– ⇒ Rep. gr. 93; De-energise high-voltage system.
– Remove tunnel support cover ⇒ General body repairs, interi‐
or; Rep. gr. 70; Dash panel; Removing and installing tunnel
support cover.
– Remove footwell vent on front passenger side ⇒ Rep. gr. 87;
Removing and installing footwell vent on front passenger
side.
– Disconnect electrical connector -4-.
– Unscrew bolts -2- and -3- from high-voltage heater (PTC)
-ZX17- -1-.
– Disconnect electrical connector - 7-, and loosen retaining
clip -5-.
152 Rep. gr.87 - Air conditioning system
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– Unscrew nut -8-.
– Detach potential equalisation line.
– Unscrew bolts -2-, -3-, -4-, -6- and -9- from cover of heat
condenser -1- and high-voltage heater (PTC) -ZX17-.
– Pull high-voltage heater (PTC) -ZX17- -1- as far as possible
downwards out heater and air conditioning unit -arrow A-.
– Loosen cover of heat condenser -2- in direction of -arrow B-,
and remove it from upper holder towards side.
– Break off locking element -1- on heater and air conditioning
unit.
7. Front heater and air conditioning unit
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– Press down floor covering as far as possible.
– Remove high-voltage heater (PTC) -ZX17- -2- in direction of
-arrow-.
Installing
Install in reverse order of removal, observing the following:
Important
•
Contact surfaces must be free of dirt, rust and grease.
– Check screw connections of potential equalisation line, and
clean them if soiled ⇒ Electrical system; Rep. gr. 97; Clean‐
ing contact surfaces; Cleaning contact surfaces.
– Fit potential equalisation line.
– Tighten nut -8-.
154 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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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.
– ⇒ Rep. gr. 93; Re-energising high-voltage system.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – heater and air condition‐
ing unit
♦ ⇒ Rep. gr. 87; Assembly overview – air duct and air distribu‐
tion in passenger compartment
♦ ⇒ General body repairs, interior; Rep. gr. 70; Dash panel;
Assembly overview – dash panel
7.18.2
Removing and installing high voltage
heater (PTC) [ZX17], right-hand drive
vehicles
Removing
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.
– ⇒ Rep. gr. 93; De-energise high-voltage system.
– Remove tunnel support cover ⇒ General body repairs, interi‐
or; Rep. gr. 70; Dash panel; Removing and installing tunnel
support cover.
– Remove footwell vent on driver side ⇒ Rep. gr. 87; Remov‐
ing and installing footwell vent on driver side.
– Disconnect electrical connector -4-.
– Unscrew bolts -2- and -3- from high-voltage heater (PTC)
-ZX17- -1-.
– Disconnect electrical connector - 7-, and loosen retaining
clip -5-.
7. Front heater and air conditioning unit
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– Unscrew nut -8-.
– Detach potential equalisation line.
– Unscrew bolts -2-, -3-, -4-, -6- and -9- from cover of heat
condenser -1- and high-voltage heater (PTC) -ZX17-.
– Pull high-voltage heater (PTC) -ZX17- -1- as far as possible
downwards out heater and air conditioning unit -arrow A-.
– Loosen cover of heat condenser -2- in direction of -arrow B-,
and remove it from upper holder towards side.
– Break off locking element -1- on heater and air conditioning
unit.
156 Rep. gr.87 - Air conditioning system
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– Press down floor covering as far as possible.
– Remove high-voltage heater (PTC) -ZX17- -2- in direction of
-arrow-.
Installing
Install in reverse order of removal, observing the following:
Important
•
Contact surfaces must be free of dirt, rust and grease.
– Check screw connections of potential equalisation line, and
clean them if soiled ⇒ Electrical system; Rep. gr. 97; Clean‐
ing contact surfaces; Cleaning contact surfaces.
– Fit potential equalisation line.
– Tighten nut -8-.
7. Front heater and air conditioning unit
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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.
