EVAPORATOR IN FRONT HEATER AND A/C UNIT, CLEANING WITH Suction Feed Spray Gun:VAG1538 AND SPRAY LANCE
Special tools and workshop equipment required
- Suction Feed Spray Gun :VAG1538 . Refer to Parts Information for currently available suction feed spray guns)
- Suction Feed Spray Gun - Probe for Evaporator (Straight) :VAG1538/5 (short version approximately 500 mm, bent to specification for this vehicle) or Suction Feed Spray Gun - Probe for Evaporator Cleaning, Curved :VAG1538/6 (medium version approximately 600 mm pre-bent). Refer to the Parts Information for the sensors that can be delivered currently.
- Commercially available angle drill and a 9 mm long drill bit (only necessity when the evaporator was not cleaned previously)
- Cleaning Solution for A/C System Evaporator "D 600 100 A2" (for cleaning fluids that can currently be delivered. Refer to the Parts Information
- Plugs 8D0 819 598. Refer to the Parts Information
- Commercially Available Vacuum Cleaner
- The evaporator in the rear heater and A/C unit (only installed on vehicles with a "High" A/C system) can currently only be clean using the Ultrasound A/C Cleaner (for example the Ultrasound A/C Cleaner :VAS6189 ) while installed. Refer to EVAPORATOR IN FRONT (AND REAR) HEATER AND A/C UNIT, CLEANING WITH THE ULTRASOUND A/C CLEANER . The evaporator is installed under the center console and is only accessible after removal of various components. Refer to Rear Fresh Air Blower -V80-, REMOVING AND INSTALLING . In this vehicle, the air escaping from the rear heater and A/C unit is drawn in either by the front heater and A/C unit or under the center console, depending on the setting on the Front A/C Display Control Head -E87- or Front Information Display Control Head 2 -J1060-, the Rear A/C Display Control Head -E265- and the prevailing environmental conditions. The air coming from the front heater and A/C unit is first routed through the dust and pollen filter and the evaporator in the front heater and A/C unit. Since the dust particles in the air are filtered out here, these cannot reach the evaporator in the rear heater and A/C unit.
- Note the cleaning solution product data sheet
- It is recommended to have several short and long spray lances, since they are used either in their straight form, or must be bent to different degrees for various vehicles (or they are already bent). Repeatedly changing the form of the spray lance will damage it and is therefore not advisable.
The recommended bend radius of the Suction Feed Spray Gun - Probe for Evaporator (Straight) VAG 1538/5 (short) or Suction Feed Spray Gun - Probe for Evaporator Cleaning, Curved VAG 1538/6 (middle length) -A- for this vehicle is shown.
TIP
The guide washer -B- is attached opposite of the spray lance holes -C-. This also allows the spray direction to be detected when the spray lance is inserted.
Preliminary work
-- Switch the ignition on.
-- Open all instrument panel vents.
-- Switch the A/C system on.
-- If equipped, deactivate the electric auxiliary heater.
-- Check by switching from fresh air to recirculating air mode to see whether the odor is actually originating from the front heater and A/C unit evaporator. Refer to ODORS IN VEHICLES WITH A/C SYSTEM INFORMATION .
- The cause or the location of the odor must be determined before cleaning the evaporator.
- Even if the odor is not caused by the evaporator (for example, the dust and pollen filter is dirty), it is advisable to clean the evaporator after eliminating the cause (the evaporator absorbs odors via the air flowing by).
-- Set the A/C system to recirculating air mode.
-- Switch off the ignition (the A/C system and Fresh Air Blower -V2- switches off with it).
-- Interrupt the power supply to the Auxiliary Heater Heating Element -Z35- by pulling on the related fuse. Refer to the appropriate Wiring Diagram.
-- Remove the glove compartment. Refer to GLOVE COMPARTMENT, REMOVING AND INSTALLING .
-- Remove and check the dust and pollen filter. Replace it if necessary after cleaning the evaporator. Refer to DUST AND POLLEN FILTER, REMOVING AND INSTALLING .
TIP
Replacing a dirty dust and pollen filter is recommended after each cleaning.
-- When removing the dust and pollen filter check the area of the dust and pollen filter (to the air intake shroud for the air in the fresh and recirculating air mode) and clean if necessary. Refer to DUST AND POLLEN FILTER, REMOVING AND INSTALLING .
-- Check the plenum chamber and the plenum chamber water drain and clean them if necessary. Refer to PLENUM CHAMBER WATER DRAIN, REMOVING AND INSTALLING .
-- Place a drip tray under the vehicle to collect the cleaning fluid that is draining out via the condensation water drain (for the outlet opening layout for the condensation water drain. Refer to CONDENSATION WATER DRAIN, REMOVING AND INSTALLING ).
