Audi q5 2008 Heating Ventilation Air Conditioner Eng

Service
Repair Manual
Audi A4 2008 ➤ ,
Audi A5 Cabriolet 2009 ➤ ,
Audi A5 Coupé 2008 ➤ ,
Audi A5 Sportback 2010 ➤ ,
Audi Q5 2008 ➤ , Audi Q5 China 2010 ➤
Heating, Ventilation and Air Conditioning
Edition 11.2017
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
80 - Heating, Ventilation
87 - Air Conditioning
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Audi A4 2008 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi ...
Heating, Ventilation and Air Conditioning - Edition 11.2017
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Type Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Odors in Vehicles with A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Front Seat Heating and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Rear Window Defogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5 Notes on A/C System Control and Regulation In Passenger Compartment . . . . . . . . . . . . 13
1.6 Notes on A/C System Control and Regulation outside Passenger Compartment . . . . . . . . 14
1.7 Notes on Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.8 Notes on Front Heater and A/C Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.9 Notes on Display and Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.10 Main Wiring Diagram for A/C System Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.1 Safety Precautions when Handling Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.2 High Voltage Vehicles Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.3 Start/Stop System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.4 Safety Precautions during Road Test with Testing Equipment . . . . . . . . . . . . . . . . . . . . . . 43
2.5 Safety Precautions when Working on Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.1 Guidelines for Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.3 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.4 Contact Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.5 A/C Components Controlled or Activated by Other Control Modules, Electrical Tests . . . . 49
3.6 Inspection of Components for the A/C System for Vehicles with High Voltage System . . . . 49
3.7 Heating Output, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.8 Cooling Output, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.9 Working on the Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.10 Refrigerant Circuit, Discharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.11 Dust and Pollen Filter with Activated Charcoal Insert, Element Information . . . . . . . . . . . . 107
3.12 Painting on Vehicles with A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.13 Refrigerant Circuit Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.1 Refrigerant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.2 Approved Refrigerant Oils and Refrigerant Oil Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.3 Oil Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
80 - Heating, Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

1 Overview - Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
87 - Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

1 Overview - A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.1 Overview - Components Outside of Passenger Compartment . . . . . . . . . . . . . . . . . . . . . . 120
1.2 Overview - Components Inside Front Passenger Compartment . . . . . . . . . . . . . . . . . . . . 135
2 Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2.1 Overview - Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2.2 Overview - Refrigerant Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.3 Overview - Refrigerant Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.4 A/C Compressor Regulator Valve N280 , Checking Switch-On Signal . . . . . . . . . . . . . . . . 192
2.5 A/C Compressor Regulator Valve N280 , Checking Activation . . . . . . . . . . . . . . . . . . . . . . 197
2.6 A/C Pressure/Temperature Sensor G395 , Removing and Installing . . . . . . . . . . . . . . . . . . 197
Contents i
2.7 A/C Pressure/Temperature Sensor G395 , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

2.8 A/C Pressure/Temperature Sensor G395 , Checking Pressure Signal . . . . . . . . . . . . . . . . 200
2.9 Refrigerant Lines to Front Battery Cooling Module, Removing and Installing, on Vehicle
Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.10 Refrigerant Lines to Rear Battery Cooling Module, Removing and Installing, on Vehicle
Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
2.11 Refrigerant Line Pass-Through in Luggage Compartment, Removing and Installing . . . . 210
2.12 Refrigerant Lines for Battery Cooling Module in Luggage Compartment, Removing and
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
2.13 Refrigerant Lines, Disconnecting from Quick-Release Couplings and Connecting . . . . . . 221
2.14 Refrigerant Lines with Inner Heat Exchanger, Removing and Installing . . . . . . . . . . . . . . 227
2.15 Expansion Valve, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
2.16 Rear Expansion Valve with Hybrid Battery Refrigerant Shut-Off Valve 2 N517 , Removing
and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
2.17 Refrigerant Lines, Disconnecting and Connecting at Condenser . . . . . . . . . . . . . . . . . . . . 253
2.18 Condenser, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
2.19 Receiver/Dryer, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
2.20 Dryer Bag/Dryer Cartridge, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
2.21 Service Connection Differences, Depending on Refrigerant (R134a or R1234yf) . . . . . . . . 278
2.22 Evacuating and Charging Valve, Removing and Installing, Low and High Pressure Side . . 281
2.23 A/C System, Starting Operation after Filling Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . 282
3 A/C Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
3.1 Overview - A/C Compressor Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
3.2 Overview - Belt Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
3.3 A/C Compressor, Removing and Installing on Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
3.4 Refrigerant Lines, Disconnecting and Connecting at A/C Compressor . . . . . . . . . . . . . . . . 312
3.5 A/C Compressor, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
3.6 Preliminary Work for Replacing Belt Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
3.7 Belt Pulley, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
3.8 A/C Compressor Input Shaft, Loosening and Tightening . . . . . . . . . . . . . . . . . . . . . . . . . . 382
3.9 A/C Compressor Input Shaft, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
3.10 Drive Plate with Overload Protection, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 384
3.11 Drive Plate with Overload Protection, Checking Run-Out and Adjusting . . . . . . . . . . . . . . 384
3.12 A/C Compressor Drive Plate, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
3.13 Drive Plate with Anti-Friction Bearing, Removing and Installing . . . . . . . . . . . . . . . . . . . . 385
4 Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
4.1 Overview - Front Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
4.2 Temperature Regulator Door Motor V68 / Rear Temperature Door Motor V137 , Removing
and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
4.3 Airflow Door Motor V71 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
4.4 Center Vent Adjustment Motor V102 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 410
4.5 Defroster Door Motor V107 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
4.6 Left Footwell Door Motor V108 / Footwell Door Motor V261 , Removing and Installing . . 414
4.7 Right Footwell Door Motor V109 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 417
4.8 Left Center Vent Motor V110 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 419
4.9 Right Center Vent Motor V111 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 422
4.10 Recirculation Door Motor V113 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 424
4.11 Left Temperature Door Motor V158 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 426
4.12 Right Temperature Door Motor V159 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 429
4.13 Hybrid Battery Recirculation Door Positioning Motor 1 V479 , Removing and Installing . . 431
4.14 Hybrid Battery Recirculation Door Positioning Motor 2 V480 , Removing and Installing . . 434
4.15 Left Retaining Plate with Left Footwell Door Motor V108 and Left Center Vent Motor V110 ,
Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
4.16 Right Retaining Plate with Right Footwell Door Motor V109 and Right Center Vent Motor
V111 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
4.17 Left Retaining Plate with Footwell Door Motor V261 , Removing and Installing . . . . . . . . 444
ii Contents
4.18 Left Retaining Plate with Left Footwell Door Motor V108 and Left Center Vent Motor V110
Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
4.19 Right Retaining Plate with the Right Footwell Door Motor V109 and Right Center Vent Motor
V111 , Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
4.20 Left Retaining Plate with Footwell Door Motor V261 , Disassembling and Assembling . . . . 449
5 Front Heater and A/C Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
5.1 Overview - Attachments for Heater and A/C Unit and Air Intake Housing . . . . . . . . . . . . . . 451
5.2 Overview - Air Distribution Housing Doors and Partitions . . . . . . . . . . . . . . . . . . . . . . . . . . 461
5.3 Overview - Heater and A/C Unit Air Intake Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
5.4 Overview - Evaporator Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
5.5 Evaporator, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
5.6 Evaporator Housing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
5.7 Evaporator, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
5.8 Auxiliary Heater Heating Element Z35 , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
5.9 Auxiliary Heater Heating Element Z35 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 511
5.10 A/C System Temperature Door Heat Output Activation, Checking . . . . . . . . . . . . . . . . . . 514
5.11 Heater and A/C Unit, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
5.12 Heater and A/C Unit Air Intake Housing, Removing and Installing . . . . . . . . . . . . . . . . . . 537
5.13 Left Radiator Housing with Temperature Doors, Removing and Installing . . . . . . . . . . . . 541
5.14 Right Radiator Housing, Removing and Installing (with Temperature Doors) . . . . . . . . . . 545
5.15 Dust and Pollen Filter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
5.16 Fresh Air Blower V2 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557
5.17 Fresh Air Blower Control Module J126 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 560
5.18 Heater Core, Preparing for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562
5.19 Heater Core, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567
5.20 Condensation Water Drain, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577
5.21 Condensation Water Drain, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
6 Air Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581
6.1 Overview - Air Routing and Air Distribution in Passenger Compartment . . . . . . . . . . . . . . 581
6.2 Air Intake and Outlet Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586
6.3 Driver Side Footwell Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593
6.4 Front Passenger Side Footwell Vent, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 594
6.5 Plugs, Installing in Center Vent Air Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595
6.6 Passenger Compartment Forced Air Extraction, Removing and Installing . . . . . . . . . . . . 595
6.7 Passenger Compartment Forced Air Extraction, Checking . . . . . . . . . . . . . . . . . . . . . . . . 596
6.8 Fresh Air Intake, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
6.9 Air Intake Duct, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
6.10 Plenum Chamber Water Drain, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 605
6.11 Plenum Chamber Water Drain, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
6.12 Plenum Chamber Water Drain, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
6.13 Instrument Panel Vents and Rear Vents, Removing and Installing . . . . . . . . . . . . . . . . . . 616
6.14 Glove Compartment Cooling Connection on Air Intake Housing . . . . . . . . . . . . . . . . . . . . 616
6.15 Rear Vent Air Guide Slots, Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
7 Coolant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
7.1 Coolant Shut-Off Valve N82 / Climatronic Coolant Shut-Off Valve N422 Location, Activation
and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
7.2 Coolant Recirculation Pump V50 ( Water Pump V36 ) Location, Activation and Function
........................................................................ 623
8 Display and Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
8.1 Display and Control Head Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
8.2 Display and Control Head, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636
8.3 Interior Temperature Sensor Fan, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 639
9 Additional Components for Control and Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 640
9.1 Sunlight Photo Sensor G107 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 640
9.2 Air Quality Sensor G238 , Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642
9.3 Air Quality Sensor G238 , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645
Contents iii
9.4 Air Quality Sensor G238 / Humidity Sensor In Fresh Air Intake Duct G657 , Removing and
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655
9.5 Outside Air Temperature Sensor G17 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 659
9.6 Center Vent Temperature Sensor G191 , Removing and Installing . . . . . . . . . . . . . . . . . . 660
9.7 Footwell Vent Temperature Sensor G192 / Left Footwell Vent Temperature Sensor G261 ,
Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 660
9.8 Right Footwell Vent Temperature Sensor G262 , Removing and Installing . . . . . . . . . . . . 661
9.9 Evaporator Vent Temperature Sensor G263 , Removing and Installing . . . . . . . . . . . . . . 662
9.10 Humidity Sensor G355 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663
9.11 Rain/Light Recognition Sensor G397 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 666
9.12 Left Front Upper Body Vent Temperature Sensor G385 , Removing and Installing . . . . . . 667
9.13 Right Front Upper Body Vent Temperature Sensor G386 , Removing and Installing . . . . 667
9.14 Humidity Sensor In Fresh Air Intake Duct G657 Function . . . . . . . . . . . . . . . . . . . . . . . . . . 669
9.15 Humidity Sensor in Fresh Air intake Duct G657 , Checking . . . . . . . . . . . . . . . . . . . . . . . . 670
10 Battery Cooling Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 671
10.1 Overview - Components Outside of Passenger Compartment . . . . . . . . . . . . . . . . . . . . . . 671
10.2 Overview - Components Inside Rear Passenger Compartment . . . . . . . . . . . . . . . . . . . . 675
10.3 Overview - Battery Cooling Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 678
10.4 Overview - Air Intake, Air Vent and Air Guide on the Battery Cooling Module . . . . . . . . . . 682
10.5 Overview - Air Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 684
10.6 Hybrid Battery Refrigerant Shut-Off Valve 1 N516 , Removing and Installing . . . . . . . . . . 688
10.7 Traction Battery A2 Rear Outlet Air Guide, Removing and Installing . . . . . . . . . . . . . . . . . . 691
10.8 Traction Battery A2 Front Outlet Air Guide, Removing and Installing . . . . . . . . . . . . . . . . 694
10.9 Traction Battery A2 Inlet Air Guide, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 696
10.10 Left and Right Air Guides on Traction Battery A2 , Removing and Installing . . . . . . . . . . . . 699
10.11 Battery Cooling Module, Bringing into Service Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
10.12 Battery Cooling Module, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704
10.13 Battery Fan 1 V457 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708
10.14 Temperature Sensor before Hybrid Battery Evaporator G756 , Removing and Installing . . 711
10.15 Temperature Sensor after Hybrid Battery Evaporator G757 , Removing and Installing . . . . 713
10.16 Condensation Water Drain, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715
10.17 Condensation Water Drain, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718
11 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721
12 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 722
iv Contents
00 – General, Technical Data

1 General Information
(Edition 11.2017)
1. General Information 1
⇒ “1.1 Type Labels”, page 2

⇒ “1.2 Odors in Vehicles with A/C System”, page 4
⇒ “1.3 Front Seat Heating and Ventilation”, page 5
⇒ “1.4 Rear Window Defogger”, page 12
⇒ “1.5 Notes on A/C System Control and Regulation In Passenger
Compartment”, page 13
⇒ “1.6 Notes on A/C System Control and Regulation outside Pas‐
senger Compartment”, page 14
⇒ “1.7 Notes on Refrigerant Circuit”, page 19
⇒ “1.8 Notes on Front Heater and A/C Unit”, page 23
⇒ “1.9 Notes on Display and Control Head”, page 26
⇒ “1.10 Main Wiring Diagram for A/C System Actuators”,
page 30
1.1 Type Labels

The Refrigerant and Capacity Type Plate Is Located at the Lower
Left on the Hood.
Note
♦ The information label provides information about the type of

refrigerant used, the refrigerant quantity filled at production
and the refrigerant oil filled.
♦ Symbols on the information label indicate the dangers which
may occur when handling refrigerant and/or when working on
the refrigerant circuit.
♦ Through 06/2016, the refrigerant circuit on all A/C systems
was filled with Refrigerant R134a. As a running change from
06/2016, refrigerant R134a or refrigerant R1234yf is filled de‐
pending on the market and the vehicle version. Refer to ⇒ A/
C Systems with Refrigerant R1234yf - General Information;
Rep. Gr. 00 ; Legal Texts and Regulations .
♦ Norms and standards can also be stated, such as the valid
SAE standards defined in the USA. The SAE J639 describes
the safety precautions for A/C systems in passenger vehicles.
The SAE J842 explains that only approved components and
materials may be used for refrigerant R1234yf, and SAE
J2845 says that only trained and certified technicians may
perform repair and service procedures on the A/C system re‐
frigerant circuit.
♦ Depending on the version and the vehicle date of manufac‐
ture, the GWP value (global warming potential) for the refrig‐
erant used may also be specified.
♦ The capacities and the type of refrigerant oil specified on the
information label show the status at the time of vehicle pro‐
duction. The current valid values must always be taken from
the vehicle-specific repair manual. Refer to
⇒ “4 Technical Data”, page 110 , ⇒ Refrigerant R134a Serv‐
icing; Rep. Gr. 87 ; Refrigerant R134a Capacities, Refrigerant
Oil and Approved Refrigerant Oil or ⇒ A/C Systems with Re‐
frigerant R1234yf - General Information; Rep. Gr. 00 ; Tech‐
nical Data .
2 Rep. Gr.00 - General, Technical Data

The Refrigerant and Capacity Type Plate Is Located at the Lower

Left on the Hood.
Version “1”
1- Refrigerant Designation, for example R134a or R1234yf
(depending on the production date and the version)
2- Refrigerant Capacity
Version “2”
1- Refrigerant Oil Designation, here it is PAG oil. Refer to
⇒ “4.2 Approved Refrigerant Oils and Refrigerant Oil Ca‐
pacities”, page 112 for more information.
2- Refrigerant Designation, for example R134a or R1234yf
(depending on the production date and the version). De‐
pending on the version of the type plate and the vehicle date
of manufacture, the GWP (Global Warming Potential) value
may also be given. Refer to ⇒ Refrigerant R134a Servicing;
Rep. Gr. 87 ; A/C System General Information (“Refrigerant
R134a”, “Environment aspects of refrigerant R134a”) or ⇒
A/C Systems with Refrigerant R1234yf - General Informa‐
tion; Rep. Gr. 00 ; Technical and Physical Principles .
3- Designates refrigerant capacity.
Note
♦ Refrigerant R134a and refrigerant oil as well as approved re‐

frigerant oil capacities. Refer to ⇒ Refrigerant R134a, Serv‐
Oil and Approved Refrigerant Oil Capacities .
♦ Capacities for refrigerant R1234yf and refrigerant oil as well
as approved refrigerant oil. Refer to
⇒ “4 Technical Data”, page 110 and ⇒ A/C Systems with Re‐
nical Data .
Version “3”
Note
Explanations about the specifications on the information label

-A-. Refer to ⇒ page 3 .
1.2 Odors in Vehicles with A/C System

Odors from the A/C system can come from various sources. Only
a portion of these odors come from the A/C unit evaporator and
can be corrected by cleaning the evaporator.
Odor Type Possible Causes and Corrective Measure
Smells like burnt oil ♦ Usually originates in the engine compartment due to leaks on the engine or
transmission
– Eliminate the leaks on the engine or transmission
Sulphurous smell similar to ♦ Leak in the exhaust system
exhaust
♦ Exhaust fumes, which get into the vehicle interior, for example, when driving
in reverse through an exhaust gas cloud
– Eliminate the leaks in the exhaust system
Fishy smell like coolant ♦ Leak in the cooling system of engine or of A/C system heater core.
– If the fishy odor is also detected in recirculation mode as well as in fresh air
mode, check the heater core for leaks.
Smells like a burned clutch ♦ Clutch plates are worn or there is an operating error
– Check the clutch
Evaporation ♦ Floor mats, retroactively installed decorative seat covers, etc.
– Check the floor mats or decorative seat covers. Replace or clean.
Rotten, moldy or musty ♦ If the plenum chamber cover is damaged or incorrectly installed, water can
smell from the front of the enter the fresh air intake via the rain water drain channel.
vehicle
– Check the fresh air intake for the A/C unit. Refer to
⇒ “6.8 Fresh Air Intake, Removing and Installing”, page 600 .
♦ Contaminants, such as leaves, pine needles, etc. collecting in the plenum
chamber
– Check the plenum chamber for contaminants. Refer to
⇒ “6.11 Plenum Chamber Water Drain, Checking”, page 607 .
♦ Water that cannot drain out of the plenum chamber
– Check the water drains. Refer to
⇒ “6.11 Plenum Chamber Water Drain, Checking”, page 607 .
Smell from the A/C unit. ♦ Too much condensation water in A/C unit
– Check the condensation water drain. Refer to
⇒ “5.20 Condensation Water Drain, Removing and Installing”, page 577 .
♦ Old or heavily contaminated dust and pollen filter.
– Check the dust and pollen filter. Refer to
⇒ “5.15 Dust and Pollen Filter, Removing and Installing”, page 556 .
♦ Deposits on evaporator slats
– Clean the evaporator. Refer to ⇒ “5.7 Evaporator, Cleaning”, page 496 .
Note
♦ The odor can only be removed by cleaning with the if it origi‐

nates in the evaporator.
♦ Numerous procedures varying in their application and effect
are available on the market for cleaning the evaporator. Audi,
for example, has currently tested and approved cleaning the
evaporator using the .

Note
♦ The odor can be removed by cleaning with the Ultrasound A/

C Cleaner - VAS6189B- only if it originates in the evaporator.
are available on the market for cleaning the evaporator. At this
time Audi has tested and approved cleaning the evaporator
using the Ultrasound A/C Cleaner - VAS6189B- or a Suction
Feed Spray Gun - VAG1538- , for example.
1.3 Front Seat Heating and Ventilation
Note
Various vehicle electrical components (for example, Rear Win‐

dow Defogger - Z1- and heated seats) that do not belong to the
heater are activated by the Climatronic Control Module - J255- A/
C display and control head. On the Rear Window Defogger - Z1- ,
for example, the turn on request is sent via the Data Bus to the
Comfort System Central Control Module - J393- , the Comfort
System Central Control Module - J393- then controls the Rear
Window Defogger - Z1- via the Rear Window Defogger Relay -
J9- . Refer to ⇒ Wiring diagrams, Troubleshooting & Component
locations. Electrical testing of these components must be per‐
formed as described in Guided Fault Finding for the A/C system
and the Comfort System Central Control Module - J393- using the
Vehicle Diagnostic Tester in the "Guided Fault Finding" function.
Components Which Participate in the Control of the Seat Heating

and Seat Ventilation
The Climatronic Control Module - J255- A/C display and control
head sends the request to switch on the seat heating/seat venti‐
lation vie the Data Bus system comfort to the respective control
unit (the control unit depends on the vehicle version and vehicle
equipment level using the Vehicle Diagnostic Tester in the "Gui‐
ded Fault Finding" function for each control unit).
♦ On vehicles without a Memory Seat/Steering Column Adjust‐
ment Control Module - J136- , the Vehicle Electrical System
Control Module - J519- directly controls the driver seat heat‐
ing; the seat ventilation, where applicable, is controlled via the
Left Front Seat Ventilation Control Module - J800- by the Ve‐
hicle Electrical System Control Module - J519- (different
measured values block assignment in the Vehicle Electrical
System Control Module - J519- ).
♦ On vehicles without a Front Passenger Memory Seat Control
Module - J521- , the Vehicle Electrical System Control Module
- J519- directly controls the passenger seat heating; the seat
ventilation, where applicable, is controlled via the Right Front
Seat Ventilation Control Module - J799- by the Vehicle Elec‐
trical System Control Module - J519- (different measured val‐
ues block assignment in the Vehicle Electrical System Control
Module - J519- ).
♦ On vehicles equipped with a driver seat with entry assist and/
or memory function, the Memory Seat/Steering Column Ad‐
justment Control Module - J136- directly controls the driver
seat heating and seat ventilation, if applicable (different meas‐
ured value block assignment in the Vehicle Electrical System
Control Module - J519- ).
♦ On vehicles with front passenger seat with power entry assist,
the Front Passenger Memory Seat Control Module - J521-
control the passenger seat heating.
♦ From MY 2010, this vehicle has a Start/Stop System for spe‐

cific engines as optional equipment. If the vehicle has the
Start/Stop System, the seat heating and ventilation can be
switched off whenever the Stop function is active (to protect
the Battery - A- ). The setting for the heated seat control (and
seat ventilation) remains stored in the Climatronic Control
Module - J255- display and control head. After the engine is
started again by the Start function, seat heating and ventilation
is switched on again using the Vehicle Diagnostic Tester in the
"Guided Fault Finding" function.
Note
♦ The activation of the Right Front Seat Ventilation Control Mod‐

ule - J799- and the Left Front Seat Ventilation Control Module
- J800- by the Vehicle Electrical System Control Module -
J519- takes place via a local Data Bus. Refer to ⇒ Wiring
diagrams, Troubleshooting & Component locations.
♦ The activation of the seat heating and seat ventilation can be
different between the Audi A5 and Audi A4. Refer to ⇒ Wiring
♦ The display of the different data for controlling the seat heating
and ventilation (by the Climatronic Control Module - J255- A/
C display and control head transmitted setting, the specified
and actual seat temperature, etc.) is performed by the different
Vehicle Electrical System Control Module - J519- measured
value blocks and/or by the Memory Seat/Steering Column Ad‐
justment Control Module - J136- using the Vehicle Diagnostic
Tester in the "Guided Fault Finding" function depending on the
vehicle version and equipment.
♦ Depending on production time period and vehicle version, the
rear seat heating is activated by, for example, the Seat Heating
Control Module - J882- , which is installed on the wheel hous‐
ing at the right rear of the luggage compartment. Refer to
⇒ Wiring diagrams, Troubleshooting & Component locations.

♦ If there is a condition, where the heating or ventilation of the

driver or front passenger seat cannot be switched on (for ex‐
ample due to a short circuit in the connection to a seat heater
element or an interruption in the power supply to the respective
control unit, etc.), this will be stored as a malfunction in the
Vehicle Electrical System Control Module - J519- , in the Mem‐
ory Seat/Steering Column Adjustment Control Module - J136-
or in Front Passenger Seat Heating Control Module - J521-
(depending on the vehicle type and the vehicle equipment
level). Currently no information is sent to the Climatronic Con‐
trol Module - J255- A/C display and control head via the Data
Bus system; the DTC memory must be read out in each control
unit or in the Comfort System Central Control Module - J393-
using the Vehicle Diagnostic Tester in the "Guided Fault Find‐
ing" function. In the event of a complaint regarding seat
heating or seat ventilation, first check the DTC memory of the
control modules activating the seat heating and seat ventila‐
tion.
♦ The function test of the heated seats and seat ventilation con‐
trol is described in the Guided Fault Finding for each control
unit ( Vehicle Electrical System Control Module - J519- , Mem‐
ory Seat/Steering Column Adjustment Control Module - J136-
or Front Passenger Memory Seat Control Module - J521- ,
depending on the vehicle version and vehicle equipment) us‐
ing the Vehicle Diagnostic Tester in the "Guided Fault Finding"
function.
♦ If, for example on the Vehicle Electrical System Control Mod‐
ule - J519- the measured current on terminal “30” falls below
the value stored in the Vehicle Electrical System Control Mod‐
ule - J519- , the heated seat and seat ventilation output will be
reduced or switched off completely in order to reduce the load
on the Generator - C- using the Vehicle Diagnostic Tester in
the "Guided Fault Finding" function.
♦ The measuring value block in the Climatronic Control Module
- J255- A/C display and control head displays which setting for
the seat heating or the seat ventilation has been selected. De‐
pending on the version and equipment level of the vehicle, the
seat heating and seat ventilation activation, the actual and
specified seat temperature, the actual current flowing through
the seat heating, etc. will appear in the individual control mod‐
ule (for example, inside measured values block for the Vehicle
Electrical System Control Module - J519- using the Vehicle
Diagnostic Tester in the "Guided Fault Finding" function.
♦ Depending on the vehicle version, the seat heating and ven‐
tilation for the front passenger seat can switch off after a
certain period of time when it recognizes that the seat is empty.
Refer to the Owner's Manual.
♦ There are different versions of the Climatronic Control Module
- J255- A/C display and control head. Refer to the Parts Cat‐
alog. The different versions can be recognized, for example,
by the symbols on the buttons -A- (for vehicles equipped with
“seat heating”) and -B- (vehicles with “seat heating/seat ven‐
tilation”)
♦ This illustration shows the Climatronic Control Module - J255-
A/C display and control head in the “Convenience” version, as
it was installed at the start of production.
♦ From MY 2012, as a running change (depending on the model
and version), a revised Climatronic Control Module - J255- is
being installed. Ensure the correct allocation. Refer to the
Parts Catalog.

♦ If installed, the recognizable differences on the “Convenience”

system are, for example, the following: the seat heating and
seat ventilation are selected via the buttons -C- and rotary ad‐
juster on the Climatronic Control Module - J255- -A- installed
from start of production. As a running change, vehicles from
MY 2012 have two separate buttons -D- and -E- on the Cli‐
matronic Control Module - J255- -B- that operate the seat
heating and the seat ventilation Also, the seat heating/seat
ventilation on version -B- still have only three settings (contrary
to the 6 setting on version -A-). A selected seat heating setting
will be turned down one setting after a certain amount of time.
The location of the buttons -F- and -G- is different between
both versions. Refer to the Owner's Manual.
♦ Both versions -A- and -B- are on the “Basis” when installed.
Only the seat heating buttons are different (when installed,
there are no noticeable differences on vehicles without seat
heating). The seat symbols in the buttons -C- and -D- point in
different directions on the Climatronic Control Module - J255-
-A- installed from start of production. The seat symbols in
buttons -C- and -D- face the same direction on the installed
Climatronic Control Module - J255- -B- from MY 2012. The
version -B- Climatronic Control Module - J255- has three seat
heating settings (version -A- has six settings). The selected
seat heating setting will be turned down one setting after a
certain period of time. Refer to the Owner's Manual.
♦ When the seat heating is on, the lamp in the button -A- or
-B- “red” turns on and the selected seat heating setting ap‐
pears in both the Climatronic Control Module - J255- -C- A/C
display control head and the MMI display for a certain period
of time on a Climatronic Control Module - J255- installed at
start of production. On a Climatronic Control Module - J255-
installed from MY 2012, the selected setting is displayed di‐
rectly in the button when the indicator lamp turns on. The seat
heating and seat ventilation can be selected separately on
these versions. Refer to the Owner's Manual and Infotainment/
MMI Owner's Manual. Therefore, ensure the correct allocation
of the Climatronic Control Module - J255- . Refer to the Parts
Catalog.
♦ The setting for the seat heating and ventilation is adjusted on
the Climatronic Control Module - J255- A/C display and control
head; this adjustment is transmitted to the Vehicle Electrical
System Control Module - J519- via the Data Bus. The specified
temperatures for the different seat heating and seat ventilation
settings are stored in the Vehicle Electrical System Control
Module - J519- . Depending on the version of the Vehicle
Electrical System Control Module - J519- and on the produc‐
tion date of the vehicle, the specified temperature for the seat
heating and ventilation can be different with the same setting
on the Climatronic Control Module - J255- A/C display and
control head using the Vehicle Diagnostic Tester in the "Gui‐
ded Fault Finding" function (for the Vehicle Electrical System
Note the Following When Operating the Seat Ventilation:
♦ When the seat ventilation is turned on, the lamp in the button
-B- turns on “blue” on a Climatronic Control Module - J255-
installed from start of production. The setting for the seat
ventilation also appears in the Climatronic Control Module -
J255- -C- A/C display control head and in the MMI display for
a certain period of time. As a running change, the selected
setting is displayed directly in the seat ventilation button when
the indicator lamp illuminates on a Climatronic Control Module
- J255- installed from MY 2012. Refer to the Owner's Manual
and Infotainment/MMI Owner's Manual
♦ The specified temperature for the seat depends on the selec‐

ted seat ventilation setting (approximately 33 °C (91 °F) at
setting 1 and approximately 18 °C (64 °F) at setting 6). If the
actual temperature in the seat is less than the specified tem‐
perature, then the seat heating will be controlled until the
specified temperature is reached using the Vehicle Diagnostic
Tester in the "Guided Fault Finding" function (for example, for
the Vehicle Electrical System Control Module - J519- ).
♦ Depending on seat temperature and selected setting of seat
ventilation, seat heater can be switched on automatically by
the control module. If necessary, only seat cushion is heated
in seat ventilation mode, seat bolster heating not switched on.
Refer to ⇒ Wiring diagrams, Troubleshooting & Component
locations.
♦ The blower activation for the seat cushion and seat backrest
(2 blowers each in the seat backrest and seat cushion) de‐
pends on the seat ventilation setting (approximately 40% of
the maximum output at setting 1, and approximately 85% at
setting 6). If the temperature of the seat is below 15 °C (59 °
F), the fans in the seat will not work. The fans for the seat and
the backrest only work when the seat is warmer than 15 °C
(59 °F) (the heating element heats the seat when the seat
ventilation is on) using the Vehicle Diagnostic Tester in the
"Guided Fault Finding" function (for example, for the Vehicle
Electrical System Control Module - J519- , the Memory Seat/
Steering Column Adjustment Control Module - J136- and the
Front Passenger Memory Seat Control Module - J521- , de‐
pending on the vehicle). Refer to ⇒ Body Interior; Rep. Gr.
72 ; Front Seats and ⇒ Body Interior; Rep. Gr. 74 ; Front Seat
Covers and Cushions (for the allocation of seat components).
♦ The seat heating activation depends on the version of the Cli‐
matronic Control Module - J255- installed (three- or six setting
seat heating or seat ventilation) and on the selected seat heat‐
ing setting and the measured value of the seat temperature
sensor (in setting 1 up to approximately 18 °C (64 °F) and in
setting 3 or 6 up to approximately 40/60 °C (104/140 °F)) using
the Vehicle Diagnostic Tester in the "Guided Fault Finding"
function. (for example, for the Vehicle Electrical System Con‐
trol Module - J519- , the Memory Seat/Steering Column Ad‐
justment Control Module - J136- and the Front Passenger
Memory Seat Control Module - J521- , depending on the ve‐
hicle) and ⇒ Body Interior; Rep. Gr. 72 ; Front Seats and ⇒
Body Interior; Rep. Gr. 74 ; Front Seat Covers and Cushions
(for the allocation of seat components).
♦ In seat ventilation mode, the seat is heated up depending on
the selected seat temperature setting and the measured seat
temperature (measured value of the temperature sensor in the
seat surface). Also, at a low seat temperature, the output of
the blower fan installed in the seat can be reduced using the
Vehicle Diagnostic Tester in the "Guided Fault Finding" func‐
tion. (for example, for the Vehicle Electrical System Control
Module - J519- , the Memory Seat/Steering Column Adjust‐
ment Control Module - J136- and the Front Passenger Mem‐
ory Seat Control Module - J521- , depending on the vehicle).

