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

• Unscrew the bolt -7-.
• Detach refrigerant line -6- with internal heat exchanger from expansion valve.
• Unscrew nuts -1- and -3- and remove refrigerant lines -2- and -4-.
• Take out the refrigerant line -5- with internal heat exchanger to the right.
• 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.

• Renew O-rings.
• Clean the connections at the expansion valve -2- and at the internal heat exchanger -4- and check for damage.
• Thoroughly clean connection area of refrigerant lines and check for damage.

Note

• Moisten O-rings with refrigerant oil before installing.
• Pay attention to correct positioning of the O-rings in the groove of the corresponding refrigerant pipe.

• Insert the O-rings -1, 3- in the groove at the connection of the internal heat exchanger.
• Insert internal heat exchanger at expansion valve.
• Tighten bolt -5-.
• Clean connections on refrigerant lines and check for damage.
• If applicable, check the fitted pin -4- for damage and correct positioning.
• Check the guide ring -2- at the refrigerant line connection for damage.

Note

• Moisten O-rings with refrigerant oil before installing.
• Pay attention to correct positioning of the O-rings in the groove of the corresponding refrigerant pipe.

• Insert the O-ring -3- in the groove -arrow- at the connection of the refrigerant line -1-.
• Insert the refrigerant lines in the corresponding connection.
• Tighten the nuts.

Note Routing and attachment of refrigerant lines.

• Refill with refrigerant and refrigerant oil.