-- Cover the carpet in the front passenger footwell with a liquid-tight foil and absorbent paper.
-- On vehicles with Auxiliary Heater Control Module -J604-, cover the connections -A- and -B-.
Risk of short circuit by lightly contacting the electric connections and with the electrically conductive tool.
- Interrupt the power supply to the Auxiliary Heater Heating Element -Z35- by pulling on the related fuse. Refer to the appropriate Wiring Diagram.
On a vehicle with an evaporator which has been cleaned with a spray lance.
-- Remove the plugs -E-.
TIP
- On RHD vehicles the pins -C- of the plugs -E- are located on the right side of the heater and A/C unit.
On a vehicle with an evaporator which has not been cleaned with a spray lance.
There is a risk of damaging the heater and A/C unit or the doors in the heater and A/C unit with the drill.
- Route the connecting lines on the heater and A/C unit so that they do not come in contact with the turning parts of the drill or the drill bit.
- Only drill carefully and with low speed.
- Do not let the drill enter deeper than maximum 10 mm in the heater and A/C unit.
-- Using a commercially available angle drill and a short drill bit (9 mm diameter) carefully drill a hole -D- in the evaporator to be cleaned installed pin -C- on the front heater and A/C unit.
-- Remove any burrs from the hole -D-.
Continuation for All Vehicles
Evaporator, Cleaning
The cleaning solution and its vapors introduce a health risk.
- Wear protective eyewear, safety gloves and protective work clothing.
- Only work with the cleaning solution in well-ventilated areas.
- Do not inhale cleaning solution vapors.
Risk of the cleaning fluid causing damage to the vehicle.
- Avoid getting any fluid on the electronic components.
- Do not spray the cleaning fluid into the air ducts leading to or in the vehicle interior.
- If vehicle interior components have come in contact with the cleaning fluid, they must be thoroughly cleaned.
Possible contamination of the heater and A/C unit by other substances
- Use a suction feed spray gun and spray lance, which have not been used with other fluids yet.
-- Fill the suction feed spray gun with the attached spray lance with one liter of cleaning solution for the A/C system evaporator.
-- Set a pressure of approximately 7.5 bar on the compressed air supply for the suction feed spray gun (minimum pressure: 5 bar/maximum pressure: 10 bar).
- This compressed air supply pressure results in a working pressure of 3.5 to 4.5 bar at the spray lance.
-- Connect the Suction Feed Spray Gun -VAS1538- to the compressed air supply.
-- Guide the spray lance -A- via the opening -B- in the heater and A/C unit (in the evaporator housing) spray direction toward the evaporator.
TIP
The guide washer -C- is attached opposite of the spray lance holes. This also allows the spray direction to be detected and fixed when the spray lance is inserted.
- The drainage of the cleaning fluid via the condensation water drain must be monitored during the cleaning procedure.
-- Clean and flush the evaporator and the surrounding housing with cleaning solution by operating the metering lever on the suction feed spray gun and moving the spray lance -A- back and forth.
-- Check if actual fluid flows over the condensation water drain in the drip tray under the vehicle.
- The condensation water drain must be cleaned before continuing the cleaning procedure if the fluid is only dripping out. Refer to CONDENSATION WATER DRAIN, REMOVING AND INSTALLING .
-- Spray the entire contents of the suction feed spray gun for cleaning the evaporator.
-- Remove the drip tray and dispose of the collected cleaning solution.
Allow the cleaning solution to work for at least 30 minutes. The vehicle can be completed at this time.
-- Insert the plugs -D- in the hole -B- and check for secure fit.
-- Reinstall all of the removed components.
-- Open all of the doors or windows.
-- Open all of the air vents on the instrument panel and in the vehicle.
-- Switch on the ignition.
-- On the Front A/C Display Control Head -E87- / Front Information Display Control Head 2 -J1060- select the airflow direction of all vents.
-- On the Front A/C Display Control Head -E87- / Front Information Display Control Head 2 -J1060- for the Fresh Air Blower -V2- set the maximum speed.
-- Then start the engine and turn on the A/C system (the A/C compressor) (the indicator lamp in the A/C or A/C Max button turns on).
-- If equipped adjust the airflow direction of the air to all vents on the Rear A/C Display Control Head -E265- version -B- (installed on vehicles with a "High" A/C system) and select the maximum speed for the Rear Fresh Air Blower -V80-.
-- Allow the A/C system to run at this setting for approximately 10 minutes (the A/C compressor is switched on). At the same time, switch the selected vent temperature back and forth between cold and warm several times on the Front A/C Display Control Head -E87-.