– ⇒ Rep. gr. 93; Re-energising high-voltage system.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – heater and air condition‐
ing unit
♦ ⇒ Rep. gr. 87; Assembly overview – air duct and air distribu‐
tion in passenger compartment
♦ ⇒ General body repairs, interior; Rep. gr. 70; Dash panel;
Assembly overview – dash panel
158 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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8
Air duct
8.1
Assembly overview – air duct and air
distribution in passenger compartment
8.1.1
Assembly overview – air duct and air distribution in passenger compart‐
ment, left-hand drive vehicle
8. Air duct
159
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1 - Front air duct for dash
panel
❑ ⇒ a8.9.1 nd installing
front air duct for dash
panel, left-hand drive
vehicles”, page 166
2 - Bolt
❑ Qty. 2
❑ 1.5 Nm
3 - Air duct for defroster vent
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing air
duct for defroster vent
4 - Spreader rivet
❑ Qty. 2
5 - Footwell vent on front pas‐
senger side
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing front
passenger side footwell
vents
6 - Bolt
❑ 1.5 Nm
7 - Footwell vent on driver
side
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing driver
side footwell vents
8 - Bolt
❑ 1.5 Nm
9 - Air duct for centre dash
panel vent
❑ ⇒ Rep. gr. 87; Removing and installing air duct for centre dash panel vent
10 - Air duct for rear vent in centre console
❑ Front
❑ ⇒ Rep. gr. 87; Removing and installing air duct for rear centre console vent
11 - Rear right footwell vent
❑ ⇒ Rep. gr. 87; Removing and installing rear footwell vent
12 - Rear left footwell vent
❑ ⇒ Rep. gr. 87; Removing and installing rear footwell vent
13 - Air duct for rear vent in centre console
❑ ⇒ Rep. gr. 87; Removing and installing air duct for rear centre console vent
8.1.2
Assembly overview – air duct and air distribution in passenger compart‐
ment, right-hand drive vehicles
160 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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1 - Front air duct for dash
panel
❑ ⇒ a8.9.2 nd installing
front air duct for dash
panel, right-hand drive
vehicles”, page 167
2 - Bolt
❑ Qty. 2
❑ 1.5 Nm
3 - Air duct for defroster vent
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing air
duct for defroster vent
4 - Spreader rivet
❑ Qty. 2
5 - Footwell vent on driver
side
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing driver
side footwell vents
6 - Bolt
❑ 1.5 Nm
7 - Footwell vent on front pas‐
senger side
❑ ⇒ Rep. gr. 87; Remov‐
ing and installing front
passenger side footwell
vents
8 - Bolt
❑ 1.5 Nm
9 - Air duct for centre dash
panel vent
❑ ⇒ Rep. gr. 87; Removing and installing air duct for centre dash panel vent
10 - Air duct for rear vent in centre console
❑ Front
❑ ⇒ Rep. gr. 87; Removing and installing air duct for rear centre console vent
11 - Rear right footwell vent
❑ ⇒ Rep. gr. 87; Removing and installing rear footwell vent
12 - Rear left footwell vent
❑ ⇒ Rep. gr. 87; Removing and installing rear footwell vent
13 - Air duct for rear vent in centre console
❑ ⇒ Rep. gr. 87; Removing and installing air duct for rear centre console vent
8. Air duct
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8.2
Removing and installing driver side
footwell vents
8.2.1
Removing and installing footwell vent
(driver side) - left-hand drive vehicles
Removing
– Remove footwell cover (driver side) ⇒ General body repairs,
interior; Rep. gr. 68; Storage compartments/covers/trim pan‐
els; Removing and installing footwell cover (driver side).
– Unplug electrical connectors -2-.
– Remove bolt -3-.
– Detach footwell vent -1- in direction of -arrow-.
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ Rep. gr. 87; Exploded view - routing of air flow and air
distribution in passenger compartment
8.2.2
Removing and installing footwell vent
(driver side) - right-hand drive vehicles
Removing
– Remove footwell cover (driver side) ⇒ General body repairs,
interior; Rep. gr. 68; Storage compartments/covers/trim pan‐
els; Removing and installing footwell cover (driver side).
– Unplug electrical connectors -1-.
– Remove bolt -3-.
162 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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– Detach footwell vent -2-.
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ Rep. gr. 87; Exploded view - routing of air flow and air
distribution in passenger compartment
8.3
Removing and installing front passen‐
ger side footwell vents
8.3.1
Removing and installing footwell vent
(front passenger side) - left-hand drive
vehicles
Removing
– Remove glove box ⇒ General body repairs, interior; Rep.
gr. 68; Storage compartments/covers/trim panels; Removing
and installing glove box.
– Unplug electrical connectors -1-.
– Remove bolt -2-.
– Take out footwell vent -3-.
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ Rep. gr. 87; Exploded view - routing of air flow and air
distribution in passenger compartment
8.3.2
Removing and installing footwell vent
(front passenger side) - right-hand
drive vehicles
Removing
– Remove glove box ⇒ General body repairs, interior; Rep.
gr. 68; Storage compartments/covers/trim panels; Removing
and installing glove box.
– Unplug electrical connectors -3-.
8. Air duct
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– Remove bolt -1-.
– Take out footwell vent -2-.
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ Rep. gr. 87; Exploded view - routing of air flow and air
distribution in passenger compartment
8.4
Removing and installing rear footwell
vent
Removing
– Remove floor covering ⇒ General body repairs, interior; Rep.
gr. 70; Passenger compartment trim panels; Removing and
installing floor covering.
– Remove bracket for centre console ⇒ General body repairs,
interior; Rep. gr. 68; Centre console; Removing and instal‐
ling bracket for centre console.
– Release footwell vent -3- from pin -2-.
– 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.
164 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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8.5
Removing and installing fresh air in‐
take
Removing
– Remove bulkhead ⇒ General body repairs, exterior; Rep.
gr. 50; Bulkhead; Removing and installing bulkhead.
8.6
Removing and installing air duct for de‐
froster vent
Removing
– Remove dash panel ⇒ General body repairs, interior; Rep.
gr. 70; Dash panel; Removing and installing dash panel.
– Release spreader rivets -4-.
– 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
8.7
Removing and installing air duct for
centre dash panel vent
Removing
– Remove dash panel ⇒ General body repairs, interior; Rep.
gr. 70; Dash panel; Removing and installing dash panel.
8. Air duct
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– Unhook air duct for centre vent -1- from fasteners -3-, and
remove it upwards.
Installing
Install in reverse order of removal.
8.8
Removing and installing air duct for
vent in centre console (rear)
Removing
– Remove brackets (front and rear) for centre console ⇒ Gen‐
eral body repairs, interior; Rep. gr. 68; Centre console; Re‐
moving and installing brackets for centre console.
– Unplug electrical connector -3-.
– Rotate rear vent temperature sender -G174- -4- and pull it
out of mounting.
– Detach air duct -1- and -2-.
Installing
Installation is carried out in reverse sequence.
8.9
Removing and installing front air duct
for dash panel
8.9.1
Removing and installing front air duct
for dash panel, left-hand drive vehicles
Removing
– Remove dash panel ⇒ General body repairs, interior; Rep.
gr. 70; Dash panel; Removing and installing dash panel.
– Unscrew bolts -2-.
166 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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– Remove front air duct for dash panel -1-.
Installing
Install in reverse order of removal, observing the following:
– Ensure proper seating of seal.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – air duct and air distribu‐
tion in passenger compartment
♦ ⇒ General body repairs, interior; Rep. gr. 70; Dash panel;
Assembly overview – dash panel
8.9.2
Removing and installing front air duct
for dash panel, right-hand drive vehi‐
cles
Removing
– Remove dash panel ⇒ General body repairs, interior; Rep.
gr. 70; Dash panel; Removing and installing dash panel.
– Unscrew bolts -2-.
– Remove front air duct for dash panel -1-.
