Cover with Air Intake Unit Door

Cover with Air Intake Unit Door

• There are different versions of the air intake unit and corresponding upper inner cover ( up to 05.04 Version"1" and after 05.04 Version "2" as a running change, distinguishing characteristics => [ Characteristics of Air Intake Unit Versions 1 and 2 ] Characteristics of Air Intake Unit Versions 1 and 2). If the Version "1" upper cover or housing produced up to 05.04 has to be replaced, replace the cover or upper housing of the air intake unit as well (you will only receive Version "2" components as the spare part).

Removing

- Switch off ignition.

- Remove the plenum chamber cover.

CAUTION!
Even when the engine is cold, both pump/valve unit valves can be hot.

- Remove the fresh air blower (V2) => [ Fresh Air Blower ] Service and Repair.

- Remove Air Flow Door Motor (V71) => [ Air Flow Door Motor with Back Pressure Door Motor Position Sensor ] Air Flow Door Motor with Back Pressure Door Motor Position Sensor.

- Remove bolts - A -.





- Remove cover - B -.

• The recirculation door - C - (with the connecting elements) and both fresh air or back pressure doors - D - and - E - are inserted in the air intake unit housing.

• The shaft/control motor connecting element - F - and the lever - G - are secured in the cover - B - with retaining tabs - H -.

• Remove the shaft/control motor connecting element.

• The lever - G - is constructed differently from the connecting element - F - and therefore cannot be removed with the special tool (pry it out with a screwdriver if necessary).

Installing

- Insert the recirculation door - C - (with the connecting elements) and both fresh air or back pressure doors - D - and - E - in the respective mounts in the air intake unit housing.





- In vehicles with a Version "1" air intake unit (running change to Version "2" beginning 05.04, distinguishing characteristics to Version "2"=> [ Characteristics of Air Intake Unit Versions 1 and 2 ] Characteristics of Air Intake Unit Versions 1 and 2) seal the area between the inner cover - A - and the housing - B - in area - C - e.g. with silicone sealant "D 176 001 A3".





- Install the cover - B -, making sure both shafts (from the shaft/control motor connecting element - F - and from the lever - G -) are inserted correctly in the respective door.





- Check the seat of the recirculation door - C - in the mount.

- Hand-tighten mounting bolts - A - (10 Nm).

- Install the fresh air blower (V2) => [ Fresh Air Blower ] Service and Repair.

- Install the removed components again in reverse order.

- Check the DTC memory for the Climatronic Control Module (J255) A/C control head and erase any faults displayed if necessary => Vehicle Diagnosis, Testing and Information System VAS 5051.

- Perform a basic setting and output diagnostic test mode on the A/C system.