Air Intake Manifold, Removing And Installing: Installing
Installation is done is reverse order, observe the following:
-- Check the evaporator -A-, air guide housing -B- and the air intake housing -C- for debris and clean it if necessary.
-- Inspect the foam seal -D- attached to the air intake housing for damages and replace it if necessary.
-- Inspect the contact surfaces/bevel -E- on the air distribution housing for damages.
If a foam seal or a contact surface/bevel is damaged, air can escape here and noises can occur when operating the A/C system.
If the air distribution housing and the air intake housing are not correctly joined, air can escape at the connection point and noises can occur when operating the A/C system.
If the contact surfaces/bevel are damaged, fill the damaged area, for example with a silicone adhesive.
-- Insert the lower retaining tabs of the air intake housing -E- into the mount on the air distribution housing -D- and move it upward.
- The air intake housing must audibly engage when inserted into the retaining tabs -B- on the air distribution housing.
If the retaining tab -B- does not engage immediately, pull the air intake housing in the area of the upper catch backward while pressing the right side forward and upward.
Leaks at the connection points.
- Do not use force when attaching the air intake housing to the A/C unit.
- If force is used to attach the air intake housing to the A/C unit, the air intake housing tabs can be permanently deformed. This can cause the A/C system to make whistling noises during operation due to minor leaks at the connection points.
Vehicles with An Additional Bolt on the Air Intake Housing
-- Attach the bolt via the installation shaft for the dust and pollen filter on the air distribution unit and tighten it.
Continuation for All
If the air intake housing no longer engages onto the air distribution housing, then it must be bolted on to the air distribution housing via the installation shaft for the air intake housing dust and pollen filter with a bolt.
-- Remove the air intake housing again.
-- Remove the dust and pollen filter. Refer to DUST AND POLLEN FILTER, REMOVING AND INSTALLING .
-- Drill a hole at bolting point -D- with a 4 mm diameter.
-- Install the air intake housing again.
-- Install the bolt -A- at the bolting point -C- via the installation shaft for the dust and pollen filter -E-.
Make sure to use the correct version of the bolt -A- to prevent damaging the bolting point -C- with a bolt that is too large.
-- Install the wiring harness so that it cannot come in contact with any moving parts (for example, the lever on the actuator).
After completing the repair work, perform the following operations on the control head using the Vehicle Diagnostic Tester in the "Guided Fault Finding" function:
-- Check the Diagnostic Trouble Code (DTC) memory and delete any currently displayed entries.
-- Perform the basic setting.
-- Perform output Diagnostic Test Mode (DTM).