Installing
Install in reverse order of removal, observing the following:
– Ensure proper seating of seal.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – air duct and air distribu‐
tion in passenger compartment
♦ ⇒ General body repairs, interior; Rep. gr. 70; Dash panel;
Assembly overview – dash panel
8. Air duct
167
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9
Coolant circuit
9.1
Assembly overview – high-voltage
heater (PTC), rear-wheel drive
9.1.1
Exploded view - high-voltage heater (PTC)
1 - PTC heater element 3 Z132❑ ⇒ Rep. gr. 87; Remov‐
ing and installing PTC
heater element 3 Z132
2 - Bolt
❑ 3x
❑ 20 Nm
3 - Bolt
❑ 3x
❑ 10 Nm
4 - Bracket
5 - Bracket
6 - Bolt
❑ 5x
❑ 10 Nm
7 - Potential equalisation line
❑ ⇒ Electric drive motor
0EH, 0EJ; Rep. gr. 93;
Potential equalisation
lines; Overview of fit‐
ting locations - potential
equalisation lines
8 - Nut
❑ 8 Nm
9 - Electrical connector
10 - Electrical connector
❑ High-voltage wire
9.2
Assembly overview – high-voltage
heater (PTC), all-wheel drive
9.2.1
Exploded view - high-voltage heater (PTC)
168 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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1 - PTC heater element 3 Z132❑ ⇒ Rep. gr. 87; Remov‐
ing and installing PTC
heater element 3 Z132
2 - Bracket
3 - Bolt
❑ 3x
❑ 10 Nm
4 - Bolt
❑ 3x
❑ 20 Nm
5 - Nut
❑ 8 Nm
6 - Electrical connector
7 - Electrical connector
❑ High-voltage wire
8 - Bolt
❑ 3x
❑ 10 Nm
9 - Bracket
10 - Warning label
❑ ⇒ Motor; Rep. gr. 93;
Warning labels; Check‐
ing warning labels
9.3
Removing and installing PTC heater el‐
ement 3 [Z132], rear-wheel drive
9.3.1
Removing and installing PTC heater el‐
ement 3 [Z132]
Removing
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.
– ⇒ Rep. gr. 93; De-energise high-voltage system.
– 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.
9. Coolant circuit
169
ID.4 2021 ➤
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– ⇒ Rep. gr. 19; Cooling system/coolant; Draining coolant
– Detach clamps -3-, and pull off coolant hoses -2-.
– Unscrew nut -3-.
– Remove potential equalisation line -2-.
– Unclip cable retainers of electrical connectors -5-.
– Disconnect electrical connectors -4- and -6-.
– Detach electrical connector -2- from bracket -1-.
– Push aside coolant hoses -2- and -4-, and unscrew bolts -3-.
170 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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– Remove heater element (PTC) 3 -Z132--1-.
Installing
Install in reverse order of removal, observing the following:
– Observe installation markings on heater element (PTC) 3
-Z132- and coolant hoses.
– 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 -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.
– ⇒ Rep. gr. 93; Re-energising high-voltage system.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – high-voltage heater
(PTC)
9. Coolant circuit
171
ID.4 2021 ➤
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9.4
Removing and installing PTC heater el‐
ement 3 [Z132], all-wheel drive
9.4.1
Removing and installing PTC heater el‐
ement 3 [Z132]
Removing
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.
– ⇒ Rep. gr. 93; De-energise high-voltage system.
– 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.
– ⇒ Rep. gr. 19; Cooling system/coolant; Draining coolant
– Detach clamps -3-, and pull off coolant hoses -2-.
– Unscrew nut -2-.
– Remove potential equalisation line -3-.
– Unclip cable retainers of electrical connectors -5-.
– Disconnect electrical connectors -1- and -4-.
– Detach electrical connector -2- from bracket -1-.
172 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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– Detach retaining clip -3- of coolant hose -5- from bracket.
– Unscrew bolts -4-.
– Remove heater element (PTC) 3 -Z132--1-.
Installing
Install in reverse order of removal, observing the following:
– Observe installation markings on heater element (PTC) 3
-Z132- and coolant hoses.
– 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 -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.
– ⇒ Rep. gr. 93; Re-energising high-voltage system.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – high-voltage heater
(PTC)
9. Coolant circuit
173
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10
Operating and display unit
10.1
Overview of fitting locations – operating
and display unit
The overview of fitting locations for the operating and display
unit is included in the overview of fitting locations for the com‐
ponents located in the front passenger compartment ⇒ Rep.
gr. 87; Overview of fitting locations – components located in
front passenger compartment.