♦ The activation of the seat ventilation is controlled by different

control units depending on the vehicle version and equipment
level. The Climatronic Control Module - J255- A/C display and
control head sends the information to the respective control
module via the selected seat ventilation setting and via the
Convenience Data Bus system (depending on the version of
the vehicle and the equipment level, it is sent to the Memory
Seat/Steering Column Adjustment Control Module - J136- ,
the Passenger Memory Seat Control Module - J521- and the
Vehicle Electrical System Control Module - J519- ). Refer to
The Memory Seat/Steering Column Adjustment Control Mod‐
ule - J136- , and the Passenger Memory Seat Control Module
- J521- then directly activate, for example, the different blow‐
ers installed in the seats. Via a LIN Bus, the Vehicle Electrical
System Control Module - J519- first activates the Right Front
Seat Ventilation Control Module - J799- and if necessary, the
Left Front Seat Ventilation Control Module - J800- (depending
on the equipment level); and the Right Front Seat Ventilation
Control Module - J799- and the Left Front Seat Ventilation
Control Module - J800- (if necessary) then activate, for exam‐
ple, the different blowers installed in the seats. Refer to ⇒ Wir‐
ing diagrams, Troubleshooting & Component locations and
use the Vehicle Diagnostic Tester in the "Guided Fault Find‐
ing" function. For the Vehicle Electrical System Control Mod‐
ule - J519- , the Memory Seat/Steering Column Adjustment
Control Module - J136- and the Front Passenger Memory Seat
Control Module - J521- .
1.4 Rear Window Defogger
Note
♦ Various vehicle electrical components (for example, Rear Win‐

dow Defogger - Z1- and heated seats) that do not belong to
the heater are activated by the Climatronic Control Module -
J255- A/C display and control head. On the Rear Window
Defogger - Z1- , for example, the turn on request is sent via
the Data Bus to the Comfort System Central Control Module -
J393- , the Comfort System Central Control Module - J393-
then controls the Rear Window Defogger - Z1- via the Rear
Window Defogger Relay - J9- . Refer to ⇒ Wiring diagrams,
Troubleshooting & Component locations. Electrical testing of
these components must be performed as described in Guided
Fault Finding for the A/C system and the Comfort System
Central Control Module - J393- using the Vehicle Diagnostic
Tester in the "Guided Fault Finding" function.
♦ If there is a condition that the rear window defogger may not
be switched on (short circuit in the connection to the Rear
Window Defogger Relay - J9- , interruption in the power supply
to the Comfort System Central Control Module - J393- etc.),
this will be stored as a malfunction in the Comfort System
Central Control Module - J393- and the information will be sent
via the Data Bus to the Climatronic Control Module - J255- A/
C display and control head; this must be read in the DTC
memory in the Comfort System Central Control Module -
J393- , using the Vehicle Diagnostic Tester in the "Guided
Fault Finding" function. The Rear Window Defogger - Z1- ac‐
tivation is displayed in the Comfort System Central Control
Module - J393- measured value block, using the Vehicle Di‐
agnostic Tester in the "Guided Fault Finding" function.
♦ If the current at the Vehicle Electrical System Control Module
- J519- or the measured current on terminal “30” falls below a
value stored in the Vehicle Electrical System Control Module
- J519- or in the Climatronic Control Module - J255- A/C control
and display head, the rear window heating will be switched off
completely (or the output reduced) and by doing so, the load
on the Generator - C- is reduced, using the Vehicle Diagnostic
♦ If the rear window defogger must be switched off due to low
voltage, the rear window defogger button indicator lamp in the
Climatronic Control Module - J255- A/C display and control
head stays on. If the switch-off lasts longer than 150 seconds,
then the Climatronic Control Module - J255- A/C display and
control head will switch off the indicator lamp.
♦ The Climatronic Control Module - J255- A/C display and con‐
trol head measured values block indicates that the rear win‐
dow defogger is switched on or why there is no activation
despite a request, using the Vehicle Diagnostic Tester in the
♦ The function test for the rear window defogger activation is
described in the Guided Fault Finding for the Comfort System
Central Control Module - J393- , using the Vehicle Diagnostic
Tester in the "Guided Fault Finding" function
♦ The rear window defogger stays switched on at outside tem‐
peratures up to 0 °C (32 °F) until ignition is switched off (rear
window defogger can be switched manually at anytime). If the
temperature becomes greater than 0 °C (32 °F) during a driv‐
ing period, the rear window defogger is switched off after the
operating time stored in the Climatronic Control Module -
J255- A/C display and control head has elapsed (approxi‐
mately 10 minutes). Refer to the Owner's Manual.

♦ The rear window defogger is switched off at an outside tem‐

perature higher than 0 °C (32 °F) by the Climatronic Control
Module - J255- A/C display and control head after approxi‐
mately 10 minutes (activation time depends on the coding and
the version of the Climatronic Control Module - J255- A/C dis‐
play and control head), using the Vehicle Diagnostic Tester in
cific engines as optional equipment. In vehicles with a Start/
Stop System, the rear window defogger can be switched off
while the stop function is active (to protect the Battery - A- ).
The setting for the Rear Window Defogger - Z1- activation re‐
mains stored in the Climatronic Control Module - J255- display
and control head. After the engine is started again via the Start
function, the rear window defogger is switched on again, using
function.
1.5 Notes on A/C System Control and Reg‐

ulation In Passenger Compartment
Note
♦ If there is a malfunction in the A/C system, first check the DTC

memory of the Climatronic Control Module - J255- A/C display
and control head, using the Vehicle Diagnostic Tester in the
"Guided Fault Finding" function. If a different control module
displays a message to read the DTC memory, also read the
DTC memory for this control module (for example, the Vehicle
Electrical System Control Module - J519- , the Comfort System
Central Control Module - J393- ); certain A/C system compo‐
nents (for example, the A/C Compressor Regulator Valve -
N280- , the A/C Pressure/Temperature Sensor - G395- ) are
no longer activated directly by the Climatronic Control Module
- J255- A/C display and control head and their measuring val‐
ues are no longer evaluated directly by the Climatronic Control
Module - J255- A/C display and control head.
♦ If no fault is displayed, read the measured value block for the
head and activate the potentially defective component with the
“output diagnosis test mode” function, using the Vehicle Diag‐
nostic Tester in the "Guided Fault Finding" function.
♦ The function “electrical testing” is not described in this repair
manual. Perform an electrical test via the “Guided Fault Find‐
ing” function, here can notes also be found on the functions
which should be tested, using the Vehicle Diagnostic Tester
in the "Guided Fault Finding" function.
♦ Temperature-dependent resistance values of the various tem‐
perature sensors are stored in one table, these can be called
up via the “Guided Fault Finding” function, using the Vehicle
♦ Electrical checking of the various control motors is described
in the guided fault-finding, using the Vehicle Diagnostic Tester
♦ Repair work on refrigerant circuit are described. Refer to
⇒ “2 Refrigerant Circuit”, page 150 .
♦ Perform the following work after completing repairs, using the

tion:
– Check the DTC memory of Climatronic Control Module - J255-

A/C display and control head and erase any errors displayed.
– Check the coding of the Climatronic Control Module - J255- A/
C display and control head.
– Check the adaptation of the Climatronic Control Module -
J255- A/C display and control head.
– Perform a basic setting on the A/C system.
Refer to
⇒ “1.2 Overview - Components Inside Front Passenger Compart‐
ment”, page 135
1.6 Notes on A/C System Control and Reg‐

ulation outside Passenger Compart‐
ment
⇒ “1.6.1 Notes on Components Outside Passenger Compart‐
ment, All Versions”, page 14
⇒ “1.6.2 Notes on Components Outside Passenger Compart‐
ment, Vehicles with High Voltage System”, page 17
1.6.1 Notes on Components Outside Passen‐

ger Compartment, All Versions
Note

♦ The electrical test of the different actuators is described in
Guided Fault Finding, using the Vehicle Diagnostic Tester in

♦ Perform the following work after completion of repair opera‐

tions:
– Check the DTC memory of the Climatronic Control Module -
J255- A/C display and control head and erase any displayed
malfunctions, using the Vehicle Diagnostic Tester in the "Gui‐
ded Fault Finding" function.
C display and control head, using the Vehicle Diagnostic Test‐
er in the "Guided Fault Finding" function.
J255- A/C display and control head, using the Vehicle Diag‐
– Perform a basic setting on the A/C system, using the Vehicle
Note
♦ Components on the outside of the passenger compartment,

which are only present for vehicles with a high voltage system
(hybrid vehicles) or those for vehicles without a high voltage
system vary. Refer to
⇒ “10.1 Overview - Components Outside of Passenger Com‐
partment”, page 671 .
♦ For removing and installing the coolant hoses from connec‐
tions to A/C heater core. Refer to
⇒ “5.19 Heater Core, Removing and Installing”, page 567 .
♦ Incorporation of the A/C heater core in the engine coolant cir‐
cuit. Refer to ⇒ Rep. Gr. 19 ; Cooling System/Coolant;
Connection Diagram - Coolant Hoses .
♦ Depending on vehicle production period, connection points
may be installed in refrigerant lines on certain versions (not
planned at this time, introduction not yet finalized). Refer to the
Parts Catalog. Like the connections to various components,
these connection points may only be loosened and opened
when the refrigerant circuit is empty. Refer to
⇒ “2.1 Overview - Refrigerant Circuit”, page 150 and ⇒ Re‐
frigerant R134a Servicing; Rep. Gr. 87 ; A/C System General
Information or ⇒ A/C Systems with Refrigerant R1234yf -
General Information; Rep. Gr. 87 ; Refrigerant Circuit; Over‐
view - Refrigerant Circuit Components .
♦ For vehicles with a 6-Cylinder gasoline engine and other en‐
gines with certain optional equipment (such as vehicles with
the Start/Stop system) but without a “Parking Heater”, a Cool‐
ant Recirculation Pump - V50- (a Water Pump - V36- ) is
installed. Refer to ⇒ , page 132 and ⇒ Rep. Gr. 19 ; Coolant
Pump/Thermostat .
♦ Depending on the version of the Climatronic Control Module -
J255- A/C display and control head, the Coolant Recirculation
Pump - V50- may be referred to as Water Pump - V36- in Gui‐
ded Fault Finding, using the Vehicle Diagnostic Tester in the
♦ The Coolant Recirculation Pump - V50- ( Water Pump - V36- )
version and activation differ depending on the vehicle version
and production period. From MY 2012 as a running change,
the pumps installed from the start of production, which were
activated via a 500 Hertz signal (500 pulses per second), are
being replaced by pumps that are activated by a variable (100
to 500 Hertz) signal depending on the engine. Pumps that are
activated by a variable signal are also equipped with a diag‐
nostic function and are activated mostly via the respective
engine control module. Therefore, ensure the correct alloca‐
tion (only the allocated pump can be activated), using the
tion. Refer to ⇒ Wiring diagrams, Troubleshooting & Compo‐
nent locations and to the Parts Catalog.

1.6.2 Notes on Components Outside Passen‐

ger Compartment, Vehicles with High
Voltage System
Note

♦ The electrical test of the different actuators is described in
Guided Fault Finding, using the Vehicle Diagnostic Tester in
♦ Perform the following work after completion of repair opera‐

tions:
malfunctions, using the Vehicle Diagnostic Tester in the "Gui‐
C display and control head, using the Vehicle Diagnostic Test‐
J255- A/C display and control head, using the Vehicle Diag‐
– Perform a basic setting on the A/C system, using the Vehicle
Observe all of the additional warnings for all work performed on
vehicles with the high voltage system. Refer to
⇒ “2.2 High Voltage Vehicles Safety Precautions”, page 36 and
⇒ Electrical System Hybrid; Rep. Gr. 93 ; High Voltage System
General Warnings .
WARNING
Risk of unintended engine start

The ignition must be turned off and the ignition key must remain
outside of the vehicle when working on vehicles with a high
voltage system.
WARNING
Handling high voltage cables:

• Do not stand on or place tools on high voltage cables and
their components as it may damage the cable insulation.
• Never bend or kink high voltage cables forcefully as it may
damage the cable insulation.
• The round high voltage connectors are color coded with
an external color ring and are mechanically coded using
the guide- or code tabs. Always make certain that the cod‐
ing matches when connecting the round connector in
order to avoid any mechanical damage the high voltage
connector.

DANGER!
There is a risk of electrocution from damaged high voltage

components.
Observe the following when working around high voltage com‐
ponents and high voltage wires:
♦ Never work around high voltage components and cables
with cutting, deformed, or sharp edged tools, or heat sour‐
ces such as welding or soldering tools, heated air, and
thermal glue.
♦ Inspect the high voltage components visually before be‐
ginning.
♦ Perform a visual inspection of the Electric Drive Power and
Control Electronics - JX1- , the Electro-Drive Drive Motor
- V141- , the Electrical A/C Compressor - V470- and the
high voltage lines when working in the engine compart‐
ment.
♦ Perform a visual inspection of the high voltage lines and
covers when working on the underbody.
the Electrobox with the High Voltage System Maintenance
Connector - TW- when working in the luggage compart‐
ment.
♦ Perform a visual inspection on all of the potential equali‐
zation cables.
Observe the following items when performing the visual in‐
spection:
♦ The components do not display any signs of external dam‐
age.
♦ The high voltage cable insulation and the potential equal‐
ization cables are not damaged.
♦ The high voltage cables do not display any abnormal de‐
formations.
♦ Every high voltage component is marked with a red warn‐
ing label.
1.7 Notes on Refrigerant Circuit

On Vehicles with a High Voltage System (Hybrid Vehicles)
General Warnings .
WARNING

voltage system.
WARNING

connector.
DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
If it is necessary to perform work in the vicinity of high voltage

components, perform a “visual inspection” of the high voltage
components and cables for damages and follow the “warnings
when working on the high voltage system”. Refer to
⇒ “2.2.2 Performing a Visual Inspection of Damage to High Volt‐

age Components and Cables”, page 41 and ⇒ Electrical Sys‐

tem Hybrid; Rep. Gr. 93 ; High Voltage System General
Warnings .
If it is necessary to perform work on the high voltage system com‐
ponents, de-energize the high voltage system. Refer to ⇒ Elec‐
trical System Hybrid; Rep. Gr. 93 ; High Voltage System, De-
Energizing and read and follow the “high voltage electrical system
general warnings” ⇒ Electrical System Hybrid; Rep. Gr. 93 ; High
Voltage System General Warnings .
Note
The A/C Compressor Control Module - J842- integrated in the

electrically-driven A/C compressor regulates the blower speed
and therefore the A/C compressor output ( Electrical A/C Com‐
pressor - V470- ).
For Vehicles without a High Voltage System
Note
♦ The A/C compressor without an A/C Clutch - N25- is always

driven when the engine is running. If the vehicle has an A/C
compressor without an A/C Clutch - N25- , then the vehicle
may only be started when the refrigerant circuit has been
properly assembled. For example; if the refrigerant lines are
not connected to A/C compressor, when the engine is running
the A/C compressor may heat up (via internal heat generation)
so much that the A/C compressor will be damaged. Such in‐
ternal heat generation results from the fact that - even with
delivery near 0% - the A/C compressor is confronted with a
fixed resistance (sealed circuit).
♦ An A/C compressor with an A/C Clutch - N25- is installed as a
running change on certain 4-Cylinder vehicles from MY 2012.
Refer to
⇒ “3.7.3 Belt Pulley, Removing and Installing, A/C Compressor
with A/C Clutch N25 ”, page 379 . The A/C clutch turns off the
A/C compressor drive completely under certain conditions (for
example “ECON”). The correct Climatronic Control Module -
J255- version must be installed and coded correctly so that the
A/C Clutch - N25- can be activated by the Climatronic Control
Module - J255- display and control head. Refer to the Parts
Catalog and use the Vehicle Diagnostic Tester in the "Guided
Fault Finding" function.
♦ To stop the A/C compressor being destroyed when the refrig‐
erant circuit is empty, it is designed such that delivery is
reduced to roughly 0% and lubrication is maintained by way of
an internal oil circuit with the oil left in the A/C compressor.
All Vehicles
Note
♦ No refrigerant may be added to the refrigerant circuit (dis‐

charge, evacuate and fill the circuit). Refer to
icing; Rep. Gr. 87 ; Refrigerant Circuit (Refrigerant R134a
Servicing, Refrigerant Circuit, Working with A/C Service Sta‐
tion) or ⇒ A/C Systems with Refrigerant R1234yf - General
Information; Rep. Gr. 87 ; Working with A/C Service Station
♦ The entire amount of refrigerant oil to be added to the refrig‐
erant circuit is located in the replacement compressor. Refer
to ⇒ “4 Technical Data”, page 110 , ⇒ Refrigerant R134a
Servicing; Rep. Gr. 87 ; Refrigerant R134a Capacities; Re‐
frigerant Oil and Approved Refrigerant Oils or ⇒ A/C Systems
with Refrigerant R1234yf - General Information; Rep. Gr. 87 ;
Working with A/C Service Station .
♦ Different refrigerant oils are required for A/C compressors
made by Denso, Sanden and Zexel/Valeo. Refer to
Oil and Approved Refrigerant Oil (Refrigerant R134a Servic‐
ing; Refrigerant R134a Capacities, Refrigerant Oil and Ap‐
proved Refrigerant Oil), ⇒ A/C Systems with Refrigerant
R1234yf - General Information; Rep. Gr. 00 ; Technical Data
and the Parts Catalog.
♦ Coat the O-ring seals lightly with refrigerant oil prior to instal‐
lation. Refer to ⇒ “3.13 Refrigerant Circuit Seals”, page 109 .
♦ The specified diameters for O-rings and the tightening speci‐
fication pertain also to the threaded connections of the refrig‐
erant lines or refrigerant hoses between the separate
components.
♦ Only install O-rings that are approved for refrigerant R134a.
Refer to ⇒ “3.13 Refrigerant Circuit Seals”, page 109 , ⇒ Re‐
frigerant R134a Servicing; Rep. Gr. 87 ; A/C System General
General Information; Rep. Gr. 87 ; Refrigerant Circuit; Over‐
view - Refrigerant Circuit Components and the Parts Catalog.
♦ Check the cooling output. Refer to
⇒ “3.8 Cooling Output, Checking”, page 73 .
♦ Check the pressures in the refrigerant circuit. Refer to ⇒ Re‐
frigerant R134a Servicing; Rep. Gr. 87 ; Refrigerant Circuit
(Refrigerant R134a Servicing, Refrigerant Circuit, Working
with A/C Service Station) or ⇒ A/C Systems with Refrigerant
R1234yf - General Information; Rep. Gr. 87 ; Working with A/
C Service Station .
♦ All other maintenance and testing procedures on the refriger‐
ant circuit not described in this repair manual. Refer to ⇒
Refrigerant R134a Servicing; Rep. Gr. 87 ; A/C System Gen‐
eral Information or ⇒ A/C Systems with Refrigerant R1234yf
- General Information; Rep. Gr. 87 ; Refrigerant Circuit; Over‐
view - Refrigerant Circuit Components .
♦ Operate the A/C system after charging the refrigerant circuit.
Refer to
⇒ “2.23 A/C System, Starting Operation after Filling Refriger‐
ant Circuit”, page 282 .

♦ From the start of production up to the change-over from MY

2012, evaporators approximately 40 mm wide (block depth)
were installed (A/C unit part number “8K_ 820 005”). From MY
2012 as a running change, an evaporator with an approxi‐
mately 50 mm width (block depth) is being installed depending
on the vehicle version (A/C unit part number “8T_ 820 005”).
Pay attention to the correct allocation of the expansion valve
to the evaporator (there are different versions). Refer to the
Parts Catalog.
1.8 Notes on Front Heater and A/C Unit

Levers and Connecting Elements on the A/C Unit. Refer to
⇒ , page 25 .
“Convenience” Versions of the A/C Unit and Air Distribution Hous‐
ing. Refer to ⇒ , page 25 .
Observe the notes for control and regulation of components in
passenger compartment. Refer to
⇒ “1.5 Notes on A/C System Control and Regulation In Passenger
Compartment”, page 13 .
There are different version of the A/C unit (for left- and right-hand
drive vehicles, vehicles equipped with the “Convenience” A/C
system version or the “Basis” version etc.). Refer to the Parts
Catalog.
Note
♦ There is a label -A- on the outside of the A/C unit with a part
number -B- that tells which version is installed. Refer to the
Parts Catalog.
♦ The part number -B- on the label -A- can be read, for example,
when the CD changer is removed (depending on the vehicle
equipment level). Refer to ⇒ Communication; Rep. Gr. 91 ;
DVD/CD Changer; CD Changer, Removing and Installing .
♦ Refer to
⇒ “4.1.1 Overview - Front Actuators, Basis Version”,
page 388
♦ Refer to
⇒ “4.1.2 Overview - Front Actuators, Convenience Version”,
page 398
Note
♦ Air guide in air conditioner and in vehicle. Refer to

⇒ “6 Air Guide”, page 581 .
♦ Air Conditioner, Removing and Installing. Refer to
⇒ “5.11 Heater and A/C Unit, Removing and Installing”,
page 520 .
♦ A/C air intake housing, removing and installing. Refer to
⇒ “5.12 Heater and A/C Unit Air Intake Housing, Removing
and Installing”, page 537 .
♦ On this vehicle, the different actuators on the A/C unit are
adapted and activated via a data wire. The different actuators
are connected in sequence to the Climatronic Control Module
- J255- A/C display and control head via this data wire (LIN
Bus). The sequence differs between the different A/C unit ver‐
sions. Refer to
⇒ “1.10 Main Wiring Diagram for A/C System Actuators”, page
30 and ⇒ Wiring diagrams, Troubleshooting & Component
locations.
♦ From 01/2008, A/C units which have an additional connection
for the glove compartment cooling are being installed as a
running change. On vehicles without glove compartment cool‐
ing, this connection is sealed with a plug. Refer to
⇒ “6.14 Glove Compartment Cooling Connection on Air Intake
Housing”, page 616 .
♦ Depending on the production date, there are different versions
of the levers and connecting elements on the A/C unit. Refer
to ⇒ , page 25 and the Parts Catalog.
♦ Revised A/C units are gradually being installed from MY 2012
(use depends on the vehicle version) (A/C unit part number
“8T_ 820 005”). With the introduction of these A/C units, other
actuators are also being installed. The actuator different ver‐
sions can currently be installed on both A/C unit versions
(interchanging is currently permitted). Refer to the Parts Cat‐
alog and use the Vehicle Diagnostic Tester in the "Guided

Note
Depending on the production date, there are different versions of

the levers and connecting elements on the A/C unit. Refer to
⇒ , page 25 and the Parts Catalog.
Levers and Connecting Elements on the A/C Unit
Note
There are different versions of the levers and connecting ele‐

ments on the A/C unit. At the start of production, the levers -A-
were installed with a closed pin and the connecting rod -B-. In MY
2008, the levers -C- have a slotted pin and connecting rod -D-.
When replacing, be sure to use the correct version. Refer to the
Parts Catalog.
“Convenience” A/C Unit Versions and Air Distribution Housing

Different Versions Installed Only on the “Convenience” A/C Sys‐
tem Version (Up to and from 08/2007 with Running Change)
Note
♦ On the “Basis” A/C system version, the A/C unit and the air
distribution housing were not changed in 2007.
♦ From 08/2007, the “Convenience” A/C unit versions with an
air distribution housing with optimized air distribution are in‐
troduced as a running change (versions “2”). Refer to the Parts
Catalog. Both versions of the A/C unit can be differentiated
from the outside by a decal -A- with the part number -B- .
♦ Pay attention to the correct allocation and adaptation of the
Climatronic Control Module - J255- display and control head
to the A/C unit (version “1” or “2”, with and without optimized
air distribution in the air distribution housing). Refer to
⇒ “8.1 Display and Control Head Location”, page 629 ( Cli‐
matronic Control Module - J255- A/C display and control head,
removing and installing).
Versions of the “Convenience” A/C Unit:
♦ A/C unit (part number “8K1 820 005”) up to index “S” (version
“1”, without optimized air distribution in the air distribution
housing).
♦ A/C unit (part number “8K1 820 005”) starting with the index
“AB” (version “2”, with optimized air distribution in the air dis‐
tribution housing).
♦ The versions of the A/C unit (with and without optimized air
distribution in the air distribution housing) can be different on
the tearing edge -G- in the installed condition with the footwells
removed and footwell door open -H- (left or right). The tearing
edge -G- is only on version “2” .
♦ As a replacement part, only the air distribution housing -A- of
version “2” (with optimized air distribution) are delivered. Refer
to the Parts Catalog.
Distinguishing Characteristics of Versions “1” and “2” Of the Air
Distribution Housing -A-
Air distribution housing -A- (versions “1”)
♦ Left and right air guide -B- approximately 12 mm wide without
tearing edge
♦ Separators -D- in the warm air guides to the left and right rear
footwells together, approximately 70 mm wide
♦ Left and right lower separators -F- without tearing edge
Air distribution housing -A- (versions “2”)
♦ Left and right air guide -C- approximately 20 mm wide without
an additional tearing edge
♦ Separators -E- in the warm air guides to the left and right rear
footwells together, approximately 35 mm wide
♦ Left and right lower separators with additional tearing edge
-G-
1.9 Notes on Display and Control Head

– Climatronic Control Module - J255- A/C display and control
head, removing and installing. Refer to
⇒ “8.2 Display and Control Head, Removing and Installing”,
page 636 .

Note

trol heads cannot currently be interchanged as usual; the
component protection is in effect. The component protection
(anti-theft protection) can only be canceled by entering spe‐
cific vehicle data, using the Vehicle Diagnostic Tester in the
"Guided Fault Finding" function
♦ If a Climatronic Control Module - J255- A/C display and control
head with active component protection (anti-theft system) is
installed in a different vehicle, only the functions necessary for
vehicle safety can be selected. Convenience functions can no
longer be selected. Refer to Vehicle Diagnostic Tester in the
♦ When replacing a Climatronic Control Module - J255- A/C dis‐
play and control head, pay attention to the exact allocation.
Different versions for vehicles with the “Basis” A/C system
version or the “Convenience” A/C system version, for vehicles
with left-hand driver or right-hand drive; with or without buttons
for seat heating and/or seat ventilation, etc. Refer to the Parts
Catalog
♦ The setting for the seat heating and ventilation is adjusted on
head; this adjustment is transmitted to the Vehicle Electrical
System Control Module - J519- via the Data Bus. The target
temperatures for the different seat heating and seat ventilation
settings are stored in the Vehicle Electrical System Control
Module - J519- . Depending on the version of the Vehicle
Electrical System Control Module - J519- and on the vehicle
date of manufacture, the specified temperature for the seat
heating and ventilation can be different with the same setting
control head, using the Vehicle Diagnostic Tester in the "Gui‐
ded Fault Finding" function (for the Vehicle Electrical System
♦ If a new Climatronic Control Module - J255- A/C display and
control head was installed and basic setting was not per‐
formed, the A/C system regulation is limited and this is dis‐
played in the DTC memory as a malfunction. After installing
head, perform the basic setting for the A/C system according
to specification, using the Vehicle Diagnostic Tester in the
trol head buttons, display and knobs are illuminated by LEDs
(the LEDs cannot be replaced).
♦ The function and indicator lamps in the buttons and in the
knobs cannot be replaced separately.
♦ If the Instrument Panel Temperature Sensor - G56- measure‐
ment is incorrect, check the Climatronic Control Module -
J255- A/C display and control head intake grille trim (it must
not be closed) and the function of the Interior Temperature
Sensor Fan - V42- , using the Vehicle Diagnostic Tester in the
♦ The selected functions are displayed when the function and
indicator lamps in the various Climatronic Control Module -
J255- A/C display and control head buttons, knobs or display
fields light up.

J255- A/C display control head, the currently selected func‐
tions will appear only on the Multi Media Interface (MMI)
display (on the “Basis” version) or on the Climatronic Control
Module - J255- A/C display control head display and on the
Multi Media Interface (MMI) display (MMI, on “Convenience”
version). The duration of display can be adjusted via the Gui‐
ded Fault Finding “Adaptation” function for the Climatronic
Control Module - J255- A/C display and control head, using
function.
♦ If no malfunction is stored and the Climatronic Control Module
- J255- A/C display and control head is not working, check the
adaptation (the function may be switched off by adjusting the
function). If necessary, reset the adaptations in all adaptation
channels to the manufacturer setting, using the Vehicle Diag‐
♦ If there is a condition, where the heating or ventilation of the
driver of passenger seat cannot be switched on, this will be
stored as a malfunction in the Vehicle Electrical System Con‐
trol Module - J519- , in the Memory Seat/Steering Column
Adjustment Control Module - J136- or in Front Passenger
Memory Seat Control Module - J521- (depending on the ve‐
hicle type and the vehicle equipment level). Currently no in‐
formation is sent to the Climatronic Control Module - J255- A/
C display and control head via the Data Bus system; the DTC
memory must be read out in each control unit or in the Comfort
System Central Control Module - J393- , using the Vehicle Di‐
agnostic Tester in the "Guided Fault Finding" function. In the
event of a complaint regarding seat heating or seat ventilation,
first check the DTC memory of the control modules activating
the seat heating and seat ventilation.
cific engines as optional equipment. On vehicles with Start/
Stop system, the Climatronic Control Module - J255- display
and control head prevents the Stop function depending on the
setting. If, for example, “defrost” is selected, the stop function
is not possible or will be interrupted and the engine will start.
The same applies in the case of heating and cooling. The dif‐
ference between the selected and actual temperature exceeds
a certain value, using the Vehicle Diagnostic Tester in the
♦ Vehicles with the Start/Stop System have an additional cool‐
ant pump for the Stop function depending on the vehicle
equipment level and on the version of the vehicle. Refer to, ⇒
Rep. Gr. 19 ; Coolant Pump/Thermostat and use the Vehicle
♦ On the Audi Q5, the Climatronic Control Module - J255- -A-

display and control head has additional trim -B-.

Note
♦ As a replacement part, the trim piece -B- is supplied with a two-

sided adhesive strip already installed -C-. Refer to the Parts
Catalog.
♦ If the trim -B- is going to be reused when replacing the display
and control unit, the Climatronic Control Module - J255- -A- is
also reused. Remove the adhesive strip -C- from the trim -B-.
Clean the adhesive surface on the trim -B- as described in the
instructions which came with the adhesive strip. Affix to the
trim piece -B- a strip (dimension: 204 mm x 10 mm) of the two-
sided adhesive tape -C- with material strength approximately
1.2 mm (for example with adhesive tape D 438 515 A1. Refer
to the Parts Catalog).
♦ At the start of production, this trim piece -B- is secured by clips
-C- into the openings -D- in the Climatronic Control Module -
J255- -A- display and control head. Later, the trim piece -B-
was redesigned so that it can be secured by a suitable two-
sided adhesive tape. The retaining tabs -F- are no longer on
these trim pieces -B-. Refer to the Parts Catalog.
♦ Since the openings -D- and slits -E- are no longer being used,
the trim piece -B- is only supplied as a replacement part in the
version that is secured with two-sided adhesive tape on the
Climatronic Control Module - J255- -A- display and control
head. Refer to the Parts Catalog
1.10 Main Wiring Diagram for A/C System

Actuators
Note
♦ Revised A/C units are gradually being installed from MY 2012

(use depends on the vehicle version) (A/C unit part number
“8T_ 820 005”). With the introduction of these A/C units, other
actuators are also being installed. The actuator different ver‐
sions can currently be installed on both A/C unit versions
(interchanging is currently permitted). Refer to the Parts Cat‐
alog and use the Vehicle Diagnostic Tester in the "Guided
♦ On this vehicle, the different actuators (-A- through -N-) on the
A/C unit are adapted and activated via a data wire. The differ‐
ent actuators (-A- through -N-) are connected in sequence to
head via this data wire (LIN Bus). If there is a malfunction on
one actuator or in the wiring, this malfunction can lead to dif‐
ferent malfunction entries with different malfunction types,
ing" function. Refer to ⇒ Wiring diagrams, Troubleshooting &
Component locations.
♦ The number of actuators on the A/C unit depends on the A/C
system version (on the “Basis” A/C system there are six ac‐
tuators, and on the “Convenience” A/C system there are 10
actuators). Refer to ⇒ Wiring diagrams, Troubleshooting &
♦ The sequence of the actuators in the wiring depends on the A/
C version (“Basis” or “Convenience” and on the vehicle ver‐
sion. Refer to ⇒ Wiring diagrams, Troubleshooting & Compo‐
nent locations. On vehicles equipped with the “Convenience”
A/C system, the Left Temperature Door Motor - V158- is in‐
stalled, for example, at position -A- . On vehicles with the
“Basis” A/C system, the Temperature Regulator Door Motor -
V68- is installed at position -A-. Refer to ⇒ Wiring diagrams,
Troubleshooting & Component locations.
Dependent on the operating condition or the function of the A/C

system Guided Fault Finding in which a malfunction appears, the
effect of the malfunction and the type of malfunction stored in the
DTC memory is different, using the Vehicle Diagnostic Tester in
♦ If there is a malfunction in the actuators sequence (two or more
terminals or actuators were interchanged while being instal‐
led)
– If these actuators were improperly adapted during the basic
setting and the activation of the doors is incorrect (incorrect
assignment)
– Depending on the adjustment range for this actuator, an in‐
correct end stop is recognized during the basic setting and this
is stored as a malfunction in the event memory, and the basic
setting is terminated.
– If the wrong door moves, then the air flow direction is incorrect.
This is not always recognized as a fault depending on the ad‐
justment range of the actuator. Always mark all connectors
before disconnecting them and perform a basic setting after
connecting them.
♦ If there is a malfunction in normal A/C system operation, then
the following DTC memory entries can result, depending on
the type of malfunction.

