Air Flow Door Motor with Back Pressure Door Motor Position Sensor
Air Flow Door Motor with Back Pressure Door Motor Position Sensor
• In the event of fault "Upper or lower limit value exceeded", check connecting element of engine/door, it must be attached to engine accurate to side and there must not be any clearance between actuator mount and connecting element.
• Various connectors of identical construction are present the air intake unit, apply identifying marks on connectors before disconnecting (risk of interchange).
• Different control motors are installed on the A/C unit and air intake unit, these control motors are distinguished by their electrical values and in their part number index , therefore mark the control motors before removing (risk of interchange).
• A potentiometer with an adjustment range of 120 ° is installed in this control motor, its part number at the start of production has index "A".
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 windshield wiper arm and cowl panel trim
- If necessary, remove the dome brace (not present in all vehicles).
- Remove the air intake unit upper cover => [ Air Intake Unit Upper Cover ] Air Intake Unit Upper Cover.
- Remove bolts - A -.
- Disconnect harness connector from actuator - B -.
- Remove the control motor - C -.
Installing
Installation is carried out in the reverse order, when doing this note the following.
- Check the position of the control motor shaft - B -, it must be located in the position depicted.
• Only install the connecting element - A - in the position where it engages without being forced in. If pretension is needed to insert the connecting element, check the motor shaft - B -. It can be rotated 180°.
• If motor shaft - B - is not in the position depicted (the connecting piece can only be attached in this position), connect terminals 5 and 6 of the control motor via a 5A fuse to a 12 V battery e.g. using adapter lead => [ Preparing Adapter Cables for Control Motor Actuation ] Preparing Adapter Cables for Control Motor Actuation (or an adapter lead from the Connector Test Kit (V.A.G 1594/C)). Rotate the control motor for as long until the shaft is located in the position depicted (the connecting element can be connected without pretension), the turning direction can be reversed by swapping Plus and Minus.
• Actuator shaft - B - does not have a stop, it rotates continuously when voltage is applied between terminals 5 and 6. Therefore, if the connecting element - A - is connected or cannot be connected, voltage should be applied only when the control motor has been removed in order to bring shaft into the correct position.
• If connecting element - A - cannot be inserted into the control motor without pretension, the shaft may be incorrectly positioned.
- Prior to installing the control motor, check the back pressure door position and the connecting element - D -.
- Check the position of the control motor shaft - E - for the back pressure door (V71) (it must be located in the position depicted).
• Make sure the connecting element is seated correctly. There must not be any play between the control motor mount - A - and the connecting element - B - (remove the connecting element if necessary).
• Only install the connecting element - A - in the position where it engages without being forced in. If pretension is necessary to insert connecting element, check the motor mount - B -. It can be turned 180°.
- Install connecting element - A - onto the back pressure door shaft.
- Install control motor - C -.
- Hand-tighten mounting bolts - A - (10 Nm).
- Connect connector - B - to the control motor - C -.
- Before installing the air intake unit upper cover, make sure the connector - B - is seated correctly and the cable is routed correctly.
- 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.
Shaft/Control Motor Connecting Element, Removing
- Insert Release Tool (T40072) - A - into connecting element - B -.
- Loosen the retainers - E - on the connecting element - B - by turning the thumbwheel on the Release Tool (T40072) - A -.
- Carefully pry the connecting piece - B - out (e.g. with a screwdriver).
• The lever - C - is constructed differently than the connecting element - B - so it cannot be removed with the Release Tool (T40072) - A - (pry it out with a screwdriver if necessary).