10.2
Removing and installing display unit for
front information display and operating
unit control unit [J685]
– The operating and display unit is integral part of the display
unit for front information display and operating unit control
unit -J685- ⇒ Communication; Rep. gr. 91; Components/con‐
trol units; Removing and installing control unit for front dis‐
play and information control panel [J685].
10.3
Removing and installing operating and
display unit for rear air conditioning
system [E265]
Removing
– Remove centre console cover ⇒ General body repairs, inte‐
rior; Rep. gr. 68; Centre console; Removing and installing
centre console cover.
– Unclip operating and display unit for rear air conditioning
system -E265--1- from mountings -arrows-.
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
174 Rep. gr.87 - Air conditioning system
ID.4 2021 ➤
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11
Other controlling and regulating
components
11.1
Removing and installing external air
quality and air humidity sensor G935
Removing
– Remove plenum chamber cover ⇒ General body repairs,
exterior; Rep. gr. 50; Bulkhead; Removing and installing ple‐
num chamber cover.
– Unplug electrical connector -3-.
– Release locking lug -1-.
– Detach external air quality and air humidity sensor -G935-2- in direction of -arrow-.
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ General body repairs, exterior; Rep. gr. 50; Bulkhead;
Exploded view - bulkhead
11.2
Removing and installing ambient tem‐
perature sensor G17
Removing
– Remove bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63; Bumper (front); Removing and installing bumper
cover.
– Unclip ambient temperature sensor -G17- -1- with bracket
-3-.
11. Other controlling and regulating components
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– Unplug electrical connector -2-.
– Unclip temperature sensor -1- from bracket -3-.
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ General body repairs, exterior; Rep. gr. 63; Bumper
(front); Exploded view - bumper cover.
11.3
Removing and installing humidity send‐
er for air conditioning system [G260]
The humidity sender for air conditioning system -G260- and
sunlight penetration photosensor -G107- are an integral part of
the rain and light sensor -G397-.
– Removing and installing humidity sender for air conditioning
system -G260- ⇒ Electrical system; Rep. gr. 92; Windscreen
wiper system; Removing and installing rain and light sensor
[G397].
11.4
Removing and installing left vent tem‐
perature sender [G150[
11.4.1
Removing and installing left vent tem‐
perature sender [G150], left-hand drive
vehicles
Removing
– Remove fuse box cover ⇒ General body repairs, interior;
Rep. gr. 68; Compartments/covers; Removing and installing
dash panel cover on driver side.
– Disconnect electrical connector -2-.
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– Turn left vent temperature sender -G150- -1- 90° clockwise,
and pull it out of mounting.
Installing
Install in reverse order of removal.
11.4.2
Removing and installing left vent tem‐
perature sender [G150], right-hand
drive vehicles
Removing
– Remove glove compartment cover ⇒ General body repairs,
interior; Rep. gr. 68; Compartments/covers; Removing and
installing glove compartment cover.
– Disconnect electrical connector -2-.
– Turn left vent temperature sender -G150- -1- 90° clockwise,
and pull it out of mounting.
Installing
Install in reverse order of removal.
11.5
Removing and installing right vent tem‐
perature sender [G151]
11.5.1
Removing and installing right vent tem‐
perature sender [G151], left-hand drive
vehicles
Removing
– Remove glove compartment cover ⇒ General body repairs,
interior; Rep. gr. 68; Compartments/covers; Removing and
installing glove compartment cover.
11. Other controlling and regulating components
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– Disconnect electrical connector -2-.
– Turn right vent temperature sender -G151- -1- 90° clock‐
wise, and pull it out of mounting.
Installing
Install in reverse order of removal.
11.5.2
Removing and installing right vent
temperature sender [G151], right-hand
drive vehicles
Removing
– Remove dash panel cover on driver side ⇒ General body re‐
pairs, interior; Rep. gr. 68; Compartments/covers; Removing
and installing dash panel cover on driver side.
– Disconnect electrical connector -2-.