– If there is a malfunction in the positive or ground connection

to an actuator, then this actuator can no longer exchange in‐
formation with the Climatronic Control Module - J255- A/C
display and control head and this actuator will store this in the
DTC memory.
– If there is a malfunction in the data wire to an actuator (for
example, an interruption in the connector to the contact “2” of
the actuator -B-), then this actuator and all the connected ac‐
tuators (-C- through -N-) in the sequence switching after this
actuator can no longer exchange information with the Clima‐
tronic Control Module - J255- A/C display and control head;
this actuator as well as all the other connected actuators will
be stored in the DTC memory.
– If a malfunction occurs in the actuator electronics (for example,
in actuator -B-), the actuator -B- can possibly still exchange
information with the Climatronic Control Module - J255- A/C
display and control head, depending on the type of malfunc‐
tion, however all the actuators connected after this one (-C-
through -N-) will be stored in the DTC memory.
♦ If there is a malfunction during the basic setting of the A/C
system, then the following malfunction entries can result, de‐
pending on the type of malfunction.
– If there is a malfunction in the positive or ground connection
to an actuator, (for example to actuator -B-), then this actuator
cannot exchange information with the Climatronic Control
Module - J255- A/C display and control head and it will not be
recognized during the basic setting. During the basic setting,
all the actuators from the last actuator beginning with -N- are
re-allocated and re-assigned; this actuator is no longer in se‐
quence. The Climatronic Control Module - J255- A/C display
and control head recognizes that an actuator is missing and
saves the first actuator in the sequence switching as missing
(for example, on left-hand drive vehicles equipped with the
“Convenience” A/C system, the Left Temperature Door Motor
- V158- ); moreover, the malfunction will display as “Automatic
Addressing Malfunctioning” and possibly by certain actuators
“Upper or Lower Values Exceeded”.
– If there is a malfunction in the data wire to an actuator (for
example, an open circuit in the connector to contact “2” of ac‐
tuator -C-), this actuator and all connected actuators in the
sequence switching after this one can no longer exchange in‐
formation with the Climatronic Control Module - J255- A/C
display and control head, and these actuators are not recog‐
nized during the basic setting. During the basic setting, all the
actuators from the last actuator beginning with -N- are re-al‐
located and re-assigned; these actuators are no longer in
sequence. The Climatronic Control Module - J255- A/C display
and control head recognizes that several actuators are miss‐
ing (only actuators -B- -A- are recognized and incorrectly
assigned and adapted as the Airflow Door Motor - V71- and
Recirculation Door Motor - V113- ). All other actuators (for ex‐
ample, on vehicles equipped with the “Convenience A/C unit”
A/C system, from the Right Footwell Door Motor - V109- up to
the Left Temperature Door Motor - V158- ) are stored in the
DTC memory as missing and the malfunction is displayed as
“Automatic Addressing malfunctioning”.
– If a malfunction occurs in the actuator electronics or during the

basic setting (for example, in actuator -C-), this actuator may
still be able to exchange information with the Climatronic Con‐
trol Module - J255- A/C display and control head, depending
on the type of malfunction. However, no data can be ex‐
changed with all actuators connected after this one (up to
actuator -N-). The Climatronic Control Module - J255- A/C dis‐
play and control head recognizes that several actuators are
missing (only actuators -C- up to -A- are recognized and in‐
correctly assigned and adapted as Recirculation Door Motor -
V113- , Airflow Door Motor - V71- and Right Footwell Door
Motor - V109- ). All other actuators (for example, on vehicles
equipped with the “Convenience A/C unit” A/C system, from
the Right Center Vent Motor - V111- up to the Left Tempera‐
ture Door Motor - V158- ) are stored in the DTC memory as
missing and the malfunction is displayed as “Automatic Ad‐
dressing malfunctioning”.

2 Safety Precautions
⇒ “2.1 Safety Precautions when Handling Refrigerant”,
page 33
Q5 Hybrid
⇒ “2.2 High Voltage Vehicles Safety Precautions”, page 36
Q5 Hybrid
⇒ “2.3 Start/Stop System Safety Precautions”, page 43
⇒ “2.4 Safety Precautions during Road Test with Testing Equip‐
ment”, page 43
⇒ “2.5 Safety Precautions when Working on Cooling System”,
page 44
2.1 Safety Precautions when Handling Re‐

frigerant
The assemblies and line system of the A/C system are filled with
the following refrigerant:
Note
Refrigerant R134a is added to vehicles which were manufactured

through calendar week 5/30/2016. Depending on the version of
vehicles which are manufactured from 5/30/216, either refrigerant
R134a or refrigerant R1234yf is added. Refer to
⇒ “1.1 Type Labels”, page 2 and
⇒ “4 Technical Data”, page 110
Refrigerant R134a
1.1.1.2 Tetrafluorethane (CF3-CH2F or CH2F-CF3)
This refrigerant is currently known under the following trade
names R134a, H-FKW 134a, SUVA 134a and KLEA 134a (other
brand names may be used in other countries).
Refrigerant R1234yf
2,3,3,3-Tetraflourprop-1-ene (C3H2F4 or CF3CF = CH2 )
This refrigerant is currently recognized under the brand name
R1234yf, HFO 1234yf, Opteon 1234yf, etc. Other brand names
may be used in other countries.
2. Safety Precautions 33
WARNING
Refrigerant 1234yf includes a gas which is combustible when

a certain percentage is present in the air (with a flammability
limit from 6.2% to 12.3% volume).
♦ Electrostatic discharge and sparks resulting from striking
tools, hot surfaces and open flames can ignite a mixture
of refrigerant R1234yf and air.
♦ There is a risk of explosion when a concentration of re‐
frigerant gas is near an ignition source.
♦ Keep any type of ignition source away from pressure res‐
ervoirs and devices with refrigerant R1234yf.
♦ When handling refrigerant and working on the refrigerant
circuit, make sure there is a good flow of oxygen (change
the air at least one time each hour in the work area and
three times per hour in enclosed spaces (for example, the
work pit).
Both Refrigerants
The following safety precautions should be observed for this re‐
frigerant (additional guidelines apply in individual countries).
Caution
Refrigerant may pose health risk!

♦ When performing repair procedures on an open refriger‐
ant circuit, first discharge the refrigerant circuit. Refer to
⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ; Refrigerant
Circuit (Refrigerant R134a Servicing, Refrigerant Circuit,
Working with A/C Service Station) or ⇒ A/C Systems with
Refrigerant R1234yf - General Information; Rep. Gr. 87 ;
♦ Only work on the refrigerant circuit in well-ventilated
areas. Ensure that there are no workshop pits, basement
staircases or shafts within a five meter radius.

WARNING
Leaking refrigerant may cause asphyxiation, frostbite, and poi‐

soning.
♦ Switch on the exhaust extracting system.
♦ Escaping refrigerant is colorless and odorless and also
heavier than air, thus displacing oxygen. If refrigerant gas
escapes, there is a risk of suffocation in poorly ventilated
areas and in workshop pits - even if it is not noticeable.
Risk of dry coughing and nausea due to toxic chemical de‐
composition products of the refrigerant gas.
♦ Do not smoke, weld, or hard-solder or soft-solder in areas
exposed to refrigerant. The high temperature of an open
flame or hot objects causes decomposition of refrigerant
gas. The resulting decomposition products are toxic.
Risk of eye injury!
♦ Keep an eye bath on hand.
♦ If liquid refrigerant has come in contact with the eyes,
thoroughly flush eyes with water for approximately 15 mi‐
nutes.
♦ Then apply eye drops and consult a doctor immediately
even if no pain is felt.
♦ Inform the doctor which type of refrigerant caused the
freezing.
Intense exposure to refrigerant on unprotected parts of the
body will result in frostbite. Avoid contact with liquid refrigerant
or refrigerant vapors!
♦ Protect hands by wearing rubber gloves.
♦ Protect eyes by wearing protective eyewear.
♦ If liquid refrigerant has come in contact with any other body
part, thoroughly flush with cool water for approximately 15
minutes.
WARNING
Danger due to refrigerant coming out under pressure.

Danger of frost bite to skin and other parts of the body.
• Evacuate the refrigerant and immediately open the refrig‐
erant circuit afterward.
• If more than 10 minutes have elapsed since evacuating
the refrigerant and the refrigerant circuit was not opened,
evacuate the refrigerant again. Pressure in the refrigerant
circuit is caused by evaporation.
2.2 High Voltage Vehicles Safety Precau‐

tions
⇒ “2.2.1 Working on Vehicles with High Voltage System (Hybrid
Vehicle)”, page 36
age Components and Cables”, page 41
2.2.1 Working on Vehicles with High Voltage

System (Hybrid Vehicle)
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
High Voltage System, Turning Off Voltage
DANGER!
Risk of electrocution
Death or serious bodily injury by electric shock.
♦ The high voltage system may only be activated by quali‐
fied personnel (Audi high voltage mechanic).
♦ Make sure that the high voltage system is completely dis‐
abled. Make sure the vehicle is de-energized using “Gui‐
ded Fault Finding” on the Vehicle Diagnostic Tester .
♦ The qualified personal (Audi high voltage technician) de‐
termines the voltage and secures the system from restart‐
ing using the Service Disconnect Lock - T40262- . Keep
the ignition key and the High Voltage System Maintenance
Connector - TW- safely with the qualified personal to se‐
cure the system from restarting.
♦ The Audi high voltage technician should put a sign on the
vehicle to identify it as a high voltage vehicle.
Note
♦ De-energize the high-voltage system:

♦ Connect the vehicle diagnostic tester.
♦ Select the Guided Fault Finding mode.
♦ Using the GO TO button, select the menu items in the following
sequence:
♦ Function/Component Selection
♦ Body
♦ Electrical Equipment
♦ OBD-capable systems
♦ 8C - Battery Regulation Control Module -J840
♦ 8C - Battery Regulation Control Module, functions
♦ 51 - De-energize the high-voltage system (Repair
Group 93)
♦ Before beginning work on the high voltage system, a high volt‐

age technician must disable the high voltage system. Refer to
⇒ Electrical System Hybrid; Rep. Gr. 93 ; High Voltage Sys‐
tem, De-Energizing .
♦ Use the respective processes for work performed on the high
voltage system, for which the system is required to be switch‐
ed on. For further information about the high voltage system.
Refer to ⇒ Electrical System Hybrid; Rep. Gr. 93 ; High Volt‐
age System General Warnings .

Note
♦ Disable the high voltage system before beginning work, for all
work performed on components of the hybrid vehicle which
are connected to the high voltage system (for example, to the
electrically-driven A/C compressor).
♦ Work performed on the A/C system, which is not directly af‐
fected by the high voltage system (for example, performing a
pressure test on the refrigerant circuit, Guided Fault Finding
for the A/C system or for the A/C Compressor Control Module
- J842- etc.), must only be performed by electrically trained
personal. Refer to ⇒ Electrical System Hybrid; Rep. Gr. 93 ;
High Voltage System General Warnings and use the Vehicle
♦ Disable the high voltage system before beginning certain work
on components of the hybrid vehicles, which are installed near
high voltage system components (for example, at the battery
cooling module, at the expansion valve for the A/C system for
the Audi Q5, etc.). Refer to ⇒ Electrical System Hybrid; Rep.
Gr. 93 ; High Voltage System, De-Energizing .
Restart the High Voltage System
DANGER!
Death or serious bodily injury by electric shock
♦ The high voltage system may only be restarted by quali‐
fied personal (Audi high voltage technicians).
♦ Make sure the vehicle is energized using the “Guided
Fault Finding” on the Vehicle Diagnostic Tester .
♦ The qualified personal (Audi high voltage technician) re‐
starts the vehicle.
Note
♦ Restart the high voltage system:

♦ Using the GO TO button, select the following menu commands
♦ Body
♦ 51 - High voltage restart (Repair Group 93)
Working on a High Voltage System When Activated or with the

Ignition Turned On
DANGER!
The engine may start unexpectedly when performing work

while the ignition is turned on or when the ready mode is acti‐
vated and may cause poisoning in enclosed spaces. Be aware
of body limbs and/or clothing when clamping or pulling.
Perform the following steps before turning on the ignition:
♦ Move the selector lever into position P.
♦ Activate the parking brake.
♦ Switch off ignition.
♦ Open the engine hood.
♦ Connect the charging unit for example Battery Charger -
VAS5903- to the battery jump start terminal for the 12V
vehicle electrical system
♦ Switch on the ignition.
Working on Vehicles with a High Voltage System

♦ If it is necessary to perform work in the vicinity of high voltage
components, perform a “visual inspection” of the high voltage
components and cables for damages and follow the “warnings
when working on the high voltage system”. Refer to
⇒ “2.2.2 Performing a Visual Inspection of Damage to High
Voltage Components and Cables”, page 41 ) and ⇒ Elec‐
trical System Hybrid; Rep. Gr. 93 ; High Voltage System
General Warnings .
♦ If it is necessary to perform work on the high voltage system
components, de-energize the high voltage system. Refer to ⇒
Electrical System Hybrid; Rep. Gr. 93 ; High Voltage System,
De-Energizing and read and follow the “high voltage electrical
system general warnings” ⇒ Electrical System Hybrid; Rep.
Gr. 93 ; High Voltage System General Warnings .
♦ Charge the vehicle battery, for example, using the Battery
Charger - VAS5903- in the battery support mode to minimize
the number of automatic starts during the test- and measuring
procedures when the ready mode is active. Refer to ⇒ Elec‐
trical Equipment; Rep. Gr. 27 ; Battery; Battery, Charging and
tem General Warnings .
♦ Move the selector level into position “P”, activate the parking
brake and arrange the necessary tools for testing and meas‐
uring procedures that require the ready mode to be active or
that require the ignition to be on, so that they cannot come into
contact with the turning components in the engine and so that
they are not in the vicinity of the turning components of a run‐
ning engine.

Note
♦ Also move the selector lever into position “P” and activate the
parking brake for testing and measuring procedures which re‐
quire the ignition to be on, but do not require the ready mode
to be active.
♦ The ready mode is displayed in the Instrument Cluster Control
Module - J285- above the “power meter”. Refer to Owner's
Manual.
♦ Activate and deactivate the ready mode. Refer to Owner's
Manual (consult the display in the Instrument Cluster Control
Module - J285- ).
2.2.2 Performing a Visual Inspection of Dam‐

age to High Voltage Components and
Cables
WARNING

voltage system.
WARNING

connector.
DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
Procedure: Performing a Visual Inspection

♦ Be aware of the power and control electronics for the electrical
system, the high voltage cables for the battery and A/C com‐
pressor, and the cables for the (electro-drive drive motor)
when performing the visual inspection in the engine compart‐
ment!
♦ Be aware of the high voltage cables and their corresponding
covers when performing the visual inspection of the floor pan‐
el.
♦ Pay attention to the Traction Battery - A2- , the high voltage
cables for the battery and the electro-box with the service plug!
Pay attention to the following items when performing a visual in‐
spection:
♦ The high voltage components do not display any signs of ex‐
ternal damage.
♦ The high voltage cable insulation must be intact and must not
be damaged.

♦ Look for any abnormal deformations of the high voltage ca‐

bles.
♦ Contact the high voltage technician or the electronics special‐
ist about any abnormalities or uncertainties!
♦ For further information about the high voltage system. Refer
to ⇒ Electrical System Hybrid; Rep. Gr. 93 ; High Voltage
System General Warnings .
WARNING
Hybrid vehicles have a high voltage system. Danger of elec‐

trical shock!
♦ Report any faults immediately to the responsible high volt‐
age technician. Refer to ⇒ Electrical System Hybrid; Rep.
Gr. 93 ; High Voltage System General Warnings .
2.3 Start/Stop System Safety Precautions
WARNING
On vehicles with the Start/Stop System, the engine could start

automatically and cause serious personal injury.
♦ If the Start/Stop System is activated (recognizable by a
message in the instrument cluster), it is possible to start
the engine automatically.
♦ Make sure the Start/Stop System is deactivated when
working on the vehicle (switch off ignition and turn on
again as needed).
2.4 Safety Precautions during Road Test

with Testing Equipment
If Testing Equipment Must Be Used during a Road Test, Observe
the Following:
WARNING
There is a risk of accident due to distraction and testing equip‐

ment that is not secured properly.
There is a risk that the front passenger airbag may deploy dur‐
ing an accident.
• Operating testing equipment while driving causes distrac‐
tions.
• There is an increased risk of personal injury if testing
equipment is not secured properly.
♦ Always secure testing equipment to the rear seat with a
strap and have them operated from there by a second
person.
2.5 Safety Precautions when Working on

Cooling System
When Working on the Cooling System, Observe the Following:
WARNING
There is a risk of scalding from hot steam and coolant.

♦ Cooling system is under pressure. The coolant tempera‐
ture can be higher than 90 °C when the engine is warm.
♦ Reduce the pressure and temperature before working on
the coolant system. Refer to ⇒ Engine Mechanical; Rep.
Gr. 00 ; Safety Precautions; Safety Precautions when
Working on Coolant System .
♦ Open the cap on the coolant expansion tank and release
the pressure in the coolant system. Refer to ⇒ Engine
Mechanical; Rep. Gr. 19 ; Coolant System/Coolant; Cool‐
ant, Draining and Filling .
Caution
Danger of overheating due to an incorrectly installed cap.

♦ The cap must engage audibly and by touch when closing.

3 Repair Information
⇒ “3.1 Guidelines for Clean Working Conditions”, page 45
⇒ “3.2 General Information”, page 45
⇒ “3.3 General Repair Information”, page 46
⇒ “3.4 Contact Corrosion”, page 48
⇒ “3.5 A/C Components Controlled or Activated by Other Control
Modules, Electrical Tests”, page 49
Q5 Hybrid
⇒ “3.6 Inspection of Components for the A/C System for Vehicles
with High Voltage System”, page 49
⇒ “3.7 Heating Output, Checking”, page 52
⇒ “3.8 Cooling Output, Checking”, page 73
⇒ “3.9 Working on the Refrigerant Circuit”, page 106
⇒ “3.10 Refrigerant Circuit, Discharging”, page 107
⇒ “3.11 Dust and Pollen Filter with Activated Charcoal Insert, El‐
ement Information”, page 107
⇒ “3.12 Painting on Vehicles with A/C System”, page 109
⇒ “3.13 Refrigerant Circuit Seals”, page 109
3.1 Guidelines for Clean Working Condi‐

tions
Even a Small Amount of Contamination Can Cause Malfunctions.
Therefore, Observe the Following Guidelines for Cleanliness
When Working on the A/C System:
♦ Immediately seal off any open lines and connections with
clean plugs taken from the Engine Bung Set - VAS6122- , for
example.
♦ Place removed parts on a clean surface and cover them with
lint-free cloths.
♦ Carefully cover or seal opened components if repairs are not
performed immediately.
♦ Only install clean parts: remove the replacement parts from
their packaging just before installing them. Do not use any
parts that have been kept out of packaging (for example, in a
toolbox).
♦ Do not work with compressed air when the system is open.
♦ Protect any disconnected connectors from dirt and moisture,
and only connect them when they are completely dry.
3.2 General Information

♦ The applicable wiring diagrams can be found in Wiring Dia‐
grams, Troubleshooting & Component Locations. Refer to
♦ A data plate in engine compartment indicates the refrigerant
used and capacity.
♦ For more information about repair procedures on vehicles with
A/C and handling refrigerant. Refer to ⇒ Refrigerant R134a
Servicing; Rep. Gr. 87 ; A/C System General Information and
⇒ A/C Systems with Refrigerant R1234yf - General Informa‐
tion; Rep. Gr. 00 ; Repair Procedures; Refrigerant and Re‐
frigerant Oil .
3. Repair Information 45
3.3 General Repair Information

Vehicles with a High Voltage System (Hybrid Vehicles)
General Warnings .
WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
Vehicles with Start/Stop System
WARNING
On vehicles with the Start/Stop System, the engine could start

automatically and cause serious personal injury.
♦ If the Start/Stop System is activated (recognizable by a
message in the instrument cluster), it is possible to start
the engine automatically.
♦ Make sure the Start/Stop System is deactivated when
working on the vehicle (switch off ignition and turn on
again as needed).
All Vehicles
WARNING
Before working on electrical system (wiring), remove relevant

fuse(s).
Note
Disconnect the Battery - A- , the Auxiliary Battery - A1- and the

Traction Battery - A2- before starting any electric welding on the
vehicle. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery;
Battery, Disconnecting and Connecting .
The A/C refrigerant system may be discharged and opened only

when it is for safety reasons or if components of the A/C refriger‐
ant system must be replaced. Refer to
⇒ “2 Safety Precautions”, page 33 and
⇒ “3.10 Refrigerant Circuit, Discharging”, page 107 .
When performing all other usual vehicle repair work, the refriger‐
ant circuit of the A/C system should remain closed.
Repairs to the heating and A/C system without opening the re‐
frigerant circuit are possible and are described in these repair
manuals. Refer to ⇒ “2 Refrigerant Circuit”, page 150 (Repairs
on the refrigerant circuit),
⇒ “1.1 Overview - Components Outside of Passenger Compart‐
ment”, page 120 (A/C system control and regulation compo‐
nents, not located in passenger compartment), and
ment”, page 135 (Components for activation and regulation of A/
C system, located in passenger compartment).
Note
The connections for the sensors/switches described in this repair

manual are fitted with a valve which closes automatically when
the switches are unscrewed. These switches can thus be re‐
placed in any Audi and Volkswagen workshop even though the
refrigerant circuit is fully charged.
Service work on the A/C system that require the refrigerant circuit
to be discharged and thus cannot be performed in every Audi and
Volkswagen workshop. Refer to
⇒ “2 Refrigerant Circuit”, page 150 (Repairing Refrigerant Cir‐
cuit). Certain tools are required to discharge the refrigerant circuit,
these work procedures must only be performed by trained per‐
sonnel as well. If necessary, bring the vehicle to a workshop that
has the required tools and in which the work can be performed by
qualified personnel. Refer to ⇒ Refrigerant R134a Servicing;
Rep. Gr. 87 ; A/C System General Information or ⇒ A/C Systems
3.4 Contact Corrosion

Contact corrosion can occur if inappropriate fasteners (bolts,
nuts, washers, rivets, plugs, grommets, adhesives etc.) are used.
For this reason, the manufacturer only installs fasteners with a
special surface coating. Also, rubber and plastic parts and adhe‐
sive consist of materials that do not conduct electricity. These

parts, which have been tested and are aluminum compatible, are
also available as replacement parts. Refer to the Parts Catalog.
Note:
♦ Always install new parts if there is any doubt as to whether
parts can be reused.
♦ Original equipment replacement parts are recommended.
They have been tested and are compatible with aluminum.
Refer to the Parts Catalog.
♦ Audi accessories are recommended. Refer to Parts Catalog.
♦ Damage due to contact corrosion is not covered by warranty.
3.5 A/C Components Controlled or Activa‐

ted by Other Control Modules, Electrical
Tests
Note
♦ Various A/C system components are no longer activated di‐

rectly by the Climatronic Control Module - J255- A/C display
and control head. The A/C Compressor Regulator Valve -
N280- , for example, is controlled by the Vehicle Electrical
System Control Module - J519- . The data is exchanged via
the Data Bus between both control modules, using the Vehicle
♦ The measured values of the different A/C system components
are no longer directly evaluated by the Climatronic Control
Module - J255- A/C display and control head. For example,
the pressure signal from the A/C Pressure/Temperature Sen‐
sor - G395- is evaluated by the Vehicle Electrical System
Control Module - J519- and the measured values are trans‐
mitted via the Data Bus to the Climatronic Control Module -
J255- A/C display and control head, using the Vehicle
Diagnostic Tester in the "Guided Fault Finding" function. Refer
to ⇒ Wiring diagrams, Troubleshooting & Component loca‐
tions.
cific engines as optional equipment. The setting on the Clima‐
tronic Control Module - J255- A/C display and control head can
prevent the stop function. If, for example, “defrost” is selected,
the stop function is not possible or will be interrupted and the
engine will start. The same applies in the case of heating and
cooling. The difference between the selected and actual tem‐
perature exceeds a certain value, using the Vehicle Diagnostic
3.6 Inspection of Components for the A/C

System for Vehicles with High Voltage
System
Hybrid Vehicles
♦ Components for the A/C system (and the refrigerant circuit)
which are the same for vehicles with and without a high voltage
system, can be tested, removed, and installed as described
for vehicles without the high voltage system (for example, ac‐
tuators on the A/C unit), using the Vehicle Diagnostic Tester
in the "Guided Fault Finding" function (for A/C system).
♦ A/C system components, which are almost identical on vehi‐
cles with and without the high voltage system (but can be, for
example, be differentiated by their function) are tested, re‐
moved and installed in the same way as described as for
vehicles without the high voltage system (for example, the Cli‐
matronic Control Module - J255- A/C display and control
head). Refer to the Parts Catalog and use the Vehicle Diag‐
nostic Tester in the "Guided Fault Finding" function (for A/C
system).
♦ A/C system (and the refrigerant circuit) components that are
different for vehicles with and without a high voltage system
(for example, the Electrical A/C Compressor - V470- with the
A/C Compressor Control Module - J842- ) are tested, re‐
moved, and installed as described for the vehicles with the
high voltage system (for example, the A/C Compressor Con‐
trol Module - J842- with address word “40”, using the Vehicle
Diagnostic Tester in the "Guided Fault Finding" function). The
A/C Compressor Control Module - J842- (and with it the Elec‐
trical A/C Compressor - V470- ) are supplied with electricity
from the Electric Drive Power And Control Electronics - JX1- .
Therefore, also check the Electric Drive Power and Control
Electronics - JX1- (address word “51”) if there is a complaint,
♦ A/C system (and the refrigerant circuit) components which are
only equipped on vehicles with a high voltage system (for ex‐
ample, the electrical components for the battery cooling mod‐
ule, the Hybrid Battery Refrigerant Shut-Off Valve 1 - N516- ,
the Hybrid Battery Refrigerant Shut-Off Valve 2 - N517- etc.)
are installed and removed as described for vehicles with a high
voltage system. These components are not directly activated
by the Climatronic Control Module - J255- A/C display and
control head. The Battery Regulation Control Module - J840-
(with address word “8C”) activates these components, using
function. Refer to ⇒ Wiring diagrams, Troubleshooting & Com‐
ponent locations.
General Warnings .
WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
– Charge the vehicle battery, for example, using the Battery

– Activate ready mode (with the ignition turned on, observe the
display in the Instrument Cluster Control Module - J285- ).
Note

Module - J285- above the “power meter”.
♦ Activate the ready mode (and observe the display in the In‐
strument Cluster Control Module - J285- ). Refer to the Own‐
er's Manual.
to be active.
3.7 Heating Output, Checking

⇒ “3.7.1 Heating Output and Temperature Door Activation, Test‐
ing Requirements”, page 52
⇒ “3.7.2 Heat Output and Temperature Door Activation, Check‐
ing”, page 59
⇒ “3.7.3 Heating Output and Temperature Door Activation,
Checking, Basis Version”, page 62
Checking, Convenience Version”, page 65
3.7.1 Heating Output and Temperature Door

Activation, Testing Requirements
General Warnings .
If it is necessary for the following procedure to perform work near
high voltage components, “perform a visual inspection of the high
voltage components and cables for damages” and “always follow
the warnings when working on the high voltage system”. Refer to
age Components and Cables”, page 41 ) and ⇒ Electrical System
Hybrid; Rep. Gr. 93 ; High Voltage System General Warnings .
WARNING

voltage system.

WARNING

connector.
DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
Working on a high voltage system when activated or with the ig‐

nition turned on
DANGER!


– Move the selector level into position “P”, activate the parking
ning engine.
Note
to be active.
Manual.
Module - J285- ).

All Vehicles
Note
From 01/2008, A/C units which have an additional connection for

the glove compartment cooling are being installed as a running
change. On vehicles without glove compartment cooling, this
connection is sealed with a plug. Refer to
Housing”, page 616 . If the plug or the air guide are not installed
correctly, then cold air will be guided into the passenger footwell
and the customer will complain about poor heating performance
on the passenger side.
♦ The coolant circuit is bled according to specifications. Refer to

⇒ Rep. Gr. 19 ; Coolant System/Coolant; Coolant, Draining
and Filling
♦ The engine is warm (the coolant temperature is higher than 80
°C (176 °F)).
♦ Radiator and condenser are clean (if necessary, clean).
♦ All air ducts, covers and seals are OK and properly installed.
♦ Air flow through dust and pollen filter not obstructed by dirt.
Refer to
⇒ “5.15 Dust and Pollen Filter, Removing and Installing”, page
556 .
♦ The air intake apparatus (in fresh air and recirculating air
mode) is not impaired by soiling or components installed as
retrofit.
♦ The glove compartment cooling connection is sealed with a
plug (on vehicles without the option “glove compartment cool‐
ing”) or the air guide into the glove compartment is installed to
specification (on vehicles with the option “glove compartment
cooling”). Refer to
Housing”, page 616 .
♦ The vehicle is not exposed to sunlight.
♦ The DTC memory of the Climatronic Control Module - J255-
display and control head was checked and erased, the basic
setting was performed and the Climatronic Control Module -
J255- A/C display and control head coding was checked, using
function.
♦ The adaptation of the Climatronic Control Module - J255- A/C
display and control head was checked, using the Vehicle Di‐
♦ All instrument panel vents are open.
♦ The hood is closed.
♦ The ignition is turned on and the ready mode is active, the
engine starts or only runs when warmer coolant is necessary
to reach the temperature setting in the passenger compart‐
ment or, for example, the Traction Battery - A2- (hybrid battery)
has not been charged enough.
♦ With the ignition turned on and at the temperature preset
“warm” on the Climatronic Control Module - J255- A/C display
and control head (“HI” in the display for the A/C display and
control head and the MMI).
DANGER!


♦ The engine is running.
♦ With the engine running and at the temperature preset “warm”
control head (“HI” in the display for the A/C display and control
head and the MMI).
All Vehicles
♦ With the engine running (ready mode is active for vehicles with
a high voltage system) and at the temperature preset “warm”
control head (“HI” in the display for the A/C display and control
head and the Multi Media Interface).
– This is not activated on vehicles with a Climatronic Refrigerant
Shut-Off Valve - N422- / Coolant Shut-Off Valve - N82- (not
installed on all vehicles). Refer to
⇒ “7.1 Coolant Shut-Off Valve N82 / Climatronic Coolant Shut-
Off Valve N422 Location, Activation and Function”,
page 619 .
– On vehicles with a regulated coolant circuit (only installed on
certain engines from MY 2011), the activation and function of
these components is OK. Refer to ⇒ Rep. Gr. 19 ; Coolant
Pump/Thermostat
Note
On vehicles with an engine with a regulated coolant circuit (for

example, with a regulated coolant pump and a Cylinder Head
Coolant Valve - N489- ), no Climatronic Coolant Shut-Off Valve -
N422- / Coolant Shut-Off Valve - N82- is currently installed. On
an engine with a regulated coolant pump, the engine control mod‐
ule activates the coolant pump, and in doing so regulates the
coolant circuit. Refer to ⇒ Rep. Gr. 19 ; Coolant Pump/Thermo‐
stat .
– This is actuated on vehicles with a Coolant Recirculation

Pump - V50- ( Water Pump - V36- ) (not on all vehicles, in‐
stalled, for example, on the 6-Cylinder FSI engines and on
vehicles having the Start/Stop System without an “parking
heater” and on high voltage vehicles). Refer to ⇒ , page 132
and
⇒ “7.2.2 Coolant Recirculation Pump V50 ( Water Pump V36 ),

Location, Activation and Function, Vehicles with 6-Cylinder

Gasoline Engine”, page 625 .
The following is set on the Climatronic Control Module - J255- A/
C display and control head “Basis” version:
♦ “Auto” operating mode (indicator lamp in the AUTO button
lights up).
♦ Temperature preset “cold” (“LO” in the MMI display).
♦ A/C compressor is turned on (the indicator lamp in the AC or
A/C button turns on).
♦ Preset for the fresh air blower “maximum speed” (in the Multi
Media Interface display, setting “10” or greater).
C display and control head “Convenience” version:
♦ “Auto” mode (the indicator lamp in both AUTO buttons illumi‐
nate).
♦ Temperature preset “cold” for the driver and front passenger
side (“LO” for the driver and front passenger side in the display
for the A/C display and control head and the MMI).
♦ Preset for the fresh air blower “maximum speed” (display in

the A/C display and control head and the MMI, setting “10” or
greater).
Note
♦ The indicator lamp in the or both AUTO button(s) goes out

when the fresh air blower speed is changed manually.
♦ The maximum possible fresh air blower speed depends on
several conditions (coolant temperature, vehicle voltage, etc.)
– On vehicles equipped with the “Convenience” A/C system, the

Rear Temperature Selection Potentiometer - G538- is set to
“cold” (installed in the rear center console vent).
vent the rear center console is open.
– The activation and function of the auxiliary heater is OK on
vehicles with a diesel engine or a gasoline engine with an
auxiliary heater.
Note
♦ The type of auxiliary heating depends on the vehicle equip‐

ment level. At the start of production, all vehicles with a diesel
engine have an Auxiliary Heater Heating Element - Z35- ; at a
later point in time, on vehicles with the optional equipment
“parking heater”, the Auxiliary Heater Heating Element - Z35-
will be discontinued and the parking heater will be actuated as
the auxiliary heater.
♦ Check the activation and function of the auxiliary heater on
vehicles with an Auxiliary Heater Heating Element - Z35- if
there is complaint about the heating output being insufficient
when the outside air temperatures are low. Refer to
⇒ “5.8 Auxiliary Heater Heating Element Z35 , Checking”,
page 506 .
♦ As a running change in MY 2010, gasoline engines that can
run on bioethanol (Flex Fuel vehicles) were introduced, which
currently have an Auxiliary Heater Heating Element - Z35- .
Refer to
page 506 .
♦ Currently an Auxiliary Heater Heating Element - Z35- is also
installed on vehicles with a high voltage system (hybrid vehi‐
cles) and a gasoline engine. Refer to
page 506 .
Functions When the Engine Is Running (Non-Hybrid Vehicles)/

Activated Ready Mode (Hybrid Vehicles):
Note
On vehicles with a high voltage system (hybrid vehicles) and on

vehicles with the start stop system, the engine only runs when an
additional heat output is needed to reach the set temperature.
– The coolant fan(s) ( Coolant Fan - V7- and Coolant Fan 2 -

V177- ) run (activation and speed depend on refrigerant circuit
pressure and engine temperature).
Note
Depending on the version of the Climatronic Control Module -

J255- A/C display and control head, the coolant fan(s) ( Coolant
Fan - V7- and Coolant Fan 2 - V177- ) are only switched on start‐
ing at a certain refrigerant circuit pressure (currently starting at a
pressure of approximately 9 bar (131 psi)). The coolant fan(s) ac‐
tivation is displayed in the measured values block, using the
– The Fresh Air Blower - V2- runs with maximum speed (“10” or
greater).
Note
The maximum possible fresh air blower speed depends on sev‐

eral conditions (coolant temperature, vehicle voltage, etc.)
– The A/C system goes into recirculating air mode for approxi‐
mately 1 minute after starting the engine (after activating the

ready mode on high voltage vehicles). The back pressure/

fresh air door is closed and the air recirculation door is opened.
The Fresh Air Blower - V2- extracts the air from the passenger
compartment below instrument panel/glove compartment.
Note
If one of these requirements is not met, check the DTC memory,

perform the output diagnostic test mode and read the measured
values block, using the Vehicle Diagnostic Tester in the "Guided
If the above mentioned requirements are fulfilled:

♦ Check the heating output and temperature door activation (on
the A/C system “Basis” version). Refer to
Checking, Basis Version”, page 62 .
♦ Check the heating output and temperature door activation (on
the A/C system “Convenience” version). Refer to
Checking, Convenience Version”, page 65 .
3.7.2 Heat Output and Temperature Door Ac‐

tivation, Checking
General Warnings .
WARNING

voltage system.
WARNING

connector.
DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.

