Special tools and workshop equipment required

• Air conditioner service station
• Engine bung set - VAS 6122-

Removal:

•  Turn off the ignition and all electricity consumers.

Vehicles without access and start authorisation system

•  Remove ignition key, if fitted.

Vehicles with access and start authorisation system

• Store ignition key outside the vehicle to prevent the ignition from being switched on unintentionally.

Continued for all vehicles

• Extract refrigerant.
• Observe instructions when working on refrigerant circuit.

Vehicles with petrol engine:

• Release hose clips -1- and -2- and remove air intake pipe.

Diesel engine vehicles:

• Press the release buttons at the crankcase breather hose -1- and detach the hose from the cylinder head cover.
• Lay bare the vacuum hoses at the air pipe -arrows-.
• Release hose clip -3-.
• Screw out the bolt -2-, swivel the air pipe with connection to the rear and detach from the turbocharger.

All vehicles (continued):

• Unscrew the speed nuts -1, 3-.
• Fold the heat shield -2- as far forwards as possible -arrow-.

• Screw out bolt -1-.
• Detach refrigerant line -2- with internal heat exchanger from expansion valve.

• Unscrew bolts -1- and -3-.
• Pull the expansion valve -4- out of the heat insulation -2-.
• Seal open lines and connections with clean plugs from the Engine sealing plug set - VAS 6122- .

Installing

Install in reverse order of removal; note the following.

• Replace the O-rings.
• Insert the O-rings -1, 4- at the connecting pipes -2, 3- to the evaporator.

Note

• There are different versions of the expansion valve (identical housing, but different control characteristic).
• Check the refrigerant pipes to the evaporator for contamination and damage.
• Moisten O-rings with refrigerant oil before installing.
• Pay attention to correct positioning of the O-rings at the evaporator connecting pipes.
• The absence of or incorrect installation of the heat insulation -2- may lead to reduced air conditioner output (heat-induced change in set characteristic control curve).

• Refill with refrigerant and refrigerant oil.