– Turn right vent temperature sender -G151- -1- 90° clock‐
wise, and pull it out of mounting.
Installing
Install in reverse order of removal.
11.6
Removing and installing left footwell
vent temperature sender [G261]
Removing
Left-hand drive vehicles
– Remove footwell vent on driver side ⇒ Rep. gr. 87; Remov‐
ing and installing footwell vent on driver side.
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Right-hand drive vehicles
– Remove footwell vent on front passenger side ⇒ Rep. gr. 87;
Removing and installing footwell vent on front passenger
side.
All vehicles (continued)
– Remove left footwell vent temperature sender -G261--2- us‐
ing commercially available plastic wedge.
Installing
Install in reverse order of removal.
Tightening torques
♦ ⇒ Rep. gr. 87; Assembly overview – air duct and air distribu‐
tion in passenger compartment
11.7
Removing and installing right footwell
vent temperature sender [G262]
Removing
Left-hand drive vehicles
– Remove glove compartment ⇒ General body repairs, interi‐
or; Rep. gr. 68; Compartments/covers; Removing and instal‐
ling glove compartment.
Right-hand drive vehicles
– Remove footwell cover on driver side ⇒ General body re‐
pairs, interior; Rep. gr. 68; Compartments/covers; Removing
and installing footwell cover on driver side.
All vehicles (continued)
– Disconnect electrical connector -1-.
– Remove right footwell vent temperature sender -G262--2using commercially available plastic wedge.
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Installing
– Install in reverse order of removal.
11.8
Removing and installing sensor for
interior carbon dioxide concentration
[G929]
Removing
– Remove tunnel support cover ⇒ General body repairs, interi‐
or; Rep. gr. 70; Dash panel; Removing and installing tunnel
support cover.
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.
– Release sensor for interior carbon dioxide concentration G929--2- using commercially available plastic wedge -3-.
– Remove sensor for interior carbon dioxide concentration G929--2-.
– Disconnect electrical connector -1-.
Installing
Install in reverse order of removal, observing the following:
Tightening torques
♦ ⇒ General body repairs, interior; Rep. gr. 70; Dash panel;
Assembly overview – dash panel
11.9
Removing and installing heater and air
conditioning system control unit J979
Removing
If heater and air conditioning system control unit -J979- is re‐
newed:
– Perform function “Replace control module” using ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00; Starting diagnosis.
– Remove glove box lid ⇒ General body repairs, interior; Rep.
gr. 68; Storage compartments/covers/trim panels; Removing
and installing glove box lid.
– Unplug electrical connectors -3-.
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– Release retaining tab -arrow- from bracket -2- using com‐
mercially available plastic wedge.
– Pull out heater and air conditioning system control unit J979-.
Installing
– Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ General body repairs, interior; Rep. gr. 68; Storage com‐
partments/covers/trim panels; Exploded view - glove box
11.10
Removing and installing vehicle interior
temperature sensor [G1090]
Removing
– Remove tunnel support cover ⇒ General body repairs, inte‐
rior; Rep. gr. 68; Compartments/covers; Overview of fitting
locations – compartments/covers.
– Disconnect electrical connector -2-.
– Release vehicle interior temperature sensor -G1090- -1- at
locking lugs -4-.
– Detach vehicle interior temperature sensor -G1090--1- from
tunnel support cover -4-.
Installing
Install in reverse order of removal, observing the following:
– Insert vehicle interior temperature sensor -G1090- into open‐
ing, and engage it on opposite side.
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Tightening torques
♦ Install tunnel support cover ⇒ General body repairs, interior;
Rep. gr. 68; Compartments/covers; Overview of fitting loca‐
tions – compartments/covers.
11.11
Removing and installing rear vent tem‐
perature sender [G174]
Removing
– Remove centre console cover ⇒ General body repairs, inte‐
rior; Rep. gr. 68; Centre console; Removing and installing
centre console cover.
– Disconnect electrical connector -2-.
– Turn rear vent temperature sender -G174- -1- in direction of
-arrow-, and pull it out of mounting.
Installing
Install in reverse order of removal.
182 Rep. gr.87 - Air conditioning system