nition turned on

DANGER!


ning engine.
Note
to be active.
Manual.
Module - J285- ).
– Activate the ready mode (observe the display in the Instrument

Cluster Control Module - J285- ). Refer to Owner's Manual.
All vehicles
Refer to
Checking, Basis Version”, page 62
Refer to
Checking, Convenience Version”, page 65

Activation, Checking, “Basis” Version
Test requirements are met. Refer to
ing Requirements”, page 52 .
– Close the engine hood.
– Close the doors, the windows, the sunroof and the rear lid.
– Open all instrument panel vents.
– Turn on the ignition and activate the ready mode, the engine
start by itself if needed (high voltage vehicles).
– Start the engine (not high voltage vehicles).
Set the following on the Climatronic Control Module - J255- A/C
display and control head:
lights up).
♦ Preset for the fresh air blower “maximum speed” (in the MMI
display, setting “10” or greater).
♦ Set the airflow direction using the knob on the A/C display and
control head to “footwell vents” and “instrument panel
vents” (displayed in the MMI display).
Note
♦ The indicator lamp in the AUTO button goes out when the vent
direction for the air or fresh air blower speed is manually
changed.
– Initiate the Guided Fault Finding for the A/C system and select
the “Read measuring value block” function, using the Vehicle
– Let the A/C system run several minutes at maximum cooling
output (A/C compressor is switched on, indicator lamp in the
AC or A/C button comes on).
– Compare the displayed measured value for the Evaporator

Vent Temperature Sensor - G263- with the measured values
of the Center Vent Temperature Sensor - G191- and the Foot‐
well Vent Temperature Sensor - G192- ).
Specified Values:
♦ The measured values for the Center Vent Temperature Sen‐
sor - G191- and Footwell Vent Temperature Sensor - G192-
may not be greater than maximum 5 °C (41 °F) after five

minutes than the Evaporator Vent Temperature Sensor -

G263- measured value.
If the required values are not reached, perform a Fault Finding at
a temperature increase on the evaporator. Refer to ⇒ page 65
– Using a commercially available thermometer, measure the air
temperature coming out of the instrument panel vents (left,
right and center) and out of the front and rear footwells and
compare the measured values with displayed measured val‐
ues from the Center Vent Temperature Sensor - G191- and
the Footwell Vent Temperature Sensor - G192- .
Specified Values:
♦ The measured values with the thermometer may be maximum
5 °C (41 °F) lower or higher than the measured values from
the Center Vent Temperature Sensor - G191- and the Footwell
Vent Temperature Sensor - G192- .
If the required values are not reached, perform a fault finding at
– Using the knob on the Climatronic Control Module - J255- A/
C display and control head, select the “Warm” temperature
setting (“Hi” in the MMI display).
temperature coming out of the instrument panel vents (left,
right and center) and out of the front and rear footwells and
compare the measured values with displayed measured val‐
ues from the Center Vent Temperature Sensor - G191- and
the Footwell Vent Temperature Sensor - G192- .
Specified Values:
♦ The measured values from the Center Vent Temperature Sen‐
sor - G191- and the Footwell Vent Temperature Sensor -
G192- in the display fields are greater than 52 °C (126 °F)
(depending on the engine temperature at the time).
♦ The measured values (temperature of the air coming out of the
vents), after 5 minutes, may be maximum 5 °C (41 °F) greater
or smaller than the measured values from the Center Vent
Temperature Sensor - G191- and the Footwell Vent Temper‐
ature Sensor - G192- .
Note
♦ Depending on the engine, for example, on the 8-Cylinder en‐

gine, it may be necessary to increase the engine RPM from
1,200 to 1,500 to reach the required temperature. The heating
output of the engine or coolant flowing through the heater core
may not be sufficient when the engine is running in idle to bring
the necessary warming energy into the heater core (for ex‐
ample, on an 8-Cylinder engine with an idle RPM of approxi‐
mately 650).
♦ At the “warm” temperature setting, the specified outflow tem‐
perature at the evaporator is controlled to approximately 10 °
C (50 °F) by the Climatronic Control Module - J255- A/C dis‐
play and control head.
♦ On high voltage vehicles, reduce the Fresh Air Blower - V2-
speed if necessary. The Coolant Recirculation Pump - V50-
delivery is not always enough to supply the requested heat
output when the engine is not running and the fresh air blower
is set to the highest setting.
If the specified values are not reached, check the following:
♦ Repeat the heating output at an engine RPM of approximately

1,500 to 2,000 (at a low fresh air blower speed on high voltage
vehicles). If the heating output is not reached at the engine
RPM (fresh air blower speed), the fault is not with the A/C unit
but rather inside the coolant circuit (incorporation of the A/C
system in the coolant circuit, engine coolant pump delivery,
the coolant flowing through the heater core in the A/C unit, etc.
Refer to
⇒ “5.19 Heater Core, Removing and Installing”, page 567 and
⇒ Rep. Gr. 19 ; Coolant System/Coolant ).
♦ The coolant circuit bleeding. Refer to ⇒ Rep. Gr. 19 ; Coolant
System/Coolant; Coolant, Draining and Filling
♦ The incorporation of the heater core for the heater in the A/C
unit into the coolant circuit. Refer to ⇒ Rep. Gr. 19 ; Cooling
System/Coolant; Connection Diagram - Coolant Hoses
♦ The activation and function of the Temperature Regulator
Door Motor - V68- and the actuation of the temperature doors
(via the connecting rod). Refer to, and use the Vehicle Diag‐
♦ Foam seal on heater core for the heater of A/C unit. Refer to
♦ Coolant thermostat (engine coolant may not warm properly if
the thermostat is malfunctioning). Refer to ⇒ Rep. Gr. 19 ;
Coolant Pump/Thermostat .
♦ Check the engine coolant pump for proper function (if the
coolant pump is defective, it is possible that not enough cool‐
ant is flowing through the heater core for the heater in the A/
C unit). Refer to ⇒ Rep. Gr. 19 ; Coolant Pump/Thermostat .
♦ For vehicles with a regulated coolant circuit (only installed on
these components (for example, the regulated coolant pump
and the Cylinder Head Coolant Valve - N489- ). Refer to ⇒
Rep. Gr. 19 ; Coolant Pump/Thermostat .
♦ The Coolant Recirculation Pump - V50- activation and function
(if the coolant pump is faulty, it is possible that not enough
coolant is flowing through the heater core for the heater in the
A/C unit) using the Vehicle Diagnostic Tester in the "Guided
Note
♦ The Coolant Recirculation Pump - V50- is not installed on all

vehicles (depending on the version, engine and when the ve‐
hicle was manufactured). The Recirculation Pump - V55-
works as the Coolant Recirculation Pump - V50- on vehicles
with an “parking heater”. The Auxiliary Heater Control Module
- J364- activates the Recirculation Pump - V55- upon request
of the Climatronic Control Module - J255- A/C display and
control head when the engine RPM is low to support the en‐
gine coolant pump, depending on the vehicle version and the
adaptation of the Auxiliary Heater Control Module - J364- ,
ing" function.
♦ The Coolant Pump - V50- maintains the coolant flow through
the heater core for the heater in the A/C unit when the engine
is not running on vehicles with a Start/Stop System and on
high voltage vehicles.

Temperature Increase Downstream from Evaporator, Determin‐

ing Malfunction
– Clamp off both coolant hoses from the engine to the A/C heater core using, for example, Hose Clamps
- Up To 40mm - 3093- . Refer to ⇒ “5.19 Heater Core, Removing and Installing”, page 567 .
– Repeat the heat output test and temperature door activation. Refer to
⇒ “3.7.3 Heating Output and Temperature Door Activation, Checking, Basis Version”, page 62 .
– Using a commercially available thermometer, measure the air temperature coming out of the instrument
panel vents (left, right and center) and out of the front and rear footwells (left and right) and compare with
displayed measured values from the Center Vent Temperature Sensor - G191- and the Footwell Vent
Temperature Sensor - G192- .
– Do the measured values agree with the values displayed and are the required values being reached?
↓ ↓
Yes No
↓ ↓
Remove Hose Clamps – - Up To 40mm - 3093- – Check the sensor at which the measure value devi‐
from both coolant hoses. ates for correct installation and its electrical connec‐
tions for contact resistance, using the Vehicle
↓ Diagnostic Tester in the "Guided Fault Finding" func‐
tion. Refer to ⇒ Wiring diagrams, Troubleshooting &
Check the activation
– and the function of the – Correct the cause for the incorrect measured valued,
Temperature Regulator Door Motor - V68- and and if necessary, replace the defective sensor.
the activation of the temperature doors (by the
connecting rod). Refer to ⇒ , page 591 and
⇒ “4.2 Temperature Regulator Door Motor V68 /
Rear Temperature Door Motor V137 , Remov‐
ing and Installing”, page 404 .
↓
• Are the Temperature Regulator Door Motor - V68- activation and functionality OK, and is the connecting
rod between the temperature doors on the left and right sides installed correctly?
↓ No
Yes ↓
↓
Check the temperature
– flap where the increase Repair cause of malfunction,
– using the Vehicle Di‐
in temperature is occurring and repair if neces‐ agnostic Tester in the "Guided Fault Finding" func‐
sary. Refer to ⇒ , page 591 . tion. Refer to ⇒ Wiring diagrams, Troubleshooting &
Repeat the heat output
– test and temperature
door activation. Refer to Repeat the heat output
– test and temperature door
⇒ “3.7.3 Heating Output and Temperature Door activation. Refer to
Activation, Checking, Basis Version”, page 62 . ⇒ “3.7.3 Heating Output and Temperature Door Ac‐
tivation, Checking, Basis Version”, page 62 .

Activation, Checking, “Convenience”
Version
Test requirements are met. Refer to
ing Requirements”, page 52 .
– Close the engine hood.
– Close the doors, the windows, the sunroof and the rear lid.
– Turn on the ignition and activate the ready mode, the engine
start by itself if needed (high voltage vehicles).
– Start the engine (not high voltage vehicles).

Set the following on the Climatronic Control Module - J255- A/C
display and control head:
♦ “Auto” for the driver and passenger side (the indicator lamp in
the AUTO buttons come on).
♦ Temperature preset for the driver and front passenger side set
to “cold” (“LO” in the Climatronic Control Module - J255- or in
the MMI display).
♦ Preset for the fresh air blower “maximum speed” (in the Cli‐
matronic Control Module - J255- display and in the MMI dis‐
play, setting “10” or greater).
♦ Set the airflow direction using the knob on the A/C display and
control head for the driver and passenger side to “footwell” and
“instrument panel vents” (in the Climatronic Control Module -
J255- and in the MMI display)
Note
♦ The indicator lamp in the AUTO - buttons turns off when per‐
forming manual changes for the airflow direction and/or the
fresh air blower speed.
♦ If the dial for setting the driver side temperature is held for a
longer time, then this setting will be taken over as well for the
passenger side.
– Set the Rear Temperature Selection Potentiometer - G538- to

– Open the vents in the rear center console.
– Initiate the Guided Fault Finding for the A/C system and select
the “Read measuring value block” function, using the Vehicle
– Let the A/C system run several minutes at maximum cooling
output (A/C compressor is switched on, indicator lamp in the
AC or A/C button comes on).
– Compare the Evaporator Vent Temperature Sensor - G263-

measured value with the measured values of the Left Front
Upper Body Vent Temperature Sensor - G385- , the Right
Front Upper Body Vent Temperature Sensor - G386- , the Left
Footwell Vent Temperature Sensor - G261- and the Right
Footwell Vent Temperature Sensor - G262- ).
Specified Values:
♦ The measured values of the temperature sensor after heat
exchanger ( Left Front Upper Body Vent Temperature Sensor
- G385- , Right Front Upper Body Vent Temperature Sensor -
G386- , Left Footwell Vent Temperature Sensor - G261- and
Right Footwell Vent Temperature Sensor - G262- ) may be a
maximum of 5 °C (41 °F) greater than the value of the Evap‐
orator Vent Temperature Sensor - G263- after five minutes.
a temperature increase on the evaporator. Refer to
⇒ page 72 .
coming out of the vents in the rear center console and the rear

footwell vents (left and right under the front seats) and com‐
pare the measured values with the temperatures displayed in
the measured values block.
Specified Values:
♦ The measured values may be 5 °C (41 °F) greater than the
displayed measured values for the temperature sensor.
C display and control head, select the “warm” temperature
setting for the front passenger side (“HI” in the Climatronic
Control Module - J255- and in the MMI display).
– Read the measured values displayed for the temperature sen‐
sor in the measured value block ( Evaporator Vent Tempera‐
ture Sensor - G263- , Left Front Upper Body Vent Temperature
Sensor - G385- , Right Front Upper Body Vent Temperature
Sensor - G386- , Left Footwell Vent Temperature Sensor -
G261- and Right Footwell Vent Temperature Sensor - G262- ).
– Using a commercially available thermometer, measure the
temperature of the air coming out of the vents in the rear center
console (left and right).
Specified Values:
♦ The temperature at the Right Front Upper Body Vent Tem‐
perature Sensor - G386- and Right Footwell Vent Tempera‐
ture Sensor - G262- increases to above 52 °C (126 °F)
(depending on the engine temperature at the time).
♦ The temperature at the Left Front Upper Body Vent Temper‐
ature Sensor - G385- and Left Footwell Vent Temperature
Sensor - G261- increases by less than 10 °C (50 °F) in contrast
to the measured value of the Evaporator Vent Temperature
Sensor - G263- .
♦ The measured temperature of the air coming out of the vents
in the rear center console increases by less than 20 °C (68 °
F).
Note

mately 650).
♦ The activation of the temperature doors for the rear vents (by
the Rear Temperature door Motor - V137- ) is performed by a
characteristic curve stored in the Climatronic Control Module
- J255- A/C display and control head.
If the setting between the left and right side in the Climatronic
Control Module - J255- and/or the setting on the Rear Tem‐
perature Selection Potentiometer - G538- greatly differs, then
the temperature doors for the rear vents are no longer set in
the end stops. The activation of the temperature doors for the
temperature of the air coming out of the rear vents depends
on the setting on the Rear Temperature Selection Potentiom‐
eter - G538- , which has a tendency to be somewhat warmer
or cooler than the air for the front vents.

♦ Repeat the heating output at an engine RPM of approximately
1,500 to 2,000 (at a low fresh air blower speed on high voltage
vehicles). If the heating output is not reached at the engine
RPM (fresh air blower speed), the fault is not with the A/C unit
but rather inside the coolant circuit (incorporation of the A/C
system in the coolant circuit, engine coolant pump delivery,
the coolant flowing through the heater core in the A/C unit, etc.
Refer to
⇒ Rep. Gr. 19 ; Coolant System/Coolant ).
♦ The activation and function of the Right Temperature Door
Motor - V159- , the Left Temperature Door Motor - V159- and
the activation of the left and right front temperature doors. Re‐
fer to,
⇒ “4.12 Right Temperature Door Motor V159 , Removing and
Installing”, page 429 and use the Vehicle Diagnostic Tester
♦ The activation and function of the Rear Temperature Door
Motor - V137- and the activation of the left and right rear tem‐
perature doors (via the connecting rod). Refer to,
⇒ “4.2 Temperature Regulator Door Motor V68 / Rear Tem‐
perature Door Motor V137 , Removing and Installing”,
page 404 and use the Vehicle Diagnostic Tester in the "Gui‐
♦ Foam seal on heater core for the heater of A/C unit. Refer to
♦ The foam seal on the Auxiliary Air Heater Heating Element -
Z35- on the honey comb. Refer to
⇒ “5.9 Auxiliary Heater Heating Element Z35 , Removing and
Installing”, page 511 .
♦ The coolant circuit bleeding. Refer to ⇒ Rep. Gr. 19 ; Coolant
System/Coolant; Coolant, Draining and Filling .

♦ The incorporation of the heater core for the heater in the A/C
unit into the coolant circuit. Refer to ⇒ Rep. Gr. 19 ; Cooling
System/Coolant; Connection Diagram - Coolant Hoses .
♦ The separations in the air distribution housing between the left
and right side and between rear and front. Refer to
⇒ “5.2 Overview - Air Distribution Housing Doors and Parti‐
tions”, page 461 .
♦ Coolant regulator (engine coolant may not warm properly if
regulator is malfunctioning). Refer to ⇒ Rep. Gr. 19 ; Coolant
Pump/Thermostat .
♦ Check the engine coolant pump for proper function (if the
coolant pump is defective, it is possible that not enough cool‐
ant is flowing through the heater core for the heater in the A/
C unit). Refer to ⇒ Rep. Gr. 19 ; Coolant Pump/Thermostat .
♦ For vehicles with a regulated coolant circuit (only installed on
these components (for example, the regulated coolant pump
and the Cylinder Head Coolant Valve - N489- ). Refer to ⇒
Rep. Gr. 19 ; Coolant Pump/Thermostat .
♦ The Coolant Recirculation Pump - V50- activation and function
(if the coolant pump is faulty, it is possible that not enough
coolant is flowing through the heater core for the heater in the
A/C unit) using the Vehicle Diagnostic Tester in the "Guided
Note
♦ The Coolant Recirculation Pump - V50- is not installed on all

vehicles (depending on the version, engine and when the ve‐
hicle was manufactured). The Recirculation Pump - V55-
works as the Coolant Recirculation Pump - V50- on vehicles
with optional equipment. The Auxiliary Heater Control Module
- J364- activates the Recirculation Pump - V55- upon request
of the Climatronic Control Module - J255- A/C display and
control head when the engine RPM is low to support the en‐
gine coolant pump, depending on the vehicle version and the
adaptation of the Auxiliary Heater Control Module - J364- ,
ing" function.
♦ The Coolant Pump - V50- maintains the coolant flow through
the heater core for the heater in the A/C unit when the engine
is not running on vehicles with a Start/Stop System and on
high voltage vehicles.

C display and control head, select the “warm” temperature
setting on the driver side (“HI” for the driver and front passen‐
ger side in the Climatronic Control Module - J255- and MMI
display).
– Read the measured values of the temperature sensor after
heat exchanger ( Left Front Upper Body Vent Temperature
Sensor - G385- , Right Front Upper Body Vent Temperature
Sensor - G386- , Left Footwell Vent Temperature Sensor -
G261- and Right Footwell Vent Temperature Sensor - G262- ).
console (left and right).
Specified Values:
♦ The temperature at the Left Front Upper Body Vent Temper‐
ature Sensor - G385- and Left Footwell Vent Temperature
Sensor - G261- increases to above 52 °C (126 °F) within five

minutes (depending on the engine temperature at the time).
♦ The temperatures of the temperature sensors displayed in the
measure values block ( Left Front Upper Body Vent Temper‐
ature Sensor - G385- , Right Front Upper Body Vent Temper‐
ature Sensor - G386- , Left Footwell Vent Temperature Sensor
- G261- and Right Footwell Vent Temperature Sensor -
G262- ) even out within five minutes (the difference in tem‐
perature is less than 5 °C (41 °F) and the temperature is
greater than 52 °C (126 °F)).
♦ The measured temperature coming out of the vents in the left
and right side of the rear center console increases but does
not reach the displayed temperatures for the temperature sen‐
sors ( Left Front Upper Body Vent Temperature Sensor -
G385- , Right Front Upper Body Vent Temperature Sensor -
Right Footwell Vent Temperature Sensor - G262- ) (tempera‐
ture has a tendency to be cooler than the setting on the Rear
Temperature Selection Potentiometer - G538- ). Refer to
⇒ page 68 .
Note

mately 650).
♦ At the “warm” temperature setting for the driver and front pas‐
senger side, the specified outflow temperature on the evapo‐
rator is regulated to approximately 10 °C (50 °F) by the
head.
If the specified values are not reached, check the following. Refer
to ⇒ page 68 .
If the specified values are not reached, proceed as follows:
– Set the Rear Temperature Selection Potentiometer - G538- to
“warm” (installed in the rear center console vent).
console and the rear footwells (left and right sides) and com‐
pare with the displayed measured values for the temperature
sensors ( Left Front Upper Body Vent Temperature Sensor -
G385- , Right Front Upper Body Vent Temperature Sensor -
Right Footwell Vent Temperature Sensor - G262- ).
Specified Values:
♦ The measured air temperature coming out of the vents in the
rear center console and the rear footwell vents (left and right
side increases and reaches within 5 minutes a value, which is
10 °C (50 °F) less than the small value measured and dis‐
played by the temperature sensors.

♦ The deviation between the measured temperature on the left

and right side is less than 5 °C (41 °F).
♦ Check the activation and function of the Rear Temperature
Door Motor - V137- and the activation of the left and right rear
temperature doors (via the connecting rod). Refer to,
♦ Additional tests should the specified values not be reached.
Refer to ⇒ page 68 .
If the specified values are not reached, proceed as follows:
C display and control head, select the “cold” temperature set‐
ting for the front passenger side (“LO” in the Climatronic Con‐
trol Module - J255- and MMI display).
– Compare the measured value of the Evaporator Vent Tem‐
perature Sensor - G263- with the measured values for the
Right Front Upper Body Vent Temperature Sensor - G386-
and the Right Footwell Vent Temperature Sensor - G262- and
read the measured values for the Left Front Upper Body Vent
Temperature Sensor - G385- and the Left Footwell Vent Tem‐
perature Sensor - G261- .
Specified Values:
♦ The measured and displayed temperatures at the Left Front
Upper Body Vent Temperature Sensor - G385- and Left Foot‐
well Vent Temperature Sensor - G261- change slightly and
remain greater than 52 °C (126 °F) (depending on the engine
temperature at the time).
♦ The temperature at the Right Front Upper Body Vent Tem‐
perature Sensor - G386- and Right Footwell Vent Tempera‐
ture Sensor - G262- drops and after five minutes at the latest,
it reaches a value of maximum 10 °C (50 °F) greater than the
values of the Evaporator Vent Temperature Sensor - G263- .
Note

mately 650).
♦ At the “warm” temperature setting for the driver and front pas‐
senger side, the specified outflow temperature on the evapo‐
rator is regulated to approximately 10 °C (50 °F) by the
head. If the “cold” temperature setting is selected for one side,
head lowers the specified outflow temperature on the evapo‐
rator and regulates this to approximately 2 °C (36 °F) .
If the specified values are not reached, check the following. Refer
to ⇒ page 68 .
If the specified values are reached, the test is complete.
Temperature Increase Downstream from Evaporator, Determin‐
ing Malfunction
– Clamp off both coolant hoses from the engine to the A/C heater core using, for example, Hose Clamps
- Up To 40mm - 3093- . Refer to ⇒ “5.19 Heater Core, Removing and Installing”, page 567 .
– Repeat the test for heating output and temperature door activation. Refer to
⇒ “3.7.4 Heating Output and Temperature Door Activation, Checking, Convenience Version”, page 65 .
– Using a thermometer, measure the temperature of the air coming out of the instrument panel vents (left,
right and center) and out of the front footwell vents (left and right) and compare them to the temperatures
displayed in the measured values block.
– Do the measured values agree with the values displayed and are the required values being reached?
↓ ↓
Yes No
↓ ↓
Remove Hose Clamps – - Up To 40mm - 3093- – Check the sensor at which the measure value devi‐
from both coolant hoses. ates for correct installation and its electrical connec‐
tions for contact resistance, using the Vehicle
↓ Diagnostic Tester in the "Guided Fault Finding" func‐
tion. Refer to ⇒ Wiring diagrams, Troubleshooting &
Check the activation
– and function of the Left – Correct the cause for the incorrect measured value,
Temperature Door Motor - V158- , of the Right and if necessary, replace the defective sensor.
Temperature Door Motor - V159- and the acti‐
vation of each temperature door. Refer to
⇒ , page 591
Check the activation – and the function of the

Rear Temperature Door Motor - V137- and the
activation of the left and right rear temperature
door (by the connecting rod). Refer to
⇒ , page 591 and
⇒ “4.2 Temperature Regulator Door Motor V68 /
Rear Temperature Door Motor V137 , Remov‐
↓
• Are the temperature flap activation and functionality OK?
↓ No
Yes ↓
↓
Check the function of
– the temperature door that Repair cause of malfunction
– using the Vehicle Diag‐
increases the temperature. Refer to nostic Tester in the "Guided Fault Finding" function.
⇒ , page 591 . Refer to ⇒ Wiring diagrams, Troubleshooting &
Component locations
Repeat heat output–test and temperature door
activation. Refer to Repeat heat output test– and temperature door acti‐
⇒ “3.7.4 Heating Output and Temperature Door vation. Refer to
Activation, Checking, Convenience Version”, ⇒ “3.7.4 Heating Output and Temperature Door Ac‐
page 65 . tivation, Checking, Convenience Version”,
page 65 .

3.8 Cooling Output, Checking

⇒ “3.8.1 Cooling Output Test Notes, Vehicles without a High Volt‐
age System”, page 73
⇒ “3.8.2 Testing Requirements for A/C System Cooling Output,
Vehicles without High Voltage System”, page 75
⇒ “3.8.3 Cooling Output, Checking, Vehicles without High Voltage
System”, page 77
⇒ “3.8.4 Specified Values Are Not Obtained (Required Cooling
Output not Achieved), Determining Malfunction, Vehicles without
High Voltage System”, page 82
⇒ “3.8.5 Ice Formation on Evaporator, Localizing Malfunction,
Vehicles without a High Voltage System”, page 85
Q5 Hybrid
⇒ “3.8.6 Cooling Output Test Notes, Vehicles with a High Voltage
System”, page 86
Q5 Hybrid
⇒ “3.8.7 A/C Cooling Output, Testing Requirements, vehicles with
a High Voltage System”, page 90
Q5 Hybrid
⇒ “3.8.8 Cooling Output, Checking, Vehicles with High Voltage
System”, page 93
Q5 Hybrid
Output is not Achieved), Determining Malfunction, Vehicles with
a High Voltage System”, page 100
Q5 Hybrid
Vehicles with a High Voltage System”, page 104
3.8.1 Cooling Output Test Notes, Vehicles

without a High Voltage System
Special tools and workshop equipment required
♦ Vehicle Diagnostic Tester with the related connecting cable.
♦ A standard thermometer (for temperature measurements, if
necessary a thermometer with two measuring probes for si‐
multaneous measurement, for example, for temperature on
the right and left)
Only for Vehicles with a Mechanically Driven A/C Compressor.
♦ A/C Cooling Output, Testing Requirements. Refer to
⇒ “3.8.2 Testing Requirements for A/C System Cooling Out‐
put, Vehicles without High Voltage System”, page 75
♦ Check the cooling output. Refer to
⇒ “3.8.3 Cooling Output, Checking, Vehicles without High
Voltage System”, page 77 .
Note

perature exceeds a certain value, using the Vehicle Diagnostic
♦ For vehicles with the Start/Stop System, an additional Coolant
Recirculation Pump - V50- ( Water Pump - V36- ) is installed
for the stop function, depending on the vehicle equipment level
and vehicle version. Refer to, ⇒ Rep. Gr. 19 ; Coolant Pump/
Thermostat and use the Vehicle Diagnostic Tester in the "Gui‐
♦ Depending on the vehicle version, the Coolant Recirculation
Pump - V50- ( Water Pump - V36- ) is activated not only when
the “Stop function” is active, but also when the engine is run‐
ning (when, for example, the “warm” temperature preset is
selected on the Climatronic Control Module - J255- A/C dis‐
play and control head (“HI” in the display on the A/C display
and control head and the display in the MMI). The Coolant
Recirculation Pump - V50- ( Water Pump - V36- is activated
to support the engine coolant pump. Refer to Vehicle Diag‐
tion (only the allocated pump can be activated), using the
♦ From MY 2012 (introduction depending on the vehicle ver‐
sion), a revised Fresh Air Blower Control Module - J126- (and
Fresh Air Blower - V2- , Climatronic Control Module - J255- A/
C display and control head, evaporator, expansion valves, ac‐
tuators and A/C units are being used. Refer to the Parts
Fault Finding" function. Read all the information regarding
these components. Refer to
page 388 .
♦ From the start of production up to the changeover from MY
were installed (A/C unit part number “8K_ 820 005”). From MY
2012 as a running change, an evaporator with an approxi‐
mately 50 mm width (block depth) is being installed depending
on the vehicle version (A/C unit part number “8T_ 820 005”).
Pay attention to the correct allocation of the expansion valve
Parts Catalog.

Refer to
⇒ “3.8.2 Testing Requirements for A/C System Cooling Output,
Vehicles without High Voltage System”, page 75
Refer to
System”, page 77
3.8.2 Testing Requirements for A/C System

Cooling Output, Vehicles without High
Voltage System
Only for Vehicles with a Mechanically Driven A/C Compressor.
♦ The ambient temperature is greater than 15 °C (59 °F).
♦ The ribbed belt for A/C compressor drive is OK and correctly
tensioned. The belt pulley actually drives the A/C compressor
(on vehicles with a 4- or 6-Cylinder engine). Refer to
⇒ “3 A/C Compressor”, page 288 .
♦ The A/C compressor ribbed belt is OK and is tensioned cor‐
rectly, the Climatronic Control Module - J255- activates the A/
C Clutch - N25- , and the belt pulley actually drives the A/C
compressor (only on certain vehicles with an A/C compressor
with a drive unit with clutch; introduction from MY 2012, for
example, on vehicles with a certain 4-Cylinder engine). Refer
to
with A/C Clutch N25 ”, page 379 and use the Vehicle Diag‐
♦ The A/C compressor drive unit is mounted correctly and the
A/C compressor is actually driven (on 8-Cylinder vehicles).
Refer to
⇒ “3.1.2 Overview - A/C Compressor Power Unit, Vehicles
with 8-Cylinder Engine”, page 290 .
Refer to
556 .
retrofit.
°C (176 °F)).
function.
♦ The engine is running.

lights up).
nate).

greater).
Note
♦ The indicator lamp in the AUTO button(s) goes out when the
fresh air blower speed is changed manually.

vent in the rear center console is open.
Functions with Engine Running:
Note

greater).

Note

– The A/C system goes in recirculating air mode (approximately

one minute after starting the engine, the back pressure/fresh
air door is closed and the air recirculation door is opened. The
Fresh Air Blower - V2- extracts the air from passenger com‐
partment below instrument panel/behind the glove compart‐
ment).
Note
If one of these requirements is not met, check the DTC memory,

perform the output diagnostic test mode and read the measured
values block, using the Vehicle Diagnostic Tester in the "Guided
3.8.3 Cooling Output, Checking, Vehicles

without High Voltage System
Not on Vehicles with a High Voltage System (Hybrid Vehicles)
Only on vehicles with mechanically driven A/C compressors
♦ The requirements for testing the cooling capacity are fulfilled.
Refer to
⇒ “3.8.2 Testing Requirements for A/C System Cooling Out‐
put, Vehicles without High Voltage System”, page 75 .
– Measure the ambient temperature (must be warmer than 15 °
C (59 °F)).
– Close the doors, the engine hood, the windows, the sunroof
and the rear lid.
– Start the engine.
– Switch off the A/C compressor (“Econ” mode set on the Cli‐
matronic Control Module - J255- A/C display and control head,
the indicator lamp in the AC or A/C button does not light up).
– Initiate the Guided Fault Finding for the A/C system, using the
tion.
– In “read measured values block” select the display group with
the measured values for the compressor control and refriger‐
ant circuit pressure and read the measured values using the
tion
♦ The A/C compressor is switched off, a current of 0 A (amps)
will be displayed.
♦ The pressure in the refrigerant circuit is same as the measured
outside temperature or greater than the value in the chart.
Ambient Temperature in ° Pressure Display Pressure in bar
C (°F) (psi)
15 (59) 3.0 (43.5)
20 (68) 4.0 (58.0)
25 (77) 5.0 (72.5)
Ambient Temperature in ° Pressure Display Pressure in bar

C (°F) (psi)
30 (86) 6.0 (87)
35 (95) 7.0 (101.5)
Note
♦ At absolute pressure, 0 bar (0 psi) corresponds to absolute

vacuum. Normal ambient pressure equals approximately 1 bar
(14.5 psi) absolute pressure and 0 bar (0 psi) pressure. On the
scales of most pressure gauges, 0 bar (0 psi) pressure corre‐
sponds to an absolute pressure of 1 bar (14.5 psi) (can be seen
from -1 mark below 0).
♦ Depending on version of the Climatronic Control Module -
J255- A/C display and control head, only integer values may
be displayed in the measured value block, if the pressure
measured lies between two values the display switches back
and forth.
♦ Pressure in refrigerant circuit is governed by ambient temper‐
ature. On account of heat given off by components (for exam‐
ple, the radiator), pressure displayed with warm engine will be
slightly higher than that given for the respective ambient tem‐
perature.
♦ If pressure displayed is below that indicated in table. Check
the signal coming from the A/C Pressure/Temperature Sensor
- G395- , using the Vehicle Diagnostic Tester in the "Guided
Fault Finding" function. If no fault can be determined at the A/
C Pressure/Temperature Sensor - G395- , there is insufficient
refrigerant in the circuit. Bring the vehicle to a workshop that
has the necessary tools and in which the work can be per‐
formed accordingly by qualified personnel. Refer to ⇒ Refrig‐
erant R134a Servicing; Rep. Gr. 87 ; A/C System General
General Information; Rep. Gr. 00 ; Legal Texts and Regula‐
tions .
If the refrigerant circuit pressure is OK.

– Switch the A/C compressor on by selecting the “Auto” mode
control head (the indicator lamp in the AUTO button(s) and the
AC or the A/C button illuminate).
– Set the temperature preset to “cold” using the knob(s) on the

head (for the driver and front passenger sides).
– On vehicles equipped with the “Convenience” A/C system, set
the Rear Temperature Selection Potentiometer - G538- to
– Using the knob(s) on the Climatronic Control Module - J255-
A/C display and control head, set the airflow direction to the
“instrument panel vents” (for the driver and front passenger
sides).

Note
♦ The indicator lamp in the one or both AUTO buttons goes out
when the vent direction for the air or fresh air blower speed is
manually changed.
– In the “read measured values block”, read the specified current

with which the A/C Compressor Regulator Valve - N280- is
activated (if the specified current is greater than 0.3 A, then
the A/C compressor should be switched on), using the Vehicle
Note
The specified current is calculated by the Climatronic Control

Module - J255- A/C display and control head. The request is sent
via the Data Bus to the Vehicle Electrical System Control Module
- J519- , using the Vehicle Diagnostic Tester in the "Guided Fault
Finding" function.
– In the “read measured values block”, read the actual current

with which the A/C Compressor Regulator Valve - N280- is
activated (if the actual current is greater than 0.3 A, then the
A/C compressor is switched on), using the Vehicle Diagnostic
Note
♦ If no or very little current is displayed in the measured value

block, check the activation of the A/C Compressor Regulator
Valve - N280- . Refer to
⇒ “2.4 A/C Compressor Regulator Valve N280 , Checking
Switch-On Signal”, page 192 .
trol head actuates the A/C Compressor Regulator Valve -
N280- via the Vehicle Electrical System Control Module -
J519- . The activation of the A/C Compressor Regulator Valve
- N280- is displayed in the Vehicle Electrical System Control
Module - J519- measured values block, using the Vehicle Di‐
♦ The actual current, which flows through the A/C Compressor
Regulator Valve - N280- , is measured by the Vehicle Electrical
System Control Module - J519- and sent to the Climatronic
Control Module - J255- A/C display and control head via the
Data Bus, using the Vehicle Diagnostic Tester in the "Guided
Fault Finding" function
– In the “read measured values block” function, read the refrig‐

erant circuit pressure measured by the A/C Pressure/Tem‐
perature Sensor - G395- ; the displayed pressure increases
above the value when the A/C compressor is switched off, us‐
function.
Note
♦ If the pressure displayed in the measured values block does

not change and the A/C compressor actuation is OK, using the
tion. Check once again, if the A/C compressor is really being
driven and the A/C Compressor Regulator Valve - N280- is
being actuated. If the A/C compressor is driven and A/C Com‐
pressor Regulator Valve - N280- is actuated, then there is a
malfunction in the refrigerant circuit. Bring the vehicle to a
workshop that has the necessary tools and in which the work
can be performed accordingly by qualified personnel. Refer to
⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ; A/C System
General Information or ⇒ A/C Systems with Refrigerant
R1234yf - General Information; Rep. Gr. 00 ; Legal Texts and
Regulations . If the A/C compressor control is not OK, then
inform the workshop of the problem at hand.
♦ The A/C Compressor Regulator Valve - N280- is activated by
head (via the A/C Compressor Regulator Valve - N280- ), so
that the temperature of air downstream from the evaporator
reaches the specified value (approximately 2 to 5 °C (36 to 41
°F)).
♦ A value greater than 0.55A is displayed after vehicle start de‐
pending on the measured temperature, engine speed and
electrical system voltage. As soon as the temperature meas‐
ured by the Evaporator Vent Temperature Sensor - G263-
nears the specified value, the activation, and thus the
compressor output, is reduced.
♦ Under certain operating conditions, residual moisture in re‐
frigerant circuit can lead to an ice build-up on the A/C Com‐
pressor Regulator Valve - N280- (and on expansion valve). A/
C compressor regulation is reduced by this ice build-up. The
evaporator is cooled too intensely and freezes. The ice on the
evaporator may cause various customer concerns. Refer to
Vehicles without a High Voltage System”, page 85 .
– Press the button for recirculating air mode on the Climatronic

Control Module - J255- A/C display and control head (symbol
for “recirculating air mode” in the recirculation button illu‐
minates).
– Set engine speed of 2000 rpm (start of time measurement).
– In “read measured values block” function, read the measured
value for the Evaporator Vent Temperature Sensor - G263- ,
ing" function.

– Compare the displayed value (for the Evaporator Vent Tem‐

perature Sensor - G263- ) with the values in the diagram.
A - Air temperature measured by the Evaporator Vent Tempera‐
ture Sensor - G263- (downstream from evaporator)
B - Ambient Temperature
C - Permissible Tolerance Range
Depending on ambient temperature, air temperature measured
must be within stated tolerance range -C- after five minutes.
Note
♦ If the required values are not reached, check the measured

value for the Evaporator Vent Temperature Sensor - G263- .
To do so, compare the displayed value of the Evaporator Vent
Temperature Sensor - G263- with the measured values from
the Center Vent Temperature Sensor - G191- (on the “Basis”
version) / the Left Front Upper Body Vent Temperature Sensor
- G385- (on the “Convenience” version) with each other.
♦ If the measured value of the Evaporator Vent Temperature
Sensor - G263- only slightly deviates from the measured value
for the Center Vent Temperature Sensor - G191- / Left Front
Upper Body Vent Temperature Sensor - G385- . Determine
the malfunction when there is a deviation from specified value.
Refer to
Output not Achieved), Determining Malfunction, Vehicles with‐
out High Voltage System”, page 82 .
Sensor - G263- is greater than the measured value of the
Center Vent Temperature Sensor - G191- or the Left Front
Upper Body Vent Temperature Sensor - G385- , then make
sure the Evaporator Vent Temperature Sensor - G263- is in‐
stalled correctly. Refer to
⇒ “9.9 Evaporator Vent Temperature Sensor G263 , Remov‐
ing and Installing”, page 662 and perform the electrical test
for this sensor, using the Vehicle Diagnostic Tester in the
♦ The function of the A/C system is, for example recognizable,
when the “low pressure side” refrigerant line (wide line be‐
tween the quick-release coupling and the A/C compressor)
cools down and the “high pressure side” refrigerant line (nar‐
row line between the condenser and quick-release coupling)
warms up. Refer to
⇒ “2.1.1 System Overview - Refrigerant Circuit, Not Opening
the Refrigerant Circuit, Vehicles without High Voltage Sys‐
tem”, page 151 .
If the measured value of the Evaporator Vent Temperature Sen‐

sor - G263- (and thus the A/C system cooling output) is OK and
if there is no complaint, the cooling output test ends.
Sensor - G263- (and thus the A/C system cooling output) is
not OK, determine the malfunction using the deviation from
specified value (the required cooling output is not reached).
Refer to
Output not Achieved), Determining Malfunction, Vehicles with‐
out High Voltage System”, page 82 .
♦ If the Evaporator Vent Temperature Sensor - G263- measured

value (and thus the A/C system cooling output) is OK, and if
there is a complaint that the vent temperatures are too high or
differ, check the activation of the temperature doors. Refer to
⇒ “3.7.2 Heat Output and Temperature Door Activation,
Checking”, page 59 .
3.8.4 Specified Values Are Not Obtained (Re‐

quired Cooling Output not Achieved),
Determining Malfunction, Vehicles with‐
out High Voltage System
– In “read measured values block”, select the display group with the measured values for the A/C com‐
pressor actuation and the refrigerant circuit pressure, using the Vehicle Diagnostic Tester in the "Guided
– Repeat the cooling output test. Refer to

⇒ “3.8.3 Cooling Output, Checking, Vehicles without High Voltage System”, page 77 .
– During the cooling output test, pay attention to the display for the compressor actuation.
– Is the activation of the A/C Compressor Regulator Valve - N280- switched off during the cooling output
test (is the specified and/or the actual current less than 0.50 A)?
↓ ↓
Yes No
↓ ↓
Continuation. Refer to • Did the pressure in refrigerant circuit increase during the cooling output
⇒ page 82 . The A/C com‐ test?
pressor activation is switched
off.
↓ ↓
Yes No
↓ ↓
Continuation. Refer to Check one more– time if the compressor
⇒ page 83 . Increase in shaft is really being driven and if the A/C
pressure in the refrigerant Compressor Regulator Valve - N280- is ac‐
circuit. tually being actuated.
If the A/C compressor
– is being driven and
the A/C Compressor Regulator Valve -
N280- is being activated, bring the vehicle
to a workshop that has the necessary tools
and in which the work can be performed by
qualified personnel. Refer to ⇒ Refrigerant
R134a Servicing; Rep. Gr. 87 ; A/C System
General Information or ⇒ A/C Systems with
Refrigerant R1234yf - General Information;
Rep. Gr. 00 ; Legal Texts and Regulations .
Bring the detected–problems to the attention

of the workshop.
Test Continuation “The A/C Compressor Actuation Is Switched

Off”
– If the activation of the A/C Compressor Regulator Valve - N280- switched off during the cooling output
test by the Climatronic Control Module - J255- A/C display and control head, are the specified current and
the actual current less than 0.50 A?
↓ ↓
Yes No
↓ ↓

– Check the DTC memory of the Cli‐ – Is the A/C Compressor Regulator Valve - N280- activation switched
matronic Control Module - J255- A/ off by the Vehicle Electrical System Control Module - J519- during
C display and control head. the cooling output test (only the actual current is less than 0.50 A)?
Correct any displayed
– faults and Check the Vehicle Electrical System
– Control Module - J519- DTC
then erase the DTC memory. memory, correct the displayed malfunction and erase the DTC
memory, using the Vehicle Diagnostic Tester in the "Guided Fault
Read the measured
– values block Finding" function.
with the compressor Shut-Off con‐
ditions of the Climatronic Control Read the display groups in the – Vehicle Electrical System Control
Module - J255- A/C display and Module - J519- measured values block, in which the measured
control head and correct the cause values for the activation of the A/C Compressor Regulator Valve -
of the switching off, using the Ve‐ N280- are displayed.
hicle Diagnostic Tester in the "Gui‐
ded Fault Finding" function. Check the activation of the –A/C Compressor Regulator Valve -
N280- by the Vehicle Electrical System Control Module - J519- and
Repeat the cooling
– output test. Re‐ correct the cause of the switching off. Refer to
fer to ⇒ “2.4 A/C Compressor Regulator Valve N280 , Checking Switch-
⇒ “3.8.3 Cooling Output, Check‐ On Signal”, page 192 .
ing, Vehicles without High Voltage
System”, page 77 . Repeat the cooling– output test. Refer to
System”, page 77 .
Test Continuation “Pressure in the Refrigerant Circuit Increases”

– Open the engine hood.

⇒ “3.8.3 Cooling Output, Checking, Vehicles without High Voltage System”, page 77 .
– From the measured values block for the Climatronic Control Module - J255- A/C display and control head,
read the refrigerant circuit pressure, using the Vehicle Diagnostic Tester in the "Guided Fault Finding"
function.
• Is the coolant fan(s) ( Coolant Fan - V7- and Coolant Fan 2 - V177- ) running during the cooling output
test. The RPM depends on the coolant temperature and on the refrigerant circuit pressure, it is determined
by the engine control module. Or the coolant fans switch off as soon as the refrigerant circuit pressure
exceeds approximately 9 bar (131 psi)?
↓ ↓
Yes No
↓ ↓
– Read the measured values blocks with the dis‐ – Check the coolant fan(s) activation, for example, in
play for the “refrigerant circuit pressure” and the the “output diagnostic test mode” function, using the
“coolant fan actuation”, using the Vehicle Diag‐ Vehicle Diagnostic Tester in the "Guided Fault Find‐
nostic Tester in the "Guided Fault Finding" func‐ ing" function.
tion.
– Service the activation of the coolant fan(s).
• Do the coolant fan(s) run at a higher speed when
the refrigerant circuit pressure increases ac‐ – Repeat the cooling output test. Refer to
cording to the request from the Climatronic Con‐ ⇒ “3.8.3 Cooling Output, Checking, Vehicles without
trol Module - J255- ? High Voltage System”, page 77 .
↓ ↓
Yes No
↓ ↓
– Bring the vehicle to a – Check the coolant fan(s) activation, for example in the “output diagnostic
workshop that has the test mode”, using the Vehicle Diagnostic Tester in the "Guided Fault Find‐
necessary tools and in ing" function.
which the work can be
performed by qualified – Service the activation of the coolant fan(s).
personnel. Refer to ⇒
Refrigerant R134a Serv‐ – Repeat the cooling output test. Refer to
icing; Rep. Gr. 87 ; A/C ⇒ “3.8.3 Cooling Output, Checking, Vehicles without High Voltage System”,
System General Infor‐ page 77 .
mation or ⇒ A/C Sys‐
tems with Refrigerant
R1234yf - General Infor‐
mation; Rep. Gr. 00 ;
Legal Texts and Regula‐
tions .
– Bring the detected prob‐

lems to the attention of
the workshop.
Note
♦ The pressure in the refrigerant circuit depends on several fac‐

tors. However, at an ambient temperature between 20 to 25 °
C (68 to 77 °F) the pressure should not exceed more than 20
bar (290 psi). Under extreme conditions (for example, during
“stop and go traffic” at a high ambient temperature and high
relative humidity), pressures up to 31 bar (450 psi) may occur
due to the extremely high cooling output.
♦ At ambient temperatures below 25 °C (77 °F), pressure in re‐
frigerant circuit does not normally exceed 16 bar (232 psi)
(coolant fans run and cool condenser).
♦ The Climatronic Control Module - J255- display and control
head calculates the refrigerant circuit pressure via the meas‐
ured value for the A/C Pressure/Temperature Sensor - G395-
and displays it, using the Vehicle Diagnostic Tester in the
♦ At an absolute pressure less than approximately 1.8 bar (26
psi) and greater than approximately 32 bar (464 psi), the Cli‐
matronic Control Module - J255- display and control head
does not switch on the A/C compressor (the A/C Compressor
Regulator Valve - N280- is not actuated). The A/C compressor
is only switched on once the absolute pressure becomes
greater than 1.8 bar (26 psi) or less than 16 bar (232 psi).
♦ Additional information regarding the refrigerant circuit pres‐
sure can be found in Guided Fault Finding, using the Vehicle
♦ To prevent abrupt A/C compressor Shut-Off due to excessive
pressure in refrigerant circuit or an excessive coolant temper‐
ature, the Climatronic Control Module - J255- A/C display and
control head regulates the A/C compressor output. As soon as
the refrigerant circuit pressure exceeds 30 bar (435 bar) (ab‐
solute pressure), full A/C compressor output is only enabled
again after pressure has become less than 27 bar (392 psi),
or the coolant temperature exceeds 115 °C (59 °F) (it is switch‐
ed off completely at 118 °C (64 °F)).

3.8.5 Ice Formation on Evaporator, Localizing

Malfunction, Vehicles without a High
Voltage System
head, so that the temperature of air downstream from the
evaporator reaches the specified value (approximately 2 to 5
°C (36 to 41 °F)).
♦ A value greater than 0.55A is displayed after vehicle start de‐
pending on the measured temperature, engine speed and
electrical system voltage. As soon as the temperature meas‐
ured by the Evaporator Vent Temperature Sensor - G263-
nears the specified value, the activation, and thus the
compressor output, is reduced.
Under certain operating conditions, residual moisture in refriger‐
ant circuit can lead to an ice build-up on the A/C Compressor
Regulator Valve - N280- (and on expansion valve). A/C compres‐
sor regulation is reduced by this ice build-up. The evaporator is
cooled too intensely and freezes. The freeze-up of the evaporator
can be the cause for the following customer complaints:
– After a long drive, A/C system repeatedly or sporadically fails
(no cooling or heating output), after switching off vehicle and
after a short time, the A/C system function is OK again.
– The windows fog up from the inside after driving for a long time;
also, when using the “Defrost” button on the Climatronic Con‐
trol Module - J255- A/C control head and the windows do not
clear up right away, after turning off the vehicle (or after turning
off the A/C) and waiting a short time, the A/C system is OK
again.
Corrective measure:
– Check the measured value from the Evaporator Vent Tem‐
perature Sensor - G263- in the “Read measured values block”
function, using the Vehicle Diagnostic Tester in the "Guided
– If the measured value of the Evaporator Vent Temperature
Sensor - G263- is too high under the conditions described by
the customer (although the A/C system is working properly,
depending on the ambient temperature greater than 10 °C (50
°F), for example), check the Evaporator Vent Temperature
Sensor - G263- (an incorrect measured value can cause the
evaporator to ice up).
Sensor - G263- is too low under the operating conditions re‐
ported by the customer (at an ambient temperature above 0 °
C (32 °F), longer when it is lower than 0 °C (32 °F)). Bring the
vehicle to a workshop that has the necessary tools and in
which the work can be performed accordingly by qualified per‐
sonnel. Refer to ⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ;
A/C System General Information or ⇒ A/C Systems with Re‐
frigerant R1234yf - General Information; Rep. Gr. 00 ; Legal
Texts and Regulations . Bring the problems determined to the
attention of the workshop.
– Check the “low pressure side” refrigerant line (wide line be‐
with the engine running. Refer to
the Refrigerant Circuit, Vehicles without High Voltage Sys‐
tem”, page 151 . If this line is thickly iced over when a problem
occurs (a very thin layer of ice is permitted), this indicates that
the temperature in the evaporator is too low. Bring the vehicle
to a workshop that has the necessary tools and in which the

work can be performed accordingly by qualified personnel.
Refer to ⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ; A/C
System General Information or ⇒ A/C Systems with Refriger‐
ant R1234yf - General Information; Rep. Gr. 00 ; Legal Texts
and Regulations . If the A/C compressor control is not OK, then
Note
Ice build-up can occur on the evaporator under extreme circum‐

stances for particularly unfavorable A/C system settings (for ex‐
ample, airflow direction is set to the instrument panel vents and
these vents are closed, set to maximum cooling output with a
minimal fresh air blower speed). At this setting, air is no longer
flowing through the evaporator and is making the temperature at
the Evaporator Vent Temperature Sensor - G263- higher than the
actual evaporator temperature. It can be assumed for the A/C
system regulation that the Evaporator Vent Temperature Sensor
- G263- measured value corresponds to the actual evaporator
temperature and continues to activate the A/C Compressor Reg‐
ulator Valve - N280- and the evaporator cools too much.
3.8.6 Cooling Output Test Notes, Vehicles

with a High Voltage System
♦ Vehicle Diagnostic Tester with the related connecting cable.
♦ Battery Charger - VAS5903-
the right and left)
Only Vehicles with Electrically-Driven A/C Compressor.
Perform only on vehicles with a high-voltage system (hybrid ve‐
hicles with electrically-driven A/C compressor).
General Warnings .
WARNING

voltage system.

WARNING

connector.
DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.

nition turned on
DANGER!


ning engine.
Note
to be active.
Manual.
Module - J285- ).

Note

er's Manual.
♦ Also move the selector lever into “P” and activate the parking
brake for testing and measuring procedures which require the
ignition to be on, but do not require the ready mode to be ac‐
tive.
For vehicles with high voltage systems, poor or insufficient cooling

by the battery cooling module, even though the evaporator cool‐
ing in the A/C system is OK, may be caused by the following:
♦ The activation or function of the actuators on the battery cool‐
ing module ( Hybrid Battery Recirculation Door Positioning
Motor 1 - V479- and Hybrid Battery Recirculation Door Posi‐
tioning Motor 2 - V480- is not OK, check the activation, using
function (for the Battery Regulation Control Module - J840- )
♦ The activation or function of the Hybrid Battery Refrigerant
Shut-Off Valve 2 - N517- (if the component for the expansion
valve on the battery cooling module is not OK, check the ac‐
tivation, using the Vehicle Diagnostic Tester in the “Guided
Fault Finding” Function for the Battery Regulation Control
Module - J840- )
♦ The measured values from the temperature sensors inside the
battery cooling module are not OK ( Temperature Sensor be‐
fore Hybrid Battery Evaporator - G756- , Temperature Sensor
after Hybrid Battery Evaporator - G757- ), check the measured
values, using the Vehicle Diagnostic Tester in the "Guided
Fault Finding" function (for the Battery Regulation Control
Module - J840- )
♦ If the air guide for the battery cooling module (to or from the
Traction Battery - A2- ) or to or from the battery cooling module
(for the vehicle forced air extraction) is not OK, check it. Refer
to ⇒ “10.5 Overview - Air Guide”, page 684 .
Note
♦ There are two evaporators installed in this vehicle (one in the

A/C unit and one in the battery cooling module). If the meas‐
ured temperature on one of the evaporators corresponds to
the target value or the target value falls short, but does not
reach the required target value on the other evaporator, the
following adjustment is performed: the Battery Regulation
Control Module - J840- activates the electric A/C compressor
with increased speed (thereby increasing the A/C cooling out‐
put and decreasing the pressure on the low pressure side as
well as the evaporator temperature) via the Electric Drive
Power and Control Electronics - JX1- and the A/C Compressor
Control Module - J842- . If the specified value for the temper‐
ature falls short at one of the evaporators, the Battery Regu‐
lation Control Module - J840- activates the Hybrid Battery
Refrigerant Shut-Off Valve 1 - N516- or the Hybrid Battery
Refrigerant Shut-Off Valve 2 - N517- , so that the evaporator
which is too cold is no longer supplied with refrigerant. Use the
Vehicle Diagnostic Tester in the “Guided Fault Finding” Func‐
tion for the A/C System.
♦ Since the evaporator output in the battery cooling module is
noticeably smaller than the evaporator output in the A/C unit,
the required specified temperature may still be reached in the
battery cooling module with too little refrigerant in the circuit,
but the specified temperature in the A/C unit evaporator will
no longer be attainable (even though the A/C compressor is
activated with an increased speed).
3.8.7 A/C Cooling Output, Testing Require‐

ments, vehicles with a High Voltage
System
Only for vehicles with a high voltage system (hybrid vehicles with
electrically driven A/C compressor), not for vehicles with mechan‐
ically driven A/C compressor
♦ The ambient temperature is greater than 15 °C (59 °F).
♦ The vehicle batteries are charged during the test in the battery
support mode via the battery charger. Refer to ⇒ Electrical
Equipment; Rep. Gr. 27 ; Battery; Battery, Charging .
Refer to
556 .
retrofit.
°C (176 °F)).
♦ There are no faults in DTC memory for the Electric Drive Pow‐
er and Control Electronics - JX1- , the Battery Regulation
Control Module - J840- and the A/C Compressor Control Mod‐
ule - J842- , using the Vehicle Diagnostic Tester in the "Guided


function.
♦ The ignition is turned on and the ready mode is activated, the
engine only runs, when, for example, the Traction Battery - A2-
DANGER!


Note

er's Manual.
to be active.

lights up).

nate).

greater).
Note
♦ The indicator lamp in the AUTO button(s) goes out when the
fresh air blower speed is changed manually.

vent in the rear center console is open.
Functions in Active Ready Mode:
Note

greater).
Note

– The A/C system goes in recirculating air mode (approximately

one minute after starting the engine/activating the ready
mode, the back pressure/fresh air door is closed and the air
recirculation door is opened, Fresh Air Blower - V2- extracts

the air from passenger compartment below instrument panel/

behind the glove compartment).
Note
If one of these requirements is not met, check the DTC memory

for the Climatronic Control Module - J255- and then perform the
output diagnostic test mode and read the measured values block,
using the Vehicle Diagnostic Tester in the "Guided Fault Finding"
function.
3.8.8 Cooling Output, Checking, Vehicles with

High Voltage System
Only for Vehicles with a High Voltage System (Hybrid Vehicles
with Electrically Driven A/C Compressor), Not for Vehicles with
Mechanically Driven A/C Compressor
♦ The requirements for testing the cooling capacity are fulfilled.
Refer to
⇒ “3.8.7 A/C Cooling Output, Testing Requirements, vehicles
with a High Voltage System”, page 90 .
– Measure the ambient temperature (must be warmer than 15 °
C (59 °F)).
– Close the doors, the engine hood, the windows, the sunroof
and the rear lid.
DANGER!


Note

er's Manual.
to be active.
– The ignition is turned on and the ready mode is activated, the

engine starts or only runs when, for example, the Traction
Battery - A2- has not been charged enough.
– Switch off the A/C compressor (set the “Econ” mode on the
head. The indicator lamp in the AC or A/C button does not
light up).
– Initiate the Guided Fault Finding for the A/C system, using the
tion.
– In the “read measured values block” function, select the dis‐
play groups with the measured values for the activation of the
A/C compressor and refrigerant circuit pressure and read the
measured values (for an Electrical A/C Compressor - V470- ,
they are displayed in various measured values blocks), using
function.
♦ The A/C compressor is turned off and there is no compressor
speed displayed.
♦ The pressure in the refrigerant circuit is same as the measured
outside temperature or greater than the value in the chart.
Ambient Temperature in ° Pressure Display Pressure in Bar
C (°F) (psi)
15 (15) 3.0 (43.5)
20 (68) 4.0 (58.0)
25 (77) 5.0 (72.5)
30 (86) 6.0 (87)
35 (95) 7.0 (101.5)

Note
♦ At absolute pressure, 0 bar (0 psi) corresponds to absolute

vacuum. Normal ambient pressure equals approximately 1 bar
(14.5 psi) absolute pressure and 0 bar (0 psi) pressure. On the
scales of most pressure gauges, 0 bar (0 psi) pressure corre‐
sponds to an absolute pressure of 1 bar (14.5 psi) (can be seen
from -1 mark below 0).
♦ Depending on version of the Climatronic Control Module -
J255- A/C display and control head, only integer values may
be displayed in the measured value block, if the pressure
measured lies between two values the display switches back
and forth.
♦ The displays for the activation of the A/C compressor are dif‐
ferent. For a mechanically driven A/C compressor, the target
and actual current for the activation of the A/C Compressor
Regulator Valve - N280- are displayed. For an Electrical A/C
Compressor - V470- , the specified and the actual speed of
the Electrical A/C Compressor - V470- , which is transmitted
by the A/C Compressor Control Module - J842- , is displayed
in another measured value block, using the Vehicle Diagnostic
♦ Pressure in refrigerant circuit is governed by ambient temper‐
ature. On account of heat given off by components (for exam‐
ple, the radiator), pressure displayed with warm engine will be
slightly higher than that given for the respective ambient tem‐
perature.
♦ If pressure displayed is below that indicated in table. Check
the signal coming from the A/C Pressure/Temperature Sensor
- G395- , using the Vehicle Diagnostic Tester in the "Guided
Fault Finding" function. If no fault can be determined at the A/
C Pressure/Temperature Sensor - G395- , there is insufficient
refrigerant in the circuit. Bring the vehicle to a workshop that
has the necessary tools and in which the work can be per‐
formed accordingly by qualified personnel. Refer to ⇒ Refrig‐
erant R134a Servicing; Rep. Gr. 87 ; A/C System General
General Information; Rep. Gr. 00 ; Legal Texts and Regula‐
tions .
If the refrigerant circuit pressure is OK.

– Switch the A/C compressor on by selecting the “Auto” mode
control head (the indicator lamp in the AUTO button(s) and the
AC or the A/C button illuminate).
– Set the temperature preset to “cold” using the knob(s) on the

head (for the driver and front passenger sides).
– On vehicles equipped with the “Convenience” A/C system, set
the Rear Temperature Selection Potentiometer - G538- to
– Using the knob(s) on the Climatronic Control Module - J255-
A/C display and control head, set the airflow direction to the
“instrument panel vents” (for the driver and front passenger
sides).
Note
♦ The indicator lamp in the one or both AUTO buttons goes out
when the vent direction for the air or fresh air blower speed is
manually changed.
– Read the RPM in “read measured values block” function, with

which the A/C Compressor Control Module - J842- activates
the Electrical A/C Compressor - V470- (a RPM higher than
800/min is displayed while the A/C compressor is running),
ing" function.
Note
♦ The specified speed is calculated by the Climatronic Control

Module - J255- A/C display and control head. The request is
sent via the Data Bus to the A/C Compressor Control Module
- J842- , using the Vehicle Diagnostic Tester in the "Guided
♦ The A/C compressor operates in the drive mode with a speed
of 800 to 8600 revolutions/minute.
♦ The A/C compressor will not activate at the maximum speed
(the A/C compressor speed is limited to about 5000/min)
specified (from approximately 8500/min) for a stopped or slow
moving vehicles (until the vehicle reaches a speed of about
45km/h (28 mph)).
♦ The A/C compressor output (the delivery volume) is not always
sufficient enough with an A/C compressor speed of 5000/min,
a very high outside air temperature (more than 35 °C (95 °F))
and a high fresh air blower speed (inefficient environmental
controls) to lower the temperature of the air after the evapo‐
rator to the specified value. To check the regulation of the A/
C compressor under these conditions, for example, activate
the fresh air blower only with approximately 40% of the maxi‐
mum voltage and check the temperature for a reduced fresh
air blower speed, using the Vehicle Diagnostic Tester in the
♦ If little to no RPM is displayed in the measured values block
(whether the required air temperature after the evaporator is
not yet achieved; the RPM is less than 4000/min), check the
activation of the Electrical A/C Compressor - V470- by the A/
C Compressor Control Module - J842- , using the Vehicle Di‐
– In the “read measured values block” function, read the refrig‐

erant circuit pressure measured by the A/C Pressure/Tem‐
perature Sensor - G395- ; the displayed pressure increases
above the value when the A/C compressor is switched off, us‐
function.

Note
♦ There is a fault in the refrigerant circuit if the pressure dis‐

played in the measured values block does not change and the
A/C compressor actuation is OK, using the Vehicle Diagnostic
Tester in the "Guided Fault Finding" function. Bring the vehicle
to a workshop that has the necessary tools and in which the
work can be performed accordingly by qualified personnel.
Refer to ⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ; A/C
System General Information or ⇒ A/C Systems with Refriger‐
ant R1234yf - General Information; Rep. Gr. 00 ; Legal Texts
and Regulations . If the A/C compressor control is not OK, then
♦ The A/C compressor is activated by the A/C Compressor Con‐
trol Module - J842- (at the request from the A/C system Cli‐
matronic Control Module - J255- A/C system display control
head) so that the air temperature according to the evaporator
reaches the specified value (approximately 2 to 5 °C (36 to 41
°F)).
♦ After the vehicle starts, the engine speed and the A/C com‐
pressor electrical system voltage are activated with a speed
greater than 3000/min depending on the measured tempera‐
ture. As soon as the temperature measured by the Evaporator
Vent Temperature Sensor - G263- nears the specified value,
the activation, and thus the compressor output, is reduced.
♦ Under certain operating conditions, residual moisture in the
refrigerant circuit can lead to ice build-up on the evaporator
expansion valve in the A/C system. The A/C compressor/ex‐
pansion valve regulation is reduced by this ice build-up. The
evaporator is either cooled too little or too intensely and po‐
tentially freezes. The ice on the evaporator may cause various
customer concerns. Refer to
⇒ “3.8.10 Ice Formation on Evaporator, Localizing Malfunc‐
tion, Vehicles with a High Voltage System”, page 104 .
♦ There are two evaporators installed in this vehicle (one in the
A/C unit and one in the battery cooling module). If the meas‐
ured temperature on one of the evaporators corresponds to
the target value or the target value falls short, but does not
reach the required target value on the other evaporator, the
following adjustment is performed: the Battery Regulation
Control Module - J840- activates the electric A/C compressor
with increased speed (thereby increasing the A/C cooling out‐
put and decreasing the pressure on the low pressure side as
well as the evaporator temperature) via the Electric Drive
Power and Control Electronics - JX1- and the A/C Compressor
Control Module - J842- . If the specified value for the temper‐
ature falls short at one of the evaporators, the Battery Regu‐
lation Control Module - J840- activates the Hybrid Battery
Refrigerant Shut-Off Valve 1 - N516- or the Hybrid Battery
Refrigerant Shut-Off Valve 2 - N517- , so that the evaporator
which is too cold is no longer supplied with refrigerant. using
function.
♦ Since the evaporator output in the battery cooling module is
noticeably smaller than the evaporator output in the A/C unit,
the required specified temperature may still be reached in the
battery cooling module with too little refrigerant in the circuit,
but the specified temperature in the A/C unit evaporator will
no longer be attainable (even though the A/C compressor is
activated with an increased speed).
– Press the button for recirculating air mode on the Climatronic

Control Module - J255- A/C display and control head (symbol
for “recirculating air mode” in the recirculation button illu‐

minates).
– In “read measured values block” function, read the measured
value for the Evaporator Vent Temperature Sensor - G263- ,
ing" function.

– Compare the displayed value (for the Evaporator Vent Tem‐

perature Sensor - G263- ) with the values in the diagram.
A - Air temperature measured by the Evaporator Vent Tempera‐
ture Sensor - G263- (downstream from evaporator)
B - Ambient Temperature
C - Permissible Tolerance Range
Depending on ambient temperature, air temperature measured
must be within stated tolerance range -C- after 5 minutes.
Note
♦ If the required values are not reached, check the measured

value for the Evaporator Vent Temperature Sensor - G263- .
To do so, compare the displayed value of the Evaporator Vent
Temperature Sensor - G263- with the measured values from
the Center Vent Temperature Sensor - G191- (on the “Basis”
version) / the Left Front Upper Body Vent Temperature Sensor
- G385- (on the “Convenience” version) with each other.
Sensor - G263- only slightly deviates from the measured value
for the Center Vent Temperature Sensor - G191- / Left Front
Upper Body Vent Temperature Sensor - G385- . Determine
the malfunction when there is a deviation from specified value.
Refer to
Output is not Achieved), Determining Malfunction, Vehicles
Sensor - G263- is greater than the measured value of the
Center Vent Temperature Sensor - G191- or the Left Front
Upper Body Vent Temperature Sensor - G385- , then make
sure the Evaporator Vent Temperature Sensor - G263- is in‐
stalled correctly. Refer to
ing and Installing”, page 662 and perform the electrical test
for this sensor, using the Vehicle Diagnostic Tester in the
♦ The function of the A/C system is, for example recognizable,
when the “low pressure side” refrigerant line (wide line be‐
cools down and the “high pressure side” refrigerant line (nar‐
row line between the condenser and quick-release coupling)
warms up. Refer to
the Refrigerant Circuit, Vehicles with High Voltage System”,
page 159 .

sor - G263- (and thus the A/C system cooling output) is OK and
if there is no complaint, the cooling output test ends.
Sensor - G263- (and thus the A/C system cooling output) is
not OK, determine the malfunction using the deviation from
specified value (the required cooling output is not reached).
Refer to
Output is not Achieved), Determining Malfunction, Vehicles
♦ If the Evaporator Vent Temperature Sensor - G263- measured

value (and thus the A/C system cooling output) is OK, and if
there is a complaint that the vent temperatures are too high or
differ, check the activation of the temperature doors. Refer to
⇒ “3.7.2 Heat Output and Temperature Door Activation,
Checking”, page 59 .
Note
The Hybrid Battery Refrigerant Shut-Off Valve 1 - N516- , which

installed in the refrigerant line for the expansion valve in front of
the evaporator in the A/C unit, is not open when it is active. Check
the function if this valve is activated or closed as refrigerant can
flow through the expansion valve, using the Vehicle Diagnostic
Tester in the "Guided Fault Finding" function (for the Battery Reg‐
ulation Control Module - J840- ).

sor - G263- (and thus the A/C system cooling output) is OK, and
if there is a complaint due to a lack of cooling output for the battery
cooling module.
♦ Check the activation and function of the battery cooling mod‐
ule components by the Battery Regulation Control Module -
J840- , using the Vehicle Diagnostic Tester in the "Guided
Note
The Hybrid Battery Refrigerant Shut-Off Valve 2 - N517- attached

to the battery cooling module expansion valve is closed when it
is not active. Check the functionality, using the Vehicle Diagnostic
Tester in the "Guided Fault Finding" function (for the Battery Reg‐
ulation Control Module - J840- ).
3.8.9 Specified Values Are Not Obtained (Re‐

quired Cooling Output is not Achieved),
Determining Malfunction, Vehicles with
a High Voltage System
– In “read measured values block”, select the display group with the measured values for the A/C com‐
pressor actuation and the refrigerant circuit pressure, using the Vehicle Diagnostic Tester in the "Guided

⇒ “3.8.8 Cooling Output, Checking, Vehicles with High Voltage System”, page 93 .
– During the cooling output test, pay attention to the display for the compressor actuation.
– Does the activation of the A/C compressor shut off during the cooling output test (the target speed is less
than 1500/minute)?
↓ ↓
Yes No
↓ ↓
Continuation. Refer to • Did the pressure in refrigerant circuit increase during the cooling output
⇒ page 101 . The A/C com‐ test?
pressor activation is switched
off.
↓ ↓
Yes No
↓ ↓

Continuation. Refer to Select the display –with the measured values

⇒ page 102 . Increase in for the activation of the Hybrid Battery Re‐
pressure in the refrigerant frigerant Shut-Off Valve 1 - N516- in the
circuit. “read measured values” function for the
Battery Regulation Control Module - J840- ,
using the Vehicle Diagnostic Tester in the
In the event that the

– Hybrid Battery Refrig‐
erant Shut-Off Valve 1 - N516- is activated,
remove the cause of the activation.
If the A/C compressor

– is being activated
and the Hybrid Battery Refrigerant Shut-Off
Valve 1 - N516- is being actuated, then
bring the vehicle to a workshop that has the
necessary tools and in which the work can
be performed accordingly by qualified per‐
sonnel. Refer to ⇒ Refrigerant R134a Serv‐
icing; Rep. Gr. 87 ; A/C System General
Information or ⇒ A/C Systems with Refrig‐
erant R1234yf - General Information; Rep.
Gr. 00 ; Legal Texts and Regulations .
Inform the workshop – of the fault (it is possi‐

ble that there is insufficient refrigerant in the
circuit, the Hybrid Battery Refrigerant Shut-
Off Valve 1 - N516- is closed or the Electri‐
cal A/C Compressor - V470- is defective).
Test Continuation “The A/C Compressor Actuation Is Switched

Off”
– If the A/C compressor activation is turned off during the cool‐
ing output test by the Climatronic Control Module - J255- A/
C display and control head (by the Battery Regulation Con‐
trol Module - J840- or by the A/C Compressor Control Module
- J842- ), is the specified speed less than 1500/min?
↓ ↓
Yes No
↓ ↓
– Check the DTC – Is the activation for the A/C compres‐
memory for the sor switched off during the cooling
Climatronic Con‐ output test by the Battery Regulation
trol Module - Control Module - J840- or by the A/C
J255- , the Battery Compressor Control Module - J842-
Regulation Con‐ (only the actual speed is less than
trol Module - J840- 1500/min)?
and the A/C Com‐
pressor Control
Module - J842- .

Correct
– any dis‐ Check the DTC – memory for the Bat‐
played faults and tery Regulation Control Module -
then erase the J840- and the A/C Compressor Con‐
DTC memory. trol Module - J842- , correct the
displayed malfunction and erase the
Read– the meas‐ DTC memory, using the Vehicle Di‐
ured values block agnostic Tester in the "Guided Fault
with the Clima‐ Finding" function.
tronic Control
Module - J255- Read the displays
– in the Battery Reg‐
compressor Shut- ulation Control Module - J840- and A/
Off conditions and C Compressor Control Module -J842-
then correct the measured values block, in which the
reason for the measured values for the Electrical A/
Shut-Off, using C Compressor - V470- activation are
the Vehicle Diag‐ displayed.
nostic Tester in
the "Guided Fault Check the actuation
– of the Electrical
Finding" function. A/C Compressor - N470- by the A/C
Compressor Control Module - J842-
Repeat
– the cool‐ and correct the cause of the Shut-Off.
ing output test. Refer to
Refer to ⇒ “2.4 A/C Compressor Regulator
⇒ “3.8.8 Cooling Valve N280 , Checking Switch-On
Output, Checking, Signal”, page 192 .
Vehicles with High
Voltage System”, Repeat the cooling
– output test. Refer
page 93 . to
⇒ “3.8.8 Cooling Output, Checking,
Vehicles with High Voltage System”,
page 93 .
Continuation of Test: “Pressure in Refrigerant Circuit Increases”
– Open the engine hood.

⇒ “3.8.8 Cooling Output, Checking, Vehicles with High Voltage System”, page 93 .
– From the measured values block for the Climatronic Control Module - J255- A/C display and control head,
read the refrigerant circuit pressure, using the Vehicle Diagnostic Tester in the "Guided Fault Finding"
function.
• Is the coolant fan(s) ( Coolant Fan - V7- and Coolant Fan 2 - V177- ) running during the cooling output
test. The RPM depends on the coolant temperature and on the refrigerant circuit pressure, it is determined
by the engine control module. Or the coolant fans switch off as soon as the refrigerant circuit pressure
exceeds approximately 9 bar (131 psi)?
↓ ↓
Yes No
↓ ↓
– Read the measured values blocks with the display for the “refrigerant – Check the coolant fan(s) ac‐
circuit pressure” and the “coolant fan actuation”, using the Vehicle Diag‐ tivation, for example, in the
nostic Tester in the "Guided Fault Finding" function. “output diagnostic test
mode” function, using the
• Do the coolant fan(s) run at a higher speed when the refrigerant circuit Vehicle Diagnostic Tester in
pressure increases according to the request from the Climatronic Control the "Guided Fault Finding"
Module - J255- ? function.
– Service the activation of the

coolant fan(s).
– Repeat the cooling output

test. Refer to
⇒ “3.8.8 Cooling Output,
Checking, Vehicles with
High Voltage System”, page
93 .

↓ ↓
Yes No
↓ ↓
– Select the display with the measured values for the ac‐ – Check the coolant fan(s) activation, for ex‐
tivation of the Hybrid Battery Refrigerant Shut-Off Valve ample in the “output diagnostic test mode”,
1 - N516- in the “read measured values” function for the using the Vehicle Diagnostic Tester in the
Battery Regulation Control Module - J840- , using the "Guided Fault Finding" function.
Vehicle Diagnostic Tester in the "Guided Fault Finding"
function. – Service the activation of the coolant fan(s).
– In the event that the Hybrid Battery Refrigerant Shut-Off – Repeat the cooling output test. Refer to
Valve 1 - N516- is activated, remove the cause of the ⇒ “3.8.8 Cooling Output, Checking, Vehicles
activation. with High Voltage System”, page 93 .
– If the A/C compressor is being activated and the Hybrid

Battery Refrigerant Shut-Off Valve 1 - N516- is being
actuated, then bring the vehicle to a workshop that has
the necessary tools and in which the work can be per‐
formed accordingly by qualified personnel. Refer to ⇒
Refrigerant R134a Servicing; Rep. Gr. 87 ; A/C System
R1234yf - General Information; Rep. Gr. 00 ; Legal
Texts and Regulations .
– Inform the workshop of the fault (it is possible that there

is insufficient refrigerant in the circuit, the Hybrid Battery
Refrigerant Shut-Off Valve 1 - N516- is closed or the
Electrical A/C Compressor - V470- is defective).

Note
♦ The pressure in the refrigerant circuit depends on several fac‐

tors. However, at an ambient temperature between 20 to 25 °
C (68 to 77 °F) the pressure should not exceed more than 20
bar (290 psi). Under extreme conditions (for example, during
“stop and go traffic” at a high ambient temperature and high
relative humidity), pressures up to 31 bar (450 psi) may occur
due to the extremely high cooling output.
♦ At ambient temperatures below 25 °C (77 °F), pressure in re‐
frigerant circuit does not normally exceed 16 bar (232 psi)
(coolant fans run and cool condenser).
head calculates the refrigerant circuit pressure via the meas‐
ured value for the A/C Pressure/Temperature Sensor - G395-
and displays it, using the Vehicle Diagnostic Tester in the
♦ At an absolute pressure of less than approximately 1.8 bar (26
psi) or greater than approximately 32 bar (464 psi), the Cli‐
matronic Control Module - J255- display and control head
does not switch on the A/C compressor (the A/C Compressor
Control Module - J842- and thus the Electrical A/C Compres‐
sor - V470- is not activated). The A/C compressor is only
switched on once the absolute pressure becomes greater than
1.8 bar (26 psi) or less than 16 bar (232 psi).
♦ Additional information regarding the refrigerant circuit pres‐
sure can be found in Guided Fault Finding, using the Vehicle
♦ To prevent abrupt A/C compressor Shut-Off due to excessive
pressure in refrigerant circuit or an excessive coolant temper‐
ature, the Climatronic Control Module - J255- A/C display and
control head regulates the A/C compressor output. As soon as
the refrigerant circuit pressure exceeds 30 bar (435 psi) (ab‐
solute pressure), full A/C compressor output is only enabled
again after pressure has become less than 27 bar (391 psi),
or the coolant temperature exceeds 115 °C (59 °F) (it is switch‐
ed off completely at 118 °C (64 °F)).
3.8.10 Ice Formation on Evaporator, Localizing

Malfunction, Vehicles with a High Volt‐
age System
♦ The Electrical A/C Compressor - V470- is activated via the A/
C Compressor Control Module - J842- by the Climatronic Con‐
trol Module - J255- A/C display control head, so that the air
temperature reaches the specified value downstream of the
evaporator (approximately 2 to 5 °C (41 °F)).
♦ After the turning on the ignition and depending on the speed
of the vehicle, the measured temperature and the electrical
system voltage, a value greater than 4000/min is displayed.
As soon as the temperature measured by the Evaporator Vent
Temperature Sensor - G263- nears the specified value, the
activation, and thus the compressor output, is reduced.
sor - G263- is faulty (too high), the following complaints may
occur:
– After a long drive, A/C system repeatedly or sporadically fails
(no cooling or heating output), after switching off vehicle and
after a short time, the A/C system function is OK again.

– The windows fog up from the inside after driving for a long time;
also, by pressing the “Defrost” button on the Climatronic Con‐
trol Module - J255- A/C display and control head, the windows
do not clear up right away, after turning off the vehicle and
waiting a short time, the A/C system is OK again.
Corrective measure:
– Check the measured value from the Evaporator Vent Tem‐
perature Sensor - G263- in the “Read measured values block”
function, using the Vehicle Diagnostic Tester in the "Guided
Sensor - G263- is too high under the conditions described by
the customer (although the A/C system is working properly,
depending on the ambient temperature greater than 10 °C (50
°F), for example), check the Evaporator Vent Temperature
Sensor - G263- (an incorrect measured value can cause the
evaporator to ice up).
– If the measured value of sensor for the Evaporator Vent Tem‐
perature Sensor - G263- is too low under the operating con‐
ditions reported by the customer (at an ambient temperature
above 0 °C (32 °F), colder than 0 °C (32 °F) for a long period
of time), check the activation of the Electrical A/C Compressor
- V470- and the Hybrid Battery Refrigerant Shut-Off Valve 1 -
N516- from the Battery Regulation Control Module - J840- . If,
for example, the Hybrid Battery Refrigerant Shut-Off Valve 1 -
N516- in hybrid mode is not properly activated (no activation,
even though it is only necessary to cool the Traction Battery -
A2- ) the evaporator in the A/C unit may ice up.
– Check the refrigerant line “low pressure side” (wide line be‐
with the engine running. Refer to
the Refrigerant Circuit, Vehicles with High Voltage System”,
page 159 . If this line is thickly iced over when a problem oc‐
curs (a very thin layer of ice is permitted), this indicates that
the temperature in the evaporator is too low. Check the meas‐
ured value for the Evaporator Vent Temperature Sensor -
G263- as well as the activation and function of the Electrical
A/C Compressor - V470- , of the Hybrid Battery Refrigerant
Shut-Off Valve 1 - N516- , of the Hybrid Battery Refrigerant
Shut-Off Valve 2 - N517- , of the A/C Compressor Control
Module - J842- and of the Battery Regulation Control Module
- J840- . Bring vehicle to a workshop that has the necessary
tools and in which the work can be performed accordingly by
qualified personnel, when a malfunction is detected at the
Electrical A/C Compressor - V470- , Hybrid Battery Refrigerant
Shut-Off Valve 1 - N516- , Hybrid Battery Refrigerant Shut-Off
Valve 2 - N517- or A/C Compressor Control Module - J842- ,
ing" function. Refer to ⇒ Vehicle Diagnostic Tester in the
"Guided Fault Finding" function and ⇒ Refrigerant R134a
Servicing; Rep. Gr. 87 ; A/C System General Information or
tion; Rep. Gr. 00 ; Legal Texts and Regulations . Bring the
problems determined to the attention of the workshop.

Note
Ice build up can occur on the evaporator under extreme circum‐

stances for particularly unfavorable A/C system settings (e.g.
airflow direction is set to the instrument panel vents and these
vents are closed, set to MAX AC for a minimal fresh air blower
speed). At this setting, air is no longer flowing through the evap‐
orator and is making the temperature at the Evaporator Vent
Temperature Sensor - G263- higher than the actual evaporator
temperature. It can be assumed for the A/C system regulation that
the Evaporator Vent Temperature Sensor - G263- measured val‐
ue corresponds to the actual evaporator temperature and contin‐
ues to activate the A/C Compressor Regulator Valve - N280- and
the evaporator cools too much.
3.9 Working on the Refrigerant Circuit

Work on refrigerant system should only be performed in a venti‐
lated rooms (workshops). Ensure that there are no workshop pits,
basement staircases or shafts within a five meter circumference.
Turn on the existing ventilation systems.
Reason:
The refrigerant emerging is not only colorless and odorless, but
also heavier than air and thus displaces oxygen. If refrigerant gas
does escape even though all the safety precautions have been
followed, there is a risk of suffocating in poorly ventilated areas
and in workshop pits - even if it is not noticeable.
Note
The escaping refrigerant/air mixture should not be inhaled, but

should be extracted via an existing exhaust-extraction ventilation
system.
Do not attempt repair on filled air conditioning systems by solder‐

ing, brazing or welding. This pertains also for welding and sol‐
dering work on the vehicle, in the event that parts of the climate
control system may heat up
Reason:
Exposure to heat creates considerable pressure in the system,
which could cause it to burst.
Corrective Measure:
Discharge the refrigerant circuit. Refer to
⇒ “3.10 Refrigerant Circuit, Discharging”, page 107 .
Note
Parts on the A/C that are damaged or leaking cannot be welded

or soldered. They must be replaced.
When servicing the A/C system, all open components and pipe
connections are to be immediately re-sealed.
Reason:
Moisture will ingress into A/C system components if they are left
open for a lengthy period. If this is the case, air conditioners can‐
not be refilled without having to replace parts of the system.

3.10 Refrigerant Circuit, Discharging

Refrigerant is never to be allowed to escape into the atmosphere,
but rather it is to be extracted from the refrigerant circuit using an
extractor or A/C service station. The drained refrigerant will be
locally recycled or is send to an environment-recycling place to
the manufacturer (different or additional laws may apply in indi‐
vidual companies). For this reason, bring vehicle to a workshop
that has the necessary tools and in which the work can be per‐
formed accordingly by qualified personnel. Refer to ⇒ Refrigerant
R134a Servicing; Rep. Gr. 87 ; A/C System General Information
or ⇒ A/C Systems with Refrigerant R1234yf - General Informa‐
tion; Rep. Gr. 00 ; Legal Texts and Regulations .
Refrigerant must never be drained out into the surrounding envi‐
ronment, but rather it is to be extracted from the refrigerant circuit
using an A/C service station. The drained refrigerant is either re‐
cycled on site or is sent back to the manufacturer for eco-friendly
disposal. Different or additional regulations may apply in other
countries. For this reason and if necessary, bring the vehicle to a
workshop that has the necessary tools and in which the work can
be performed by qualified personnel. Refer to ⇒ Refrigerant
R134a Servicing; Rep. Gr. 87 ; A/C System General Information
or ⇒ A/C Systems with Refrigerant R1234yf - General Informa‐
tion; Rep. Gr. 00 ; Legal Texts and Regulations .
Reason:
If refrigerant R134a and refrigerant R1234yf is released into the
environment, it enhances the greenhouse effect.
Note
♦ Refrigerant R134a has far less of a greenhouse effect than

R12.
♦ Refrigerant R1234yf has far less of a greenhouse effect than
R134a refrigerant.
♦ Refrigerant R134a and refrigerant R1234yf do not affect the
ozone layer of the Earth's atmosphere (refrigerant R134a and
refrigerant R1234yf do not contain chlorine atoms). Depletion
of the ozone layer in the upper atmosphere is however only
brought about by the splitting of carbon–chlorine bonds (as is
the case, for example, with refrigerant R12).
♦ The Global Warming Potential (GWP) of R1234yf is approxi‐
mately 4, while the GWP of R134a is approximately 1400
(GWP of carbon dioxide = 1). Refer to ⇒ A/C Systems with
Refrigerant R1234yf - General Information; Rep. Gr. 00 ; Le‐
gal Texts and Regulations .
Disconnect the connector from the A/C Compressor Regulator

Valve - N280- or from the High Pressure Sensor - G65- after dis‐
charging the A/C system.
Reason:
The A/C Compressor Regulator Valve - N280- is no longer acti‐
vated and the A/C compressor runs in neutral. The A/C compres‐
sor is designed so the lubrication of the A/C compressor
components at idle is guaranteed by an internal oil circuit (as long
as there is enough refrigerant oil in the A/C compressor).
3.11 Dust and Pollen Filter with Activated

Charcoal Insert, Element Information
♦ There are different versions of the dust and pollen filter (with‐
out and with a filter element with activated charcoal). Refer to
the Parts Catalog. On vehicles equipped with the “Conven‐

ience” A/C system, there is currently a dust and pollen filter

with an activated charcoal filter element installed; on vehicles
equipped with the “Basis” A/C system, there is a dust and pol‐
len filter without the activated charcoal filter element installed.
♦ In MY 2012, vehicles with a “Convenience” A/C system will
have a modified dust and pollen filter with an activated char‐
coal filter element installed as a running change. This filter with
an improved interception rate for fine particulates has approx‐
imately the same air resistance values as the filter installed
prior to the change, and for this reason will be in installed in
vehicles built up to the change. Refer to the Parts Catalog.
♦ The dust and pollen filter has an additional filter insert made
of activated charcoal on vehicles with the “Convenience” A/C
system. These vehicles also have an Air Quality Sensor -
G238- . Refer to
⇒ “9.2 Air Quality Sensor G238 , Function”, page 642 .
♦ The activated charcoal filter element functions as a dust and
pollen filter, however in addition the activated charcoal filter
can also filter out gaseous pollutants, for example, ozone,
benzene, nitrogen dioxide from the air flow. The basic task of
the activated charcoal layer in the dust and pollen filter is to
keep load peaks out of the passenger compartment.
♦ The activated charcoal also has the task of removing certain
gaseous contaminants from the air flowing through. The acti‐
vated charcoal layer in the dust and pollen filter reacts differ‐
ently to various pollutants in the air.
- Certain pollutants bond permanently in the activated charcoal
layer.
- Others are converted into innoxious bonds as in a catalytic con‐
verter.
- For the rest the activated charcoal works as a condenser (ca‐
pacitor). With increasing load pollutants are absorbed, until a
certain saturation is reached. If the amount of pollutants decrea‐
ses, the activated charcoal layer continuously releases the ab‐
sorbed particles.
♦ Because a portion of the gaseous pollutant particles as well
as dust and pollen bond permanently to the activated charcoal
layer, the dust and pollen filter should be changed more often
than scheduled under the following conditions:
– If vehicle is driven in areas with constant strong air pollution.
the activated charcoal layer in the dust and pollen filter is sa‐
turated faster than planned.
– If vehicle is predominantly driven with the “automatic recircu‐
lating” mode switched off.
♦ If possible, the A/C system on vehicles with a Air Quality Sen‐
sor - G238- should always be operated in “automatic recircu‐
lation” mode. However, if it is desired or necessary to switch
this mode off, the following must be observed:
- Activated charcoal layer in dust and pollen filter becomes satu‐
rated after a certain time.
- A saturated filter can no longer absorb pollutants and allows
them to pass unhindered.
♦ The most important task of the dust and pollen filter activated
charcoal filter element and the Air Quality Sensor - G238- is
keep the load peaks out from the passenger compartment. For
this the following must be observed:
– The vehicle is driven in an area with relatively clean air. with
few air pollutants. The switch-over from fresh air mode to re‐
circulating air mode will occur at a different time than on a

vehicle driven in an area that has high air pollutants, for ex‐
ample, in an industrial area.
– Independently of the basic load, the changeover from fresh to
recirculating mode always occurs, when the pollutant-load in‐
creases (for example, when driving to through an exhaust
cloud of a Diesel truck).
3.12 Painting on Vehicles with A/C System

When performing paint work repairs, object temperatures of 80 °
C (176 °F) are not to be exceeded in drying booths or their pre-
heating areas.
Reason:
Exposure to heat creates considerable pressure in the system,
which could cause it to burst.
3.13 Refrigerant Circuit Seals

♦ Always use O-rings only once, replace.
♦ Coat the O-rings with refrigerant oil before installing.
♦ Make sure O-rings are seated properly on pipe or in groove.
♦ Check the connections on the components and refrigerant
lines for damage (even a small scratch can lead to leakage).
♦ Perform the work under clean conditions (even the smallest
deposit such as a hair may cause a leak).
Note
♦ Only O-rings, that are durable against refrigerant R134a and/

or refrigerant R1234yf as well as the related refrigerant oil,
may be installed. These O-rings can be color-coded to avoid
confusion (for example, “red”, “light purple” or “dark purple”).
♦ The dimensions -a and b- are different depending on the com‐
ponent location of the O-ring seal. Refer to the Parts Catalog.
♦ In addition to the color-coded O–ring seals, use is also made
at the factory of black O–ring seals for certain connections.

4 Technical Data
⇒ “4.1 Refrigerant Capacities”, page 110
⇒ “4.2 Approved Refrigerant Oils and Refrigerant Oil Capacities”,
page 112
⇒ “4.3 Oil Distribution”, page 116
4.1 Refrigerant Capacities

⇒ “4.1.1 Refrigerant R134a Capacities”, page 110
⇒ “4.1.2 Refrigerant R1234yf Capacities”, page 111
4.1.1 Refrigerant R134a Capacities

Refrigerant R134a and refrigerant oil. Refer to ⇒ Refrigerant
R134a, Servicing; Rep. Gr. 87 ; Refrigerant R134a Capacities,
Refrigerant Oil and Approved Refrigerant Oil Capacities .
– Discharging, evacuating and filling the refrigerant circuit. Refer
to ⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ; Refrigerant
Circuit .
– Operate the A/C system after charging the refrigerant circuit.
Refer to
Note
♦ Depending on the time period of production and the engine,

the compressor construction type may vary. Refer to the Parts
Catalog.
♦ Depending on the type of A/C compressor, different refrigerant
oil capacities can be provided for the refrigerant circuit. Refer
to the Parts Catalog and ⇒ Refrigerant R134a Servicing; Rep.
Gr. 87 ; Refrigerant R134a Capacities, Refrigerant Oil and
Approved Refrigerant Oil .
♦ Always fill the refrigerant circuit up to the upper tolerance limit
(some refrigerant remains in filler hoses).
♦ Additional notes. Refer to ⇒ Refrigerant R134a Servicing;
Rep. Gr. 87 ; A/C System, General Information .

4.1.2 Refrigerant R1234yf Capacities
Note
♦ When charging the high-pressure side of refrigerant circuits,

always use maximum amount of refrigerant (some of the re‐
frigerant remains in the charging hoses).
♦ The specified capacities for refrigerant R1234yf apply if no
other different specifications are given, also for the “S” and
“RS” versions of this vehicle model.
♦ Make sure the A/C Service Station is on the same level as the
vehicle (maximum difference: 50 cm) when charging the re‐
frigerant circuit. If a difference in height is too large, a differ‐
ence between the amount of refrigerant displayed on the
service station and the actual amount filled in the circuit may
result (depending on the version of the A/C Service Station).
The filling precision of the A/C service station may change.
♦ The capacities for the refrigerant R1234yf and the correspond‐
ing refrigerant oil are no longer in the main repair manual, but
rather in this repair manual. Refer to
⇒ “4.2.3 Refrigerant Oil Capacities in Refrigerant Circuits for
Refrigerant R1234yf”, page 115 and ⇒ A/C Systems with Re‐
nical Data .
♦ Pay attention to the different capacities for refrigerant R134a
in vehicles without a rear A/C unit (with an evaporator) and in
vehicles with a high-voltage system (with two evaporators).
♦ For additional information on evacuating and charging the re‐
frigerant circuit, refer to ⇒ A/C Systems with Refrigerant
C Service Station .
– Discharge, evacuate and charge the refrigerant circuit. Refer

to ⇒ A/C Systems with Refrigerant R1234yf - General Infor‐
mation; Rep. Gr. 87 ; Working with A/C Service Station .
Refer to
Refrigerant R1234yf Capacity
Vehicle Production Capacity in Differing Features of
Model Period Grams This Refrigerant Circuit
Audi From 520+/- 15 • None
Q5, Au‐ 06/2016
di A5
and Au‐
di S5
(Coupe
, Cab‐
riolet
and
Sport‐
back)
4. Technical Data 111

4.2 Approved Refrigerant Oils and Refriger‐

ant Oil Capacities
⇒ “4.2.1 Approved Refrigerant Oils and Refrigerant Oil Capacities
for Refrigerant R134a”, page 112
⇒ “4.2.2 Approved Refrigerant Oils for Refrigerant R1234yf”, page
113
⇒ “4.2.3 Refrigerant Oil Capacities in Refrigerant Circuits for Re‐
frigerant R1234yf”, page 115
4.2.1 Approved Refrigerant Oils and Refriger‐

ant Oil Capacities for Refrigerant R134a
The special refrigerant oil that is only used for refrigerant circuits
with refrigerant R134a is not always commercially available. Re‐
fer to the Parts Catalog.
Refrigerant R134a and refrigerant oil. Refer to ⇒ Refrigerant
R134a, Servicing; Rep. Gr. 87 ; Refrigerant R134a Capacities,
Refrigerant Oil and Approved Refrigerant Oil Capacities .
– Discharging, evacuating and filling the refrigerant circuit. Refer
to ⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ; Refrigerant
Circuit .
– Operate the A/C system after filling the refrigerant circuit. Re‐
fer to
ant Circuit”, page 282 and ⇒ Refrigerant R134a Servicing;
Rep. Gr. 87 ; A/C System, General Information (Refrigerant
R134a, Servicing; A/C System, General Information). After re‐
charging, before activating the A/C system.
Caution
Malfunctions due to filling the A/C system with the wrong re‐
frigerant oil.
♦ Only fill the refrigerant circuit with approved refrigerant
oils. Refer to the Parts Catalog. The correct refrigerant oil
depends on the manufacturer and the type of A/C com‐
pressor installed. Refer to ⇒ Refrigerant R134a Servicing;
Rep. Gr. 87 ; Refrigerant R134a Capacities, Refrigerant
Oil and Approved Refrigerant Oil .
Malfunctions due to improper filling of the A/C system with re‐
frigerant oil.
♦ Too much refrigerant oil in the refrigerant circuit increases
the pressures and reduces the cooling output of the sys‐
tem.
♦ Too little refrigerant oil in the refrigerant circuit can lead to
A/C compressor failure due to lubrication problems.
Danger of corrosion in the refrigerant circuit.
♦ Refrigerant oil absorbs moisture. Do not use refrigerant oil
from containers that have been left open for a long period
of time. Refer to ⇒ Refrigerant R134a, Servicing; Rep.
Gr. 87 ; A/C System General Information .
Important Information
Refrigerant oil attracts moisture. Close any opened containers
immediately after use to prevent moisture from entering.

Note
♦ The specification about the usability of the refrigerant oil is

given on the bottle the refrigerant oil is delivered in.
♦ This time specification does not need to be observed when the
delivered bottle is tightly sealed.
♦ Refrigerant oil from a delivered bottle that is tightly sealed can
also be used after the time specified on the delivered bottle.
4.2.2 Approved Refrigerant Oils for Refriger‐

ant R1234yf
Note
♦ As PAG (polyalkylene glycol) oil is highly hygroscopic (attracts

water), opened containers are to be immediately resealed so
as to be air-tight.
♦ PAG oil from containers which have been open for a lengthy
period is no longer usable.
Caution
Malfunctions due to filling the A/C system with the wrong re‐
frigerant oil.
♦ Only fill the refrigerant circuit with approved refrigerant
oils. Refer to the Parts Catalog. The correct refrigerant oil
depends on the manufacturer and the type of A/C com‐
pressor installed.
Malfunctions due to improper filling of the A/C system with re‐
frigerant oil.
♦ Too much refrigerant oil in the refrigerant circuit increases
the pressures and reduces the cooling output of the sys‐
tem.
♦ Too little refrigerant oil in the refrigerant circuit can lead to
A/C compressor failure due to lubrication problems.
Danger of corrosion in the refrigerant circuit.
♦ Refrigerant oil absorbs moisture. Do not use refrigerant oil
from containers that have been open for a long period of
time. Refer to ⇒ A/C Systems with Refrigerant R1234yf -
General Information; Rep. Gr. 00 ; Repair Information,
Refrigerant and Refrigerant Oil .
Important Information
Refrigerant oil attracts moisture. Close any opened containers
immediately after use to prevent moisture from entering.

Note
♦ The specification about the usability of the refrigerant oil is

given on the bottle the refrigerant oil is delivered in.
♦ This time specification does not need to be observed when the
delivered bottle is tightly sealed.
♦ Refrigerant oil from a delivered bottle that is tightly sealed can
also be used after the time specified on the delivered bottle.
♦ The refrigerant oils specified for refrigerant R134a are not

suitable for refrigerant R1234yf. Refer to the Parts Catalog.
♦ The special refrigerant oil that is only used for refrigerant cir‐
cuits with refrigerant R1234yf is not always commercially
available. Refer to the Parts Catalog.
♦ Refrigerant oils specifically designed for each compressor can
therefore be obtained from the replacement parts program.
♦ If a faulty A/C compressor is replaced with an A/C compressor
from another manufacturer check for the A/C compressor to
be installed has the same refrigerant oil approved which is al‐
ready in the refrigerant circuit (from the removed A/C com‐
pressor). The refrigerant circuit must be cleaned (flushed) if
the A/C compressor to be installed requires a different refrig‐
erant oil than the refrigerant oil used for the removed A/C
compressor. Refer to ⇒ A/C Systems with Refrigerant
R1234yf - General Information; Rep. Gr. 87 ; Refrigerant Cir‐
cuit; Components, Replacing .
♦ The use of other refrigerant oils could cause system failure, as
they do not always mix and thus circulate with refrigerant
R1234yf (for compressor lubrication).
♦ There are different refrigerant oils used for the “Denso”-, “Del‐
phi/Mahle”-, “Visteon” and “Sanden” A/C compressors. Refer
♦ The refrigerant oil (part number G 055 535 M2, external label
ND 12)) to be used on refrigerant circuits with a “Denso” A/C
compressor is the same for mechanically and electrically-driv‐
en A/C compressors. Refer to the Parts Catalog.
♦ The refrigerant oil (part number G 052 535 M2, external label
SP A2) is to be used for mechanically and electrically-driven
“Sanden”-, “Delphi/Mahle” or “Visteon” A/C compressors. Re‐

Note
♦ Since different refrigerant oils are used depending on the A/C

compressor manufacturer, a certain small amount (up to max‐
imum 10%) of refrigerant oil may be released in the respective
vehicle refrigerant circuit with a different specification as the
respective A/C compressor installed. This is so that the A/C
service station does not have to be cleaned after every pro‐
cedure on different vehicles. Therefore for Audi, up to a max‐
imum of 10% SP A2 refrigerant oil may be filled on a vehicle
with a “Denso” A/C compressor (with ND 12 refrigerant oil), or
up to a maximum of 10% ND 12 refrigerant oil may be filled on
a vehicle with a “Sanden”, “Delphi/Mahle” or “Visteon” A/C
compressor (with SP A2 refrigerant oil). However, other re‐
frigerant oils that are not specified here may not be filled
(different properties due to different viscosity, other or missing
additives, etc.).
♦ Instead of discharging via the A/C service station, the extrac‐
ted refrigerant oil can either be filled when discharging the
refrigerant circuit via an open connection before evacuating
the refrigerant circuit, or at the removed valve -3- via a service
connection -1 or 2- using a commercially available syringe.
Refer to ⇒ A/C Systems with Refrigerant R1234yf - General
Information; Rep. Gr. 87 ; Working with A/C Service Station .
This is useful for example when a refrigerant oil is specified for
a refrigerant circuit, that is normally only seldom used. Always
fill with fresh coolant oil. Refer to the Parts Catalog. The allo‐
cation of the service connection -1 or 2- in the vehicle is
different. Refer to
partment”, page 120
Refer to
⇒ “4.2.3 Refrigerant Oil Capacities in Refrigerant Circuits for Re‐
frigerant R1234yf”, page 115
4.2.3 Refrigerant Oil Capacities in Refrigerant

Circuits for Refrigerant R1234yf
Note
♦ Depending on the time period of production and the engine,

the compressor construction type may vary. Refer to the Parts
Catalog.
♦ Depending on the A/C compressor type, different refrigerant
oil capacities may be designated for the refrigerant circuit. Re‐
♦ There are different refrigerant oils used for the “Denso”-, “Del‐
phi”-, “Visteon” and “Sanden” A/C compressors. Refer to
⇒ “4.2.2 Approved Refrigerant Oils for Refrigerant R1234yf”,
page 113 and the Parts Catalog.
♦ For additional information about refrigerant oil, refer to ⇒ A/C
Systems with Refrigerant R1234yf - General Information; Rep.
Gr. 00 ; Repair Information; Refrigerant and Refrigerant Oil .
♦ Refer to
⇒ “4.2.2 Approved Refrigerant Oils for Refrigerant R1234yf”,
page 113 .
♦ Overview and characteristics for the refrigerant circuit. Refer
to ⇒ “2.1 Overview - Refrigerant Circuit”, page 150 .

Ve‐ Pro‐ Total Quantity Quantity of Differing Fea‐

hicle duction of Oil in Re‐ Refrigerant tures of this
Mod Period frigerant Cir‐ Oil in Re‐ Refrigerant
el cuit in cm3 placement Circuit
Compressor
in cm3
Audi From 110 +/- 10 110 +/- 10 • A/C com‐
A5, 06/201 pressor
Audi 6 manufac‐
S5, tured by
Audi “Denso”
Q5, from type “6
Audi SES 14”
RS without A/C
Q5 clutch or
type “6 SAS
14” with A/
C clutch
Note
♦ The capacities also apply to the Audi S5, Audi SQ5 and Audi
RS 5.
♦ The replacement compressor contains the full quantity of oil
intended for the refrigerant circuit. If the A/C compressor is
replaced, the amount of oil in the A/C compressor must then
be adjusted. Refer to ⇒ A/C Systems with Refrigerant R1234yf
- General Information; Rep. Gr. 87 ; Refrigerant Circuit; Com‐
ponents, Replacing .
♦ At the start of production, mechanically-driven A/C compres‐
sors from different manufacturers are installed on all vehicles.
♦ These A/C compressors are available as replacement parts
with different oil fill capacities, therefore note capacity on the
A/C compressor and the exact part number. Refer to the Parts
Catalog
♦ The reason for the different oil capacities inside the A/C com‐
pressor is due to the design of the A/C compressor (with or
with an oil separator on the high pressure connection) or to the
design of the refrigerant circuit if the A/C compressors are
have the identical design. Pay attention to the different ca‐
pacities. Too much oil in the circuit leads to higher pressures
and reduces cooling output of the system. Too little oil may
lead to lubrication problems in the compressor.
♦ A data plate may be attached to the A/C compressor by the
manufacturer, indicating the part number and refrigerant oil
quantity.
4.3 Oil Distribution

♦ When the A/C system is being used, the refrigerant oil that was
in the A/C compressor before switching on the A/C system for
the first time is distributed throughout the entire refrigerant cir‐
cuit.
♦ Depending on the previous operating condition of the A/C sys‐
tem before switching off and the ambient temperatures, the
distribution of the refrigerant oil in the refrigerant circuit varies.
A general statement about the refrigerant oil distribution in the
refrigerant circuit is therefore not possible. Therefore, observe
the notes for replacing the refrigerant circuit components. Re‐
fer to ⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ; Refriger‐
ant Circuit Components, Replacing or ⇒ A/C Systems with

Refrigerant R1234yf - General Information; Rep. Gr. 87 ; Re‐

frigerant circuit; Components, Replacing .

5 Special Tools

80 – Heating, Ventilation
1 Overview - Heating
♦ For the Audi A4, Audi A5 and Audi Q5 only one Heating, Ven‐
tilation and Air Conditioning system is offered. Heating without
an A/C system is not currently offered.
♦ All information required for servicing the heating and A/C sys‐
tem can be found the A/C system. Refer to
partment”, page 120 and
⇒ “1.2 Overview - Components Inside Front Passenger Com‐
partment”, page 135 .
1. Overview - Heating 119

87 – Air Conditioning
1 Overview - A/C System
ment”, page 120
ment”, page 135
1.1 Overview - Components Outside of Pas‐

senger Compartment
Component Group “1”. Refer to ⇒ , page 120 .
Component Group “1”
Note
The following illustrations show the location of the components on an Audi A5 Coupe; an Audi A5 Sportback,
Audi A4, Audi Q5, etc. The location of the components varies slightly. The description of the components is not
different; removing and installing is performed in the same way as on the Audi A5 Coupe.
120 Rep. Gr.87 - Air Conditioning

1 - Rear Window Defogger -

Z1-
❑ The request to the rear
window defogger is sent
by the Climatronic Con‐
trol Module - J255- A/C
display and control head
via the Data Bus to the
Comfort System Central
Control Module - J393- .
The Rear Window De‐
fogger - Z1- is activated
by the Comfort System
Central Control Module
- J393- . Refer to Elec‐
trical Equipment and
use the Vehicle Diag‐
nostic Tester in the "Gui‐
ded Fault Finding" func‐
tion.
❑ Notes on function of the
rear window defogger.
Refer to
⇒ “1.4 Rear Window De‐
fogger”, page 12 .
❑ Rear window, removing
and installing. Refer to
⇒ Body Exterior; Rep.
Gr. 64 ; Rear Window;
Rear Window, Remov‐
ing and Installing .
2 - Comfort System Central
Control Module - J393-
❑ The Rear Window De‐
fogger - Z1- is activated
by the Comfort System
Central Control Module
- J393- . Refer to Elec‐
trical Equipment and
❑ Removing and installing, checking. Refer to Electrical System and use the Vehicle Diagnostic Tester in
3 - Information Label
❑ Includes the specifications for the refrigerant type and the designated capacity. Refer to
⇒ “4 Technical Data”, page 110 , ⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ; Refrigerant R134a
Capacities; Refrigerant Oil and Approved Refrigerant Oils and ⇒ A/C Systems with Refrigerant R1234yf
- General Information; Rep. Gr. 00 ; Technical Data .
4 - Plenum Chamber Water Drains
❑ A water drain is installed at left and right in plenum chamber.
❑ Removing and installing. Refer to
⇒ “6.10 Plenum Chamber Water Drain, Removing and Installing”, page 605 .
❑ Checking. Refer to ⇒ “6.11 Plenum Chamber Water Drain, Checking”, page 607 .
❑ Cleaning. Refer to ⇒ “6.12 Plenum Chamber Water Drain, Cleaning”, page 611 .
5 - Coolant Shut-Off Valve
❑ Depending on the engine, the Shut-Off valve is installed in the coolant feed and return line form the
engine to the A/C heater core.
1. Overview - A/C System 121

Note
♦ The vacuum from the Climatron‐

ic Coolant Shut-Off Valve -
N422- activates the Shut-Off
valve on start-of-production ve‐
hicles.
♦ On certain vehicles (depending
on the engine), vacuum-control‐
led coolant Shut-Off valves were
installed on vehicles without a
“parking heater” from start of pro‐
duction. Shut-Off valves that are
directly activated were installed
later as a running change. Refer
to the ⇒ Wiring diagrams, Trou‐
bleshooting & Component loca‐
tions and use the Vehicle Diag‐
nostic Tester in the "Guided
♦ This valve is referred to as a Cli‐
matronic Coolant Shut-Off Valve
- N422- or a Coolant Shut-Off
Valve - N82- depending on the
engine version and on the time of
production. Refer to ⇒ Wiring di‐
agrams, Troubleshooting &
Component locations and use
the Vehicle Diagnostic Tester in
the "Guided Fault Finding" func‐
tion.
❑ For the allocation of the coolant Shut-Off valve and of the Climatronic Coolant Shut-Off Valve - N422-
on the engine or inside the plenum chamber. Refer to
⇒ “7.1 Coolant Shut-Off Valve N82 / Climatronic Coolant Shut-Off Valve N422 Location, Activation and
Function”, page 619 .
6 - Climatronic Coolant Shut-Off Valve - N422- / Coolant Shut-Off Valve - N82-
❑ The component location and the version of the Climatronic Coolant Shut-Off Valve - N422- may differ. It
could be installed in the engine compartment or in the plenum chamber depending on the engine and
the version of the vehicle. Refer to
– The Climatronic Coolant Shut-Off Valve - N422- is currently only installed on certain vehicles with a 4-
or 6-Cylinder engine.
❑ Activation and function. Refer to
❑ For the allocation of the coolant Shut-Off valve and the Climatronic Coolant Shut-Off Valve - N422- inside
the vehicle. Refer to

Note
♦ On certain vehicles (depending

on the engine), vacuum-control‐
led coolant Shut-Off valves were
installed on vehicles without a
“parking heater” from start of pro‐
duction. Shut-Off valves that are
directly activated were installed
later as a running change. Refer
to the ⇒ Wiring diagrams, Trou‐
bleshooting & Component loca‐
tions and use the Vehicle Diag‐
♦ This valve is referred to as a Cli‐
- N422- or a Coolant Shut-Off
Valve - N82- depending on the
engine version and on the time of
production. Refer to ⇒ Wiring di‐
agrams, Troubleshooting &
Component locations and use
tion.
♦ The Climatronic Coolant Shut-
Off Valve - N422- / Coolant Shut-
Off Valve - N82- is not installed
in all versions with a 4-Cylinder
or 6-Cylinder engine. Installation
on vehicles without an “parking
heater” depends also on the
market.
♦ On vehicles with an engine with
a regulated coolant circuit (for
example, with a regulated cool‐
ant pump and a Cylinder Head
Coolant Valve - N489- ), no Cli‐
- N422- / Coolant Shut-Off Valve
- N82- is currently installed. On
an engine with a regulated cool‐
ant pump, the engine control
module activates the coolant
pump, and in doing so regulates
the coolant circuit. Refer to ⇒
Rep. Gr. 19 ; Coolant Pump/
Thermostat .
7 - Outside Air Temperature Sensor - G17-

❑ The measured value of the Outside Air Temperature Sensor - G17- is evaluated by the Vehicle Electrical
System Control Module - J519- and is transmitted via the Data Bus to the Climatronic Control Module -
J255- A/C display and control head. Use the Vehicle Diagnostic Tester in the "Guided Fault Finding"
function.
❑ If there is a complaint due to an excessive measured value on the Outside Air Temperature Sensor -
G17- . Refer to ⇒ “9.5 Outside Air Temperature Sensor G17 , Removing and Installing”, page 659 .
⇒ “9.5 Outside Air Temperature Sensor G17 , Removing and Installing”, page 659 .
8 - Coolant Fan - V7- and Coolant Fan 2 - V177-
❑ Different versions of the Coolant Fan - V7- and Coolant Fan 2 - V177- are installed depending on vehicle
equipment. Refer to the Parts Catalog.
❑ The request to switch on the Coolant Fan - V7- is transmitted by the Climatronic Control Module - J255-
A/C display and control head via the Data Bus to the engine control module. The engine control module

then activates the fan(s) ( Coolant Fan - V7- and Coolant Fan 2 - V177- ) directly or via the Coolant Fan
Control Module - J293- . Refer to ⇒ Wiring diagrams, Troubleshooting & Component locations and ⇒
Rep. Gr. 19 ; Radiator/Coolant Fan; Overview - Radiator/Coolant Fan .
❑ Check the coolant fan activation by the Climatronic Control Module - J255- A/C display and control head.
Use the Vehicle Diagnostic Tester in the "Guided Fault Finding" function.
❑ The respective engine control module switches, for example, the Coolant Fan - V7- and Coolant Fan 2
- V177- (directly or via the Coolant Fan Control Module - J293- ) continuously to the desired output
(depending on engine type). Use the Vehicle Diagnostic Tester in the "Guided Fault Finding" function.
Refer to ⇒ Wiring diagrams, Troubleshooting & Component locations.
9 - Air Quality Sensor - G238- / Humidity Sensor In Fresh Air Intake Duct - G657-
❑ Different version. Refer to the Parts Catalog.
Note
♦ There are different versions de‐

pending on the vehicle date of
manufacture and the A/C system
version (“Basis” or “Conven‐
ience”) is installed. The “Basis”
A/C system does not have a hu‐
midity sensor in the Humidity
Sensor in Fresh Air intake Duct -
G657- / Air Quality Sensor -
G238- until the MY 2012 change‐
over. From MY 2012 it has a
humidity sensor in Humidity Sen‐
sor in Fresh Air intake Duct -
G657- without an Air Quality
Sensor - G238- (black housing).
From MY 2012, the “Conven‐
ience” A/C system has an Air
Quality Sensor - G238- without a
Humidity Sensor in Fresh Air in‐
take Duct - G657- . From this
change, a Humidity Sensor in
Fresh Air intake Duct - G657- is
installed with an Air Quality Sen‐
sor - G238- (brown housing).
♦ Only vehicles with the “Conven‐
ience” A/C system have an Air
take Duct - G657- (from start of
production up the changeover).
Refer to
⇒ “8.1 Display and Control Head
Location”, page 629 and to the
Parts Catalog.

♦ From MY 2012, the vehicle ver‐

sion was changed-over as a run‐
ning change beginning with Audi
A4 and Audi A5. Refer to
Location”, page 629 . Vehicles,
built before the changeover and
with the “Convenience” A/C sys‐
tem, have an Air Quality Sensor
- G238- (not installed on the “Ba‐
sis” version). For vehicles built
since this changeover (and for
the Audi Q5 Hybrid), a Humidity
G657- is installed on the “Basis”
version and a Humidity Sensor in
Fresh Air intake Duct - G657-
with the Air Quality Sensor -
G238- is installed on vehicles
with the “Convenience” version.
❑ Function. Refer to ⇒ “9.2 Air Quality Sensor G238 , Function”, page 642 .
❑ Function. Refer to ⇒ “9.14 Humidity Sensor In Fresh Air Intake Duct G657 Function”, page 669 .
❑ Checking. Refer to ⇒ “9.3 Air Quality Sensor G238 , Checking”, page 645 .
❑ Checking. Refer to ⇒ “9.15 Humidity Sensor in Fresh Air intake Duct G657 , Checking”, page 670 .
⇒ “9.4 Air Quality Sensor G238 / Humidity Sensor In Fresh Air Intake Duct G657 , Removing and In‐
stalling”, page 655 .
❑ The Vehicle Electrical System Control Module - J519- evaluates the measured value from the Air Quality
Sensor - G238- / Humidity Sensor in Fresh Air intake Duct - G657- and then transmits it to the Climatronic
Control Module - J255- display and control head via the Data Bus. The Climatronic Control Module -
J255- display and control head switches, for example, to recirculating air mode when requested, if there
is no Shut-Off condition present. Use the Vehicle Diagnostic Tester in the "Guided Fault Finding" function.
10 - Fresh Air Intake with Intake Grille
❑ Check cowl panel trim with the cover for the fresh air intake for correct installation and damage. Check
the seals between the fresh air intake cover, the cowl panel trim and the window cross member for
damage and proper fit. These seals prevent water from entering between the window cross member and
the cowl panel trim and running into the A/C intake shroud. Refer to ⇒ Body Exterior; Rep. Gr. 50 ;
Bulkhead; Plenum Chamber Cover, Removing and Installing .
❑ Removing and installing. Refer to ⇒ “6.8 Fresh Air Intake, Removing and Installing”, page 600 and ⇒
Body Exterior; Rep. Gr. 50 ; Bulkhead; Plenum Chamber Cover, Removing and Installing .
❑ Make sure the intake grille fits correctly. The intake grille prevents foreign objects such as leaves from
getting into the A/C intake shroud.
❑ Depending on the version, for some countries with high dust levels (for example China), a filter is installed
instead of intake air grille, which prevents dust and sand from entering the fresh air blower. Refer to the
Parts Catalog.
❑ Removing and installing. Refer to ⇒ “6.8 Fresh Air Intake, Removing and Installing”, page 600 .
Note
The fresh air intake shaft may have

an additional cover with a rain water
drain channel depending on the ver‐
sion of the vehicle and the plenum
chamber cover installed. Refer to
⇒ “6.8 Fresh Air Intake, Removing
11 - Forced Air Extraction

❑ A forced air extraction vent is installed at left and right under rear bumper.
❑ Sealing doors on air extraction vent must be able to move freely and close automatically.
❑ In order for the passenger compartment ventilation to function properly, the air ducts that run through
the luggage compartment trim must be unobstructed.

❑ Checking. Refer to ⇒ “6.7 Passenger Compartment Forced Air Extraction, Checking”, page 596 .
1 - Refrigerant Line with Inner

Heat Exchanger
❑ In this refrigerant line,
liquid warm refrigerant
from the high pressure
side is released into the
low pressure side as
flowing vaporous refrig‐
erant energy. This in‐
creases the cooing effi‐
ciency of the A/C sys‐
tem.
❑ Refrigerant line, remov‐
ing and installing. Refer
to
⇒ “2.14 Refrigerant
Lines with Inner Heat
Exchanger, Removing
and Installing”,
page 227 .
❑ Refrigerant line, discon‐
necting from quick-cou‐
pling connection and
connecting. Refer to
Lines, Disconnecting
from Quick-Release
Couplings and Connect‐
ing”, page 221 .
2 - Expansion Valve
❑ Refrigerant line with in‐
ner heat exchanger, dis‐
connecting and recon‐
necting. Refer to
Exchanger, Removing
and Installing”,
page 227 .
❑ There are different versions depending on the refrigerant (R134a or R1234yf). Refer to the Parts Catalog.
❑ Removing and installing. Refer to ⇒ “2.15 Expansion Valve, Removing and Installing”, page 242 .
Note
From the start of production up to

the changeover from MY 2012,
evaporators approximately 40 mm
wide (block depth) were installed (A/
C unit part number “8K_ 820 005”).
From MY 2012 as a running change,
an evaporator with an approximate‐
ly 50 mm width (block depth) is be‐
ing installed depending on the vehi‐
cle version (A/C unit part number
“8T_ 820 005”). Pay attention to the
correct allocation of the expansion
valve to the evaporator (there are
different versions). Refer to the
Parts Catalog.

3 - Coolant Pipes to the Heat Exchanger In A/C Unit

❑ Coolant hoses, removing and installing; coolant circuit, bleeding. Refer to
⇒ “5.19 Heater Core, Removing and Installing”, page 567 (Heater Core, Removing and Installing).
4 - Low Pressure Side Service Connection
❑ To measure and discharge the refrigerant circuit. Refer to ⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ;
Refrigerant Circuit (Refrigerant R134a Servicing, Refrigerant Circuit, Working with A/C Service Station)
or ⇒ A/C Systems with Refrigerant R1234yf - General Information; Rep. Gr. 87 ; Working with A/C
Service Station .
Caution
Danger due to refriger‐
ant coming out under
pressure when there is a
faulty valve in the refrig‐
erant circuit.
Danger of frost bite to
skin and other parts of
the body.
Only
♦ remove when the
refrigerant circuit is emp‐
ty; the connection is with‐
out a valve. Refer to ⇒
Refrigerant R134a Serv‐
icing; Rep. Gr. 87 ; A/C
System General Informa‐
tion or ⇒ A/C Systems
with Refrigerant R1234yf
- General Information;
Rep. Gr. 87 ; Refrigerant
circuit; Overview - Refrig‐
erant Circuit Compo‐
nents .
❑ Cap with seal, always install

❑ There are different versions (with primary sealing valve or with Schrader valve) depending on the refrig‐
erant line. For distinguishing characteristics. Refer to ⇒ Refrigerant R134a, Servicing; Rep. Gr. 87 ; A/
C System, General Information (Refrigerant R134a, Servicing; A/C System, General Information).
❑ There are different versions depending on the refrigerant (R134a or R1234yf). Refer to
⇒ “2.21 Service Connection Differences, Depending on Refrigerant (R134a or R1234yf)”, page 278 or
the Parts Catalog.
Note
Depending on the allocation of the

service connection to the refrigerant
line and vehicle version, it may be
necessary to remove the left auxili‐
ary reinforcement on the tower
brace so that the A/C service station
service coupling can be connected
(for example, on the Audi Q5). Refer
to ⇒ Suspension, Wheels, Steering;
Rep. Gr. 40 ; Suspension Strut, Up‐
per Control Arm; Overview - Sus‐
pension Strut, Upper Control Arm
and ⇒ Refrigerant R134a Servicing;
Rep. Gr. 87 ; Refrigerant Circuit
(Refrigerant R134a Servicing,
Working with A/C Service Station) or
⇒ A/C Systems with Refrigerant
R1234yf - General Information;
Rep. Gr. 87 ; Working with A/C
Service Station .

5 - Refrigerant Line Quick-Release Coupling - Low Pressure Side
WARNING
The quick-release cou‐
pling connectors may be
unlocked and opened
only if the refrigerant cir‐
cuit is empty.
❑ Refrigerant line, disconnecting from quick-coupling connection and connecting. Refer to

⇒ “2.13 Refrigerant Lines, Disconnecting from Quick-Release Couplings and Connecting”, page 221 .
6 - High Pressure Side Service Connection
❑ To measure, discharge and fill the refrigerant circuit, refer to ⇒ Refrigerant R134a Servicing; Rep. Gr.
87 ; Refrigerant Circuit (Refrigerant R134a Servicing, Refrigerant Circuit, Working with A/C Service Sta‐
tion) or ⇒ A/C Systems with Refrigerant R1234yf - General Information; Rep. Gr. 87 ; Working with A/
C Service Station .
Caution
erant circuit.
the body.
Only
♦ remove when the
nents .
❑ Cap with seal, always install

erant line. For differentiations, refer to ⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ; A/C System General
Information or ⇒ A/C Systems with Refrigerant R1234yf - General Information; Rep. Gr. 87 ; Refrigerant
Circuit; Overview - Refrigerant Circuit Components .
the Parts Catalog.

Note

Service Station .
7 - Refrigerant Line Quick-Release Coupling - High Pressure Side
WARNING
unlocked and opened
cuit is empty.
8 - Receiver/Dryer
❑ It may only be removed when the refrigerant circuit is empty; bring the vehicle to a workshop that has
the necessary tools and in which the work can be performed by qualified personnel. Refer to ⇒ Refrig‐
erant R134a Servicing; Rep. Gr. 87 ; A/C System General Information or ⇒ A/C Systems with Refrigerant
R1234yf - General Information; Rep. Gr. 00 ; Legal Texts and Regulations .
❑ The receiver/dryer is installed directly on the condenser. Refer to
⇒ “2.19 Receiver/Dryer, Removing and Installing”, page 267 (Receiver/Dryer, Removing and Installing).
❑ There are different versions. Refer to the Parts Catalog.
Note
The receiver/dryer may be attached

to or integrated in the condenser,
depending on the version of the con‐
denser. Refer to
⇒ “2.19 Receiver/Dryer, Removing
and Installing”, page 267 and
⇒ “2.20 Dryer Bag/Dryer Cartridge,
Removing and Installing”,
page 271 .
❑ Dryer cartridge (on a condenser with an integrated receiver/dryer), removing and installing. Refer to
⇒ “2.20 Dryer Bag/Dryer Cartridge, Removing and Installing”, page 271 .
9 - Condenser
❑ It may only be removed when the refrigerant circuit is empty; bring the vehicle to a workshop that has
the necessary tools and in which the work can be performed by qualified personnel. Refer to ⇒ Refrig‐
erant R134a Servicing; Rep. Gr. 87 ; A/C System General Information or ⇒ A/C Systems with Refrigerant
R1234yf - General Information; Rep. Gr. 00 ; Legal Texts and Regulations .
❑ There are different versions (depending on vehicle equipment level). Refer to the Parts Catalog.
❑ Refrigerant lines, removing and installing. Refer to
⇒ “2.17 Refrigerant Lines, Disconnecting and Connecting at Condenser”, page 253 .

❑ Condenser, removing and installing. Refer to ⇒ “2.18 Condenser, Removing and Installing”, page 259 .
Note
It may be necessary to discharge

the refrigerant circuit and remove
the refrigerant pipes from the con‐
denser in order to remove the con‐
denser from the front end or to
remove the radiator depending on
the version of the radiator and the
condenser (for example, on the Audi
RS 4, Audi SQ5 and the Audi RS 5).
Refer to
⇒ “2.17 Refrigerant Lines, Discon‐
necting and Connecting at Con‐
denser”, page 253 .
10 - A/C Pressure/Temperature Sensor - G395-

⇒ “2.6 A/C Pressure/Temperature Sensor G395 , Removing and Installing”, page 197 .
❑ To check the signal, use the Vehicle Diagnostic Tester in the ”Guided Fault Finding” Function.
Note
The A/C Pressure/Temperature

Sensor - G395- exchanges informa‐
tion with the Vehicle Electrical Sys‐
tem Control Module - J519- via the
“LIN Bus”. Refer to
⇒ “2.8 A/C Pressure/Temperature
Sensor G395 , Checking Pressure
Signal”, page 200 .
11 - Mechanically Driven A/C Compressor

❑ A/C Compressor, Removing and Installing on Bracket, Vehicles with 4-Cylinder Engine and 6-Cylinder
TDI Engine. Refer to ⇒ “3.3 A/C Compressor, Removing and Installing on Bracket”, page 298 .
Note
♦ On vehicles with a 6-Cylinder

gasoline engine or an 8-Cylinder
FSI engine, the A/C compressor
can only be removed and instal‐
led at the bracket when the re‐
frigerant circuit is discharged.
Refer to
⇒ “3.5 A/C Compressor, Remov‐
ing and Installing”, page 325 (A/
C Compressor, Removing and
Installing).

♦ At start of production, A/C com‐

pressors manufactured by
“Denso” (type “6 SEU 14” on 4-
and 6-cylinder vehicles and type
“7 SEU 17” on 8-cylinder FSI ve‐
hicles) were installed. A/C com‐
pressors from different manufac‐
turers may also be installed at a
later time. Refer to the Parts Cat‐
alog and ⇒ Refrigerant R134a
Servicing; Rep. Gr. 87 ; Refrig‐
erant R134a Capacities; Refrig‐
erant Oil and Approved Refriger‐
ant Oils or
and ⇒ A/C Systems with Refrig‐
erant R1234yf - General Infor‐
mation; Rep. Gr. 00 ; Technical
Data .
♦ For additional information. Refer
to
⇒ “2.1 Overview - Refrigerant
Circuit”, page 150 .
12 - A/C Compressor Regulator Valve - N280-

❑ Check activation and function. Refer to
⇒ “2.4 A/C Compressor Regulator Valve N280 , Checking Switch-On Signal”, page 192 .
Note
♦ Installed only on vehicles equip‐

ped with a mechanically driven
A/C compressor
♦ Certain malfunctions at the A/C
Compressor Regulator Valve -
N280- (for example, a stuck
valve or a short circuit in the coil)
can lead to a complaint regard‐
ing the A/C compressor (A/C
system is not cooling, the evap‐
orator ices over, etc.). If the A/C
N280- (and not the A/C compres‐
sor itself) is the cause, the A/C
compressor can be serviced by
replacing the A/C Compressor
Regulator Valve - N280- . Refer
to ⇒ Refrigerant R134a, Servic‐
ing; Rep. Gr. 87 ; Refrigerant
Circuit Components, Replacing
or ⇒ A/C Systems with Refriger‐
ant R1234yf - General Informa‐
tion; Rep. Gr. 87 ; Refrigerant
Circuit; Components, Replac‐
ing .
♦ The A/C Compressor Regulator
Valve - N280- is not available as
a replacement part for all A/C
compressors. If the A/C Com‐
pressor Regulator Valve - N280-
is not available as an individual
A/C compressor part (different
versions), then the entire A/C
compressor must be replaced.

1 - Coolant Recirculation
Pump - V50- ( Water Pump -
V36- )
❑ Component location for
example on 6-Cylinder
FSI vehicles. Refer to
⇒ “7.2.2 Coolant Recir‐
culation Pump V50
( Water Pump V36 ), Lo‐
cation, Activation and
Function, Vehicles with
6-Cylinder Gasoline En‐
gine”, page 625 .
Note
♦ The Coolant Recirculation Pump

- V50- ( Water Pump - V36- ) is
only installed on vehicles without
a “parking heater”. Refer to
⇒ “7.2.2 Coolant Recirculation
Pump V50 ( Water Pump V36 ),
Location, Activation and Func‐
tion, Vehicles with 6-Cylinder
♦ For vehicles with a 6-Cylinder
TFSI engine, may also have a
Coolant Recirculation Pump -
V50- ( Water Pump - V36- ) in‐
stalled in this location, depend‐
ing on the vehicle version. Refer
to ⇒ Rep. Gr. 19 ; Coolant
Pump/Thermostat .
♦ For vehicles with a “parking heat‐
er”, the Recirculation Pump -
V55- assumes the function of the
V50- (the Water Pump - V36- ).
♦ Depending on the version of the
Climatronic Control Module -
J255- A/C display and control
head, the Coolant Recirculation
Pump - V50- may be referred to
as Water Pump - V36- in Guided
Fault Finding. Use the Vehicle
Diagnostic Tester in the "Guided
♦ Currently, on vehicles with an 8-
Cylinder FSI engine, there is no
V50- (introduction still open). Re‐
fer to ⇒ Rep. Gr. 19 ; Coolant
Pump/Thermostat and to the
Parts Catalog.


- V50- ( Water Pump - V36- ) ver‐
sion and activation differ de‐
pending on the vehicle version
and production period. From MY
2012 as a running change, the
pumps installed from the start of
production, which were activated
via a 500 Hertz signal (500 pul‐
ses per second), are being re‐
placed by pumps that are activa‐
ted by a variable (100 to 500
Hertz) signal depending on the
engine. Pumps that are activated
by a variable signal are also
equipped with a diagnostic func‐
tion and are activated mostly via
the respective engine control
module. Therefore, ensure the
correct allocation (only the allo‐
cated pump can be activated).
Use the Vehicle Diagnostic Test‐
er in the "Guided Fault Finding"
function. Refer to ⇒ Wiring dia‐
grams, Troubleshooting & Com‐
ponent locations and to the Parts
Catalog.
- V50- can be installed in differ‐
ent locations. For vehicles with a
6-Cylinder engine, the Coolant
Recirculation Pump - V50- can
be installed, for example, on the
longitudinal member as illustra‐
ted or it is assembled between
the plenum chamber bulkhead
and the engine. Refer to ⇒ Rep.
Gr. 19 ; Coolant Pump/Thermo‐
stat .
2 - Coolant Recirculation Pump - V50- ( Water Pump - V36- )

❑ Installed position for example by vehicles with 4-Cylinder engines and specific vehicles with a 6-Cylinder
engine. Refer to
⇒ “7.2.1 Coolant Recirculation Pump V50 ( Water Pump V36 ), Location, Activation and Function, Ve‐
hicles with 4- or 6-Cylinder Engine”, page 623 .
Note

- V50- ( Water Pump - V36- ) is
only installed on vehicles from
MY 2010 with the “Start/Stop
System” but without a “parking
heater”. Refer to
⇒ “7.2.1 Coolant Recirculation
Pump V50 ( Water Pump V36 ),
Location, Activation and Func‐
tion, Vehicles with 4- or 6-Cylin‐
der Engine”, page 623 .

♦ Vehicles with the “Start/Stop

System” and a “parking heater”
do not have a Coolant Recircu‐
lation Pump - V50- ( Water Pump
- V36- ). For these vehicles, the
Recirculation Pump - V55- as‐
sumes the function of the Cool‐
ant Recirculation Pump - V50-
(the Water Pump - V36- ).
head, the Coolant Recirculation
Pump - V50- may be referred to
as Water Pump - V36- in Guided
Fault Finding. Use the Vehicle
- V50- ( Water Pump - V36- ) ver‐
sion and activation differ de‐
pending on the vehicle version
and production period. From MY
2012 as a running change, the
pumps installed from the start of
production, which were activated
via a 500 Hertz signal (500 pul‐
ses per second), are being re‐
placed by pumps that are activa‐
ted by a variable (100 to 500
Hertz) signal depending on the
engine. Pumps that are activated
by a variable signal are also
equipped with a diagnostic func‐
tion and are activated mostly via
module. Therefore, ensure the
correct allocation (only the allo‐
cated pump can be activated).
ponent locations and to the Parts
Catalog.
- V50- can be installed in differ‐
ent locations. For most vehicles
with a 4-Cylinder engine and for
certain vehicles with a 6-Cylinder
engine, it is located between the
plenum chamber bulkhead and
the engine.
♦ The activation of the Coolant Re‐
circulation Pump - V50- varies. If
the vehicle has a high voltage
system (hybrid vehicles), then
the Climatronic Control Module -
J255- requests the activation via
module. Use the Vehicle Diag‐
Fault Finding" function. Refer to
⇒ Wiring diagrams, Trouble‐
shooting & Component loca‐
tions.

1.2 Overview - Components Inside Front

Passenger Compartment
Note
The following illustrations show the location of the components

on an Audi A5 Coupe; an Audi A5 Sportback, Audi A4, Audi Q5,
etc. The location of the components varies slightly. The descrip‐
tion of the components is not different; removing, installing and
checking is performed in the same way as on the Audi A5 Coupe.
Components on the Left Side. Refer to ⇒ , page 135 .

Components on the Right Side. Refer to ⇒ , page 144 .
Components on the Left Side
1 - Left Seat (Driver Seat) with

Seat Heating and Seat Venti‐
lation Components
❑ Seat heating compo‐
nents ( Left Front Seat
Temperature Sensor -
G344- , Left Front Seat
Heating Element - Z45- )
and seat ventilation
(control module and var‐
ious blowers). Refer to
⇒ Body Interior; Rep.
Gr. 72 ; Front Seats and
⇒ Body Interior; Rep.
Gr. 74 ; Front Seat Cov‐
ers and Cushions .
❑ The seat heating and
seat ventilation are not
installed in all vehicles
(optional equipment).
❑ The Climatronic Control
Module - J255- A/C dis‐
play and control head
adjusts the seat heating
and seat ventilation.
The activation of the
seat heating and seat
ventilation is displayed
in the measured values
block of the Climatronic
A/C display and control
head. To check, using
the Vehicle Diagnostic
Tester in the "Guided
❑ Different control mod‐
ules activate the seat
heating and the seat
ventilation, depending
on the vehicle equipment and version. Refer to ⇒ “1.3 Front Seat Heating and Ventilation”, page 5 , and
use the Vehicle Diagnostic Tester in the "Guided Fault Finding" function. (for the Vehicle Electrical Sys‐
tem Control Module - J519- , the Memory Seat/Steering Column Adjustment Control Module - J136- and
the Front Passenger Memory Seat Control Module - J521- , depending on the vehicle).
❑ Seating heating and ventilation, servicing. Refer to ⇒ Body Interior; Rep. Gr. 72 ; Front Seats and ⇒
Body Interior; Rep. Gr. 74 ; Front Seat Covers and Cushions .

❑ For information about seat heating and ventilation function. Refer to

⇒ “1.3 Front Seat Heating and Ventilation”, page 5 .
Note
♦ If there is a condition, where the

heating or ventilation of the driv‐
er or passenger seat cannot be
switched on, this will be stored as
a malfunction in the Vehicle
Electrical System Control Mod‐
ule - J519- , in the Memory Seat/
Steering Column Adjustment
Control Module - J136- or in
Front Passenger Memory Seat
Control Module - J521- (depend‐
ing on the vehicle version and
the vehicle equipment level).
Currently no information is sent
to the Climatronic Control Mod‐
ule - J255- A/C display and con‐
trol head on this vehicle via the
Data Bus system; the DTC mem‐
ory must be read out in each con‐
trol unit or in the Comfort System
Central Control Module - J393- ,
using the Vehicle Diagnostic
Tester in the "Guided Fault Find‐
ing" function. In the event of a
complaint regarding seat heating
or seat ventilation, first check the
DTC memory of the control mod‐
ules activating the seat heating
♦ The setting for the seat heating
and ventilation is adjusted on the
head; this adjustment is trans‐
mitted to the Vehicle Electrical
System Control Module - J519-
via the Data Bus. The specified
temperatures for the different
seat heating and seat ventilation
settings are stored in the Vehicle
ule - J519- . Depending on the
version of the Vehicle Electrical
and on the vehicle date of man‐
ufacture, the specified tempera‐
ture for the seat heating and
ventilation can be different with
the same setting on the Clima‐
tronic Control Module - J255- A/
C display and control head, us‐
ing the Vehicle Diagnostic Tester
in the "Guided Fault Finding"
function (for the Vehicle Electri‐
cal System Control Module -
J519- ).
2 - Left Condensation Water Drain (Driver Side)

❑ Removing and Installing. Refer to
❑ Checking. Refer to ⇒ “5.21 Condensation Water Drain, Checking”, page 578 .

3 - Accelerator Mechanism
❑ The request to switch off the A/C compressor kick-down (via the A/C Compressor Regulator Valve -
N280- ) comes from the engine control module (the data is exchanged through the Data Bus). The actual
activation of the A/C Compressor Regulator Valve - N280- can be read in the measured values block for
the Climatronic Control Module - J255- A/C display and control head, using the Vehicle Diagnostic Tester
in the "Guided Fault Finding" function (the A/C system and, depending on engine, the fuel injection and
ignition system or the diesel direct injection and glow plug system).
4 - Diagnostic Connection
❑ Perform the Guided Fault Finding for the A/C system, using the Vehicle Diagnostic Tester in the "Guided
5 - Vehicle Electrical System Control Module - J519-
❑ The A/C system activates different components, for example, the Rear Window Defogger - Z1- via the
Comfort System Central Control Module - J393- . Refer to Electrical System and use the Vehicle Diag‐
❑ Removing and installing, checking. Refer to Electrical Equipment
6 - Left Front Upper Body Vent Temperature Sensor - G385-
– Installed only in the “Convenience” A/C system.
⇒ “9.12 Left Front Upper Body Vent Temperature Sensor G385 , Removing and Installing”, page 667 .
7 - Defroster Vent/Left Side Window
❑ To remove and install. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instrument Panel; Overview - Instrument
Panel .
8 - Left Instrument Panel Vent
❑ Instrument panel vent, removing and installing. Refer to
⇒ “6.13 Instrument Panel Vents and Rear Vents, Removing and Installing”, page 616 and ⇒ Body
Interior; Rep. Gr. 70 ; Instrument Panel; Instrument Panel Vent, Removing and Installing .
9 - Instrument Cluster Control Module - J285-
❑ With Outside Air Temperature Display - G106- in the driver information system
❑ If there is a complaint due to an excessive display value Outside Air Temperature Display - G106- (due
to an excessive measured value of the Outside Air Temperature Sensor - G17- ). Refer to
⇒ “9.5 Outside Air Temperature Sensor G17 , Removing and Installing”, page 659 .
❑ To check, using the Vehicle Diagnostic Tester in the "Guided Fault Finding" function.
10 - Front Information Display Control Head - J685-
❑ Multi Media Interface (MMI) Display
❑ Different versions and operation; depending on the version of the MMI (“Infotainment” or “Basis”) and
the vehicle equipment level. Refer to the Owner's Manual Infotainment/MMI.
❑ Functions (and various additional A/C system functions) selected on the Climatronic Control Module -
J255- display and control head are shown via the MMI display. Refer to Infotainment/MMI Operating
Instructions.
❑ Via the button “car” of the Radio - R- or the Multimedia System Control Head - E380- (depending on the
vehicle equipment level), various additional functions of the A/C system can be started and their setting
changed. Refer to the Infotainment/MMI operating instructions.
❑ On the Audi A5 Coupe and Audi A4 from MY 2009, revised Climatronic Control Module - J255- display
and control heads are being installed as a running change (this has been already done on the Audi Q5
since the start of production). -item 14- ⇒ Item 14 (page 140) and refer to the Parts Catalog. On vehicles
with these display and control heads, and depending on the coding and adaptation, for example the
display on the screen for the “MMI” (Multi Media Interface), when using the buttons and knobs, the display
and control head no longer switches to “A/C system”. The selected functions for the A/C system appear
in the display sequentially (different versions), using the Vehicle Diagnostic Tester in the "Guided Fault
Finding" function, the Owner's Manual and “Infotainment/MMI” Operating Instructions.

Note
♦ Ensure the correct allocation,

coding and adaptation for the Cli‐
matronic Control Module - J255-
display and control head to the
Front Information Display Con‐
trol Head Control Module -
J523- / Information Electronics
Control Module 1 - J794- (differ‐
ent versions depending on the
production period and vehicle
equipment level). Refer to the
Parts Catalog. If the allocation,
coding and adaptation are incor‐
rect, the A/C function cannot be
displayed or selected in the MMI.
♦ From MY 2010, this vehicle has
a Start/Stop System for specific
engines as optional equipment.
On vehicles with Start/Stop sys‐
tem, the Climatronic Control
Module - J255- display and con‐
trol head prevents the Stop func‐
tion depending on the setting. If,
for example, “defrost” is selec‐
ted, the stop function is not pos‐
sible or will be interrupted and
the engine will start. The same
applies in the case of heating
and cooling. The difference be‐
tween the selected and actual
temperature exceeds a certain
value, using the Vehicle Diag‐
♦ Vehicles with the Start/Stop Sys‐
tem have an additional coolant
pump for the Stop function de‐
pending on the vehicle equip‐
ment level and on the version of
the vehicle. Refer to, ⇒ Rep. Gr.
19 ; Coolant Pump/Thermostat
and use the Vehicle Diagnostic
ing" function.
♦ If the vehicle has a Start/Stop
System, then only the Climatron‐
ic Control Module - J255- display
and control heads may be instal‐
led with the part number 8T1 820
043 starting with index “AG” or
with part number 8K_ 820 043.
Refer to
Location”, page 629 and the
Parts Catalog.
11 - Humidity Sensor - G355-

⇒ “9.10 Humidity Sensor G355 , Removing and Installing”, page 663 .
– Not installed on all vehicles (depends on when the vehicle was manufactured and on the vehicle equip‐
ment).

Note
♦ At the start of production, the Hu‐

midity Sensor - G355- was only
installed on the “Convenience”
A/C system.
Location”, page 629 . Vehicles
with the “Basis” A/C system built
after the changeover have a Hu‐
midity Sensor - G355- .
♦ The Comfort System Central
Control Module - J393- or the
Data Bus On Board Diagnostic
Interface - J533- evaluates the
measured value from the Humid‐
ity Sensor - G355- for vehicles
manufactured before the
changeover. The Vehicle Electri‐
J519- evaluates the measured
value from the Humidity Sensor -
G355- on vehicles manufactured
from the product changeover.
Refer to, Electrical Equipment
ing" function.
♦ Depending on time period of pro‐
duction (from MY 2012 as a run‐
ning change) and vehicle ver‐
sion, the Humidity Sensor -
G355- no longer operates as an
individual part in the DTC mem‐
ory. On these vehicles, the Rain/
Light Recognition Sensor -
G397- is displayed as the fault
location in the event of a devia‐
tion on the Humidity Sensor -
G355- .
12 - Radio - R-
❑ Depending on the vehicle equipment level, a Multimedia System Control Head - E380- may be installed
instead of the Radio - R- .
❑ Using the “Car” button, various additional A/C system functions can be started and their setting changed.
Refer to the Owner's Manual Infotainment/MMI
13 - Interior Temperature Sensor Fan - V42- and Instrument Panel Temperature Sensor - G56-
❑ Installed in the Climatronic Control Module - J255- A/C display and control head.
❑ Interior Temperature Sensor Fan - V42- , removing and installing. Refer to
⇒ “8.3 Interior Temperature Sensor Fan, Removing and Installing ”, page 639 .
❑ The Instrument Panel Temperature Sensor - G56- is integrated in the Climatronic Control Module - J255-
A/C display and control head and cannot be replaced separately.

Note
On the “Convenience” A/C system,

if the intermediate piece on the air
guides to the rear footwell vents and
on the air guide to the rear center
console vents is installed incorrect‐
ly, warm or cold air can escape and
influence the A/C system. This air is
then taken in by the Interior Tem‐
perature Sensor Fan - V42- and the
measured value from the Instrument
Panel Temperature Sensor - G56-
will be different from the actual tem‐
perature inside the passenger com‐
partment.
14 - Climatronic Control Module - J255- Display and Control Head, “Basic” Version
❑ There are different versions (for vehicles without or with seat heating, left- or right side steering, de‐
pending on the time of manufacture and vehicle equipment level). For allocation, -item 15-
⇒ Item 15 (page 143) and refer to the Parts Catalog.
⇒ “8.2 Display and Control Head, Removing and Installing”, page 636 .
A/C display and control head (cannot be replaced separately).
❑ The Interior Temperature Sensor Fan - V42- is installed in the Climatronic Control Module - J255- A/C
display and control head, however it cannot be replaced individually. Refer to
❑ The Guided Fault Finding of the Climatronic Control Module - J255- display and control head is to be
performed as described in Guided Fault Finding, using the Vehicle Diagnostic Tester in the "Guided Fault
Finding" function.
❑ Also observe additional notes for the Climatronic Control Module - J255- A/C display and control head.
Refer to ⇒ “1.9 Notes on Display and Control Head”, page 26 .
Note
♦ On the Audi A5 Coupé and Audi

A4 from MY 2009, the Climatron‐
and control heads with the part
number 8T1 820 043 starting
with the index “T” or are installed
(on the Audi Q5 this was already
installed since the start of pro‐
duction). Refer to the Parts Cat‐
alog and -item 15-
⇒ Item 15 (page 143) .
♦ From MY 2010, a Start/Stop Sys‐
tem will be offered as an option
for this vehicle with certain en‐
gines. Refer to -item 15-
⇒ Item 15 (page 143) and use
tion.
♦ If the vehicle has a Start/Stop
System, then only the Climatron‐
and control heads may be instal‐
led with the part number 8T1 820
043 starting with index “AG”. Re‐

Note
♦ Updated Fresh Air Blower Con‐

trol Module - J126- , Fresh Air
Blower - V2- , Climatronic Con‐
trol Module - J255- A/C display
and control head, Vehicle Elec‐
trical System Control Module -
J519- , Comfort System Central
Control Module - J393- , Air
Quality Sensor - G238- and A/C
units are being installed as a run‐
ning change from MY 2012 (de‐
pending on the vehicle version).
Pay attention to the correct ver‐
sion and allocation of these com‐
ponents. Refer to the Parts Cat‐
alog and use the Vehicle
♦ If the allocation or adaptation of
J255- to the Fresh Air Blower
Control Module - J126- (with the
part number 8K0 820 521 or 8T0
820 521) is not according to the
specification, then the Fresh Air
Blower - V2- is not regulated by
the Fresh Air Blower Control
Module - J126- . There may not
always be an entry in the DTC
memory even though the activa‐
tion of the Fresh Air Blower - V2-
is not OK. Make sure the Clima‐
tronic Control Module - J255- is
adapted correctly. Refer to the
Parts Catalog and use the Vehi‐
cle Diagnostic Tester in the "Gui‐
♦ At the start of production, the Hu‐
midity Sensor - G355- was only
installed on the “Convenience”
A/C system. Since the introduc‐
tion of the Start/Stop System
from MY 2010, the Humidity
Sensor - G355- is also being in‐
stalled in vehicles with the “Ba‐
sis” A/C system and this optional
equipment.

♦ The Comfort System Central

Control Module - J393- or the
Data Bus On Board Diagnostic
Interface - J533- evaluates the
measured value from the Humid‐
ity Sensor - G355- for vehicles
manufactured before the version
changeover (except for the Audi
Q5 hybrid). The Vehicle Electri‐
J519- evaluates the measured
value from the Humidity Sensor -
G355- on vehicles manufactured
from the product changeover
(and on all Audi Q5 hybrids). Re‐
fer to, Electrical Equipment and
use the Vehicle Diagnostic Test‐
function.
duction (from MY 2012 as a run‐
ning change) and vehicle ver‐
sion, the Humidity Sensor -
G355- no longer operates as an
individual part in the DTC mem‐
ory. On these vehicles, the Rain/
Light Recognition Sensor -
G397- is displayed as the fault
location in the event of a devia‐
tion on the Humidity Sensor -
G355- .
♦ Different versions of the Humidi‐
ty Sensor in Fresh Air intake
Duct - G657- / Air Quality Sensor
- G238- are being installed de‐
pending on the vehicle date of
manufacture and A/C system
version (“Basis” or “Conven‐
ience”). The “Basis” A/C system
does not, for example, have a
humidity sensor in the Humidity
G657- / Air Quality Sensor -
G238- until the MY 2012 change‐
over. From MY 2012 it has a
humidity sensor in Humidity Sen‐
sor in Fresh Air intake Duct -
G657- without an Air Quality
Sensor - G238- (black housing).
From MY 2012, the “Conven‐
ience” A/C system has an Air
take Duct - G657- . From this
change, a Humidity Sensor in
installed with an Air Quality Sen‐
sor - G238- (brown housing).
♦ The Air Quality Sensor - G238-
without the Humidity Sensor in
only installed on vehicles with
the “Convenience” A/C system
(from the start of production up to
the version changeover in MY
2012). Refer to the Parts Cata‐
log.


Location”, page 629 . Vehicles,
built before the changeover and
with the “Convenience” A/C sys‐
tem, have an Air Quality Sensor
- G238- (not installed on the “Ba‐
sis” version). For vehicles built
since this changeover (and for
the Audi Q5 Hybrid), a Humidity
G657- is installed on the “Basis”
version and a Humidity Sensor in
Fresh Air intake Duct - G657-
with the Air Quality Sensor -
G238- is installed on vehicles
with the “Convenience” version.
♦ The buttons and knobs have
LEDs that cannot be replaced in‐
dividually.
♦ The function and indicator lamps
in the buttons and in the knobs
cannot be replaced separately.
15 - Climatronic Control Module - J255- Display and Control Head, “Convenience” Version
❑ Different versions (for vehicles without or with heated seats/seat ventilation, left- or right side steering,
depending on the time of manufacturer and equipment level), allocation Parts Catalog
⇒ “8.2 Display and Control Head, Removing and Installing”, page 636 .
display and control head (cannot be replaced separately).
❑ The Interior Temperature Sensor Fan - V42- is installed in the Climatronic Control Module - J255- A/C
display and control head, however it cannot be replaced individually. Refer to
❑ The Guided Fault Finding of the Climatronic Control Module - J255- display and control head is to be
performed as described in Guided Fault Finding, using the Vehicle Diagnostic Tester in the "Guided Fault
Finding" function.
❑ Also observe additional notes for the Climatronic Control Module - J255- A/C display and control head.
Refer to ⇒ “1.9 Notes on Display and Control Head”, page 26 .
❑ The buttons, displays and rotatory switches are lit with LEDs; they cannot be replaced individually
❑ The function and indicator lamps in the buttons and in the dials cannot be replaced separately.
❑ On the Audi A5 Coupé and Audi A4 from MY 2009, the Climatronic Control Module - J255- display and
control heads with the part number 8T1 820 043 starting with the index “T” are installed (on the Audi Q5
this was already installed since the start of production). Refer to the Parts Catalog. On vehicles with these
display and control heads, and depending on the coding and adaptation, for example the display on the
screen for the “MMI” (Multi Media Interface), when using the buttons and knobs, the display and control
head no longer switches to “A/C system”. The selected functions for the A/C system appear in the display
sequentially, using the Vehicle Diagnostic Tester in the "Guided Fault Finding" function, the “Infotainment/
MMI” Operating Instructions and the Owner's Manual.

Note
♦ Pay attention to the correct allo‐

cation, coding and adaptation of
J255- display and control head to
the Front Information Display
Control Head Control Module -
J523- to the Information Elec‐
tronics Control Module 1 - J794- .
Refer to the Parts Catalog and
function. If the allocation, coding
or adaptation are incorrect, the
A/C system functions cannot be
displayed or selected in the MMI.
♦ The Climatronic Control Module
- J255- display and control heads
with the part number 8T1 820
043 up to index “S” are installed
on vehicles with a Front Informa‐
tion Display Control Head Con‐
trol Module - J523- .
♦ The Climatronic Control Module
- J255- display and control heads
with the part number 8T1 820
043 beginning with index “T” may
be installed on vehicles with an
Information Electronics Control
Module 1 - J794- . In order to be
able to select and display the dif‐
ferent functions, the coding and
adaptation must be correct for
the vehicle equipment level.
♦ Read the information regarding
the vehicle updates from MY
2012 -item 14-
⇒ Item 14 (page 140)
16 - Multimedia System Control Head - E380-

❑ Depending on the vehicle equipment level, a Radio - R- may be installed instead of the Multimedia System
Control Head - E380- .
❑ Using the “Car” button, various additional A/C system functions can be started and their setting changed.
Refer to the Owner's Manual Infotainment/MMI
❑ In order for the various A/C system functions to be selected on the Multimedia System Control Head -
E380- and displayed on the Front Information Display Control Head - J685- , the correct version of the
Climatronic Control Module - J255- display and control head must be installed and coded correctly and
adapted -item 15- ⇒ Item 15 (page 143) .
Components on the Right Side
Note
Depending on production time period and vehicle version, the rear seat heating is activated by, for example,
the Seat Heating Control Module - J882- , which is installed on the wheel housing at the right rear of the luggage
compartment. Refer to ⇒ Wiring diagrams, Troubleshooting & Component locations.

1 - Defroster Vent/Windshield
❑ Removing and instal‐
ling. Refer to ⇒ Body
Interior; Rep. Gr. 70 ;
Instrument Panel; Front
Center Defroster Vent,
Removing and Instal‐
ling .
2 - Sunlight Photo Sensor -
G107-
❑ To remove and install.
Refer to
⇒ “9.1 Sunlight Photo
Sensor G107 , Remov‐
ing and Installing”, page
640 and ⇒ Body Interi‐
or; Rep. Gr. 70 ; Instru‐
ment Panel; Overview -
Instrument Panel .
3 - Vents for Indirect Ventila‐
tion/Loud Speaker Cover, In‐
strument Panel, Center
❑ Vent, removing and in‐
stalling. Refer to ⇒ Body
Instrument Panel; Over‐
view - Instrument Pan‐
el .
❑ The vent for indirect
ventilation is only instal‐
led on vehicles equip‐
ped with the “Conven‐
ience” A/C system. On
vehicles equipped with
the “Basis” A/C system,
the cover is installed
and the opening for the
A/C is sealed (different
version of the A/C system and the air guide under the dash panel).
4 - A/C Unit with Evaporator and Add-On Components
❑ There are different versions depending on the vehicle version and equipment level. Refer to
⇒ “4 Actuators”, page 388 and the Parts Catalog.
❑ Air guide in the air conditioner and in vehicle. Refer to ⇒ “6 Air Guide”, page 581 .
❑ A/C unit components. Refer to ⇒ “4 Actuators”, page 388 .
❑ Clean the evaporator of the A/C system using the Ultrasound A/C Cleaner - VAS6189B- . Refer to
⇒ “5.7 Evaporator, Cleaning”, page 496 .
❑ A/C unit, removing and installing. Refer to
⇒ “5.11 Heater and A/C Unit, Removing and Installing”, page 520 .
Note
From 01/2008, A/C units which have

an additional connection for the
glove compartment cooling are be‐
ing installed as a running change.
On vehicles without glove compart‐
ment cooling, this connection is
sealed with a plug. Refer to
⇒ “6.14 Glove Compartment Cool‐
ing Connection on Air Intake Hous‐
ing”, page 616 .

5 - Left Center Instrument Panel Vent

6 - Right Center Instrument Panel Vent
7 - Defroster Vent/Right Side Window
❑ Removing and installing. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instrument Panel; Overview - Instrument
Panel .
8 - Right Instrument Panel Vent
9 - Dust and Pollen Filter (with or without Activated Charcoal Filter Element)
❑ Follow the replacement intervals. Refer to Maintenance Tables.
❑ There are different versions depending on the vehicle version and equipment level. Refer to the Parts
Catalog.
– On vehicles with the “Basis” A/C system without activated charcoal filter element
– On vehicles with the “Convenience” A/C system with an activated charcoal filter element There is an Air
Quality Sensor - G238- installed on these vehicles. Refer to
⇒ “3.11 Dust and Pollen Filter with Activated Charcoal Insert, Element Information”, page 107 .
❑ Removing and installing. Refer to ⇒ “5.15 Dust and Pollen Filter, Removing and Installing”, page 556 .
Note
♦ In MY 2012, vehicles with a

“Convenience” A/C system will
have a modified dust and pollen
filter with an activated charcoal
filter element installed as a run‐
ning change. This filter with an
improved interception rate for
fine particulates has approxi‐
mately the same air resistance
values as the filter installed prior
to the change, and for this rea‐
son will be in installed in vehicles
built up to the change. Refer to
the Parts Catalog.
♦ If the customer requests it, it is
permitted the exchange a dust
and pollen filter without an acti‐
vated charcoal filter element that
came with the vehicle from the
manufacturer for a dust and pol‐
len filter with an activated char‐
coal filter element so long as the
vehicle has the “Basis” A/C sys‐
tem. Refer to the Parts Catalog.
10 - Right Front Upper Body Vent Temperature Sensor - G386-

⇒ “9.13 Right Front Upper Body Vent Temperature Sensor G386 , Removing and Installing”,
page 667 .
❑ Installed only in the “Convenience” A/C system.

11 - Right Condensation Water Drain (Front Passenger Side)

❑ Checking. Refer to ⇒ “5.21 Condensation Water Drain, Checking”, page 578 .
12 - Right Seat (Front Passenger Seat) with Seat Heating and Seat Ventilation Components
❑ Seat heating components ( Right Front Seat Temperature Sensor - G345- and Right Front Seat Heating
Element - Z45- ) and seat ventilation (control module and various blowers). Refer to ⇒ Body Interior;
Rep. Gr. 72 ; Front Seats and ⇒ Body Interior; Rep. Gr. 74 ; Front Seat Covers and Cushions .
❑ The seat heating and seat ventilation are not installed in all vehicles (optional equipment).
❑ The Climatronic Control Module - J255- A/C display and control head adjusts the seat heating and seat
ventilation. The activation of the seat heating and seat ventilation is displayed in the measured values
block of the Climatronic Control Module - J255- A/C display and control head. To check, using the Vehicle
❑ Different control modules activate the seat heating and the seat ventilation, depending on the vehicle
equipment and version. Refer to ⇒ Wiring diagrams, Troubleshooting & Component locations and use
the Vehicle Diagnostic Tester in the "Guided Fault Finding" function. (for the Vehicle Electrical System
Control Module - J519- , the Memory Seat/Steering Column Adjustment Control Module - J136- and the
Front Passenger Memory Seat Control Module - J521- , depending on the vehicle).
❑ Seating heating and ventilation, servicing. Refer to ⇒ Body Interior; Rep. Gr. 72 ; Front Seats and ⇒
Body Interior; Rep. Gr. 74 ; Front Seat Covers and Cushions .
❑ For information about seat heating and ventilation function. Refer to
⇒ “1.3 Front Seat Heating and Ventilation”, page 5 .
Note
♦ If there is a condition, where the

heating or ventilation of the driv‐
er or passenger seat cannot be
switched on, this will be stored as
a malfunction in the Vehicle
ule - J519- , in the Memory Seat/
Steering Column Adjustment
Control Module - J136- or in
Front Passenger Memory Seat
Control Module - J521- (depend‐
ing on the vehicle version and
the vehicle equipment level).
Currently no information is sent
to the Climatronic Control Mod‐
ule - J255- A/C display and con‐
trol head on this vehicle via the
Data Bus system; the DTC mem‐
ory must be read out in each con‐
trol unit or in the Comfort System
Central Control Module - J393- ,
ing" function. In the event of a
complaint regarding seat heating
or seat ventilation, first check the
DTC memory of the control mod‐
ules activating the seat heating

♦ The setting for the seat heating

and ventilation is adjusted on the
head; this adjustment is trans‐
mitted to the Vehicle Electrical
via the Data Bus. The target tem‐
peratures for the different seat
heating and seat ventilation set‐
tings are stored in the Vehicle
ule - J519- . Depending on the
version of the Vehicle Electrical
and on the vehicle date of man‐
ufacture, the specified tempera‐
ture for the seat heating and
ventilation can be different with
the same setting on the Clima‐
tronic Control Module - J255- A/
C display and control head, us‐
function (for the Vehicle Electri‐
J519- ).
13 - Vent in Rear Center Console

❑ To remove and install. Refer to
Interior; Rep. Gr. 68 ; Center Console; Overview - Center Console .
– Only installed on the “Convenience” A/C system (on the “Basis” A/C system, the opening in the center
console is sealed).
14 - Rear Temperature Selection Potentiometer - G538-

– Only installed on the “Convenience” A/C system (on the “Basis” A/C system, the opening in the center
console is sealed).
❑ The Rear Temperature Selection Potentiometer - G538- is vent component and cannot be replaced
separately. Refer to the Parts Catalog.
❑ To remove and install. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Center Console; Overview - Center
Console .
❑ To check using the Vehicle Diagnostic Tester in the "Guided Fault Finding" function.

2. Refrigerant Circuit 149

2 Refrigerant Circuit
⇒ “2.1 Overview - Refrigerant Circuit”, page 150
⇒ “2.2 Overview - Refrigerant Line”, page 187
⇒ “2.3 Overview - Refrigerant Lines”, page 190
⇒ “2.4 A/C Compressor Regulator Valve N280 , Checking Switch-
On Signal”, page 192
⇒ “2.5 A/C Compressor Regulator Valve N280 , Checking Acti‐
vation”, page 197
⇒ “2.6 A/C Pressure/Temperature Sensor G395 , Removing and
Installing”, page 197
⇒ “2.7 A/C Pressure/Temperature Sensor G395 , Checking”,
page 198
⇒ “2.8 A/C Pressure/Temperature Sensor G395 , Checking Pres‐
sure Signal”, page 200
⇒ “2.9 Refrigerant Lines to Front Battery Cooling Module, Re‐
moving and Installing, on Vehicle Floor”, page 201
⇒ “2.10 Refrigerant Lines to Rear Battery Cooling Module, Re‐
moving and Installing, on Vehicle Floor”, page 205
⇒ “2.11 Refrigerant Line Pass-Through in Luggage Compart‐
ment, Removing and Installing ”, page 210
⇒ “2.12 Refrigerant Lines for Battery Cooling Module in Luggage
Compartment, Removing and Installing”, page 215
⇒ “2.13 Refrigerant Lines, Disconnecting from Quick-Release
Couplings and Connecting”, page 221
⇒ “2.14 Refrigerant Lines with Inner Heat Exchanger, Removing
and Installing”, page 227
⇒ “2.15 Expansion Valve, Removing and Installing”, page 242
Q5 Hybrid
⇒ “2.16 Rear Expansion Valve with Hybrid Battery Refrigerant
Shut-Off Valve 2 N517 , Removing and Installing”, page 248
⇒ “2.17 Refrigerant Lines, Disconnecting and Connecting at Con‐
denser”, page 253
⇒ “2.18 Condenser, Removing and Installing”, page 259
⇒ “2.19 Receiver/Dryer, Removing and Installing”, page 267
⇒ “2.20 Dryer Bag/Dryer Cartridge, Removing and Installing”,
page 271
⇒ “2.21 Service Connection Differences, Depending on Refriger‐
ant (R134a or R1234yf)”, page 278
⇒ “2.22 Evacuating and Charging Valve, Removing and Installing,
Low and High Pressure Side”, page 281
⇒ “2.23 A/C System, Starting Operation after Filling Refrigerant
Circuit”, page 282
2.1 Overview - Refrigerant Circuit

⇒ “2.1.1 System Overview - Refrigerant Circuit, Not Opening the
Refrigerant Circuit, Vehicles without High Voltage System”, page
151
⇒ “2.1.2 System Overview - Refrigerant Circuit, Not Opening the
Refrigerant Circuit, Vehicles with High Voltage System”,
page 159

⇒ “2.1.3 System Overview - Refrigerant Circuit, Opening the Re‐

frigerant Circuit, Vehicles without High Voltage System”,
page 165
⇒ “2.1.4 System Overview - Refrigerant Circuit, Opening the Re‐
frigerant Circuit, Vehicles with High Voltage System”, page 177
2.1.1 System Overview - Refrigerant Circuit, Not Opening the Refrigerant Circuit,
Vehicles without High Voltage System
Note
♦ Refrigerant circuit, servicing. Refer to ⇒ “2 Refrigerant Circuit”, page 150 .

♦ The parts identified with 1) can be serviced or replaced by any workshop. The work procedures identified
with 1) can be performed by any workshop. These components and work procedures do not affect the
refrigerant circuit.
♦ Refrigerant circuit components not identified with 1) cannot be serviced or replaced by all workshops. This
also applies to all refrigerant hoses and refrigerant lines. Components not identified with 1) can only be
serviced or replaced by a workshop that has all the necessary equipment and tools. In these workshops
only trained technicians may perform this work. The refrigerant circuit must be discharged to do this. Refer
to ⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ; A/C System General Information or ⇒ A/C Systems with
Refrigerant R1234yf - General Information; Rep. Gr. 00 ; Legal Texts and Regulations .
HD = High Pressure Side

ND = Low Pressure Side
Arrows point in direction of refrigerant flow.

1 - A/C Compressor Regulator

Valve - N280-
❑ Checking activation and
functionality. Refer to
⇒ “2.4 A/C Compressor
Regulator Valve N280 ,
Checking Switch-On
Signal”, page 192 1) .
2 - A/C Compressor
❑ A/C compressor, re‐
moving from bracket
and reinstalling, vehi‐
cles with 4-Cylinder and
6-Cylinder TDI engine.
Refer to
⇒ “3.3 A/C Compressor,
Removing and Installing
on Bracket”, page 298
1).
❑ There are different ver‐

sions depending on the
refrigerant (R134a or
R1234yf). Refer to the
Parts Catalog.
Note
♦ On vehicles with a 6-Cylinder

gasoline engine or an 8-Cylinder
FSI engine, the A/C compressor
can only be removed and instal‐
led at the bracket when the re‐
frigerant circuit is discharged.
Refer to
ing and Installing”, page 325 (A/
C Compressor, Removing and
Installing).
♦ At start of production, A/C com‐
pressors manufactured by
“Denso” (type “6 SEU 14” on 4-
later time. Refer to
⇒ “4.2 Approved Refrigerant Oils
and Refrigerant Oil Capacities”,
page 112 , the Parts Catalog and
⇒ Refrigerant R134a Servicing;
Rep. Gr. 87 ; Refrigerant R134a
Capacities; Refrigerant Oil and
Approved Refrigerant Oils or
Data .
duction and on engine, compres‐
sor construction type may vary.

♦ The A/C compressors are avail‐

able as replacement parts with
different oil capacities, therefore
note capacity on the A/C com‐
pressor and the exact part num‐
ber. Refer to
Capacities, Refrigerant Oil and
Approved Refrigerant Oils or
Data .
♦ Depending on A/C compressor
type, different refrigerant oil ca‐
pacities may be designated for
the refrigerant circuit. The rea‐
son for the different oil capacities
in the A/C compressor for an oth‐
erwise identical refrigerant cir‐
cuit is the design of the compres‐
sor. Observe these oil capaci‐
ties. Too much oil in the
refrigerant circuit increases the
pressures and reduces the cool‐
ing output of the A/C system. Too
little oil can cause lubrication
problems in the A/C compressor.
Refer to
page 112 , ⇒ Refrigerant R134a
erant R134a Capacities; Refrig‐
ant Oils or
Data .
♦ When installing the refrigerant
lines and the corresponding
brackets, make sure there is ad‐
equate distance between the
belt, bracket and belt pulley.

♦ An A/C compressor with an A/C

Clutch - N25- is installed as a
running change on certain 4-Cyl‐
inder vehicles from MY 2012.
The A/C clutch turns off the A/C
compressor drive completely un‐
der certain conditions (for exam‐
ple “ECON”). The correct Clima‐
tronic Control Module - J255-
version must be installed and
coded correctly so that the A/C
Clutch - N25- can be activated by
J255- display and control head.
function.
3 - Belt Pulley- A/C Compressor Drive Unit/Belt Pulley with A/C Clutch - N25-
❑ A/C compressor belt pulley, replacing Applies to vehicles with 4- and 6-Cylinder engine 1). Refer to
❑ Ribbed belt, removing and installing. Applies to vehicles with a 4- and 6-Cylinder engine 1). Refer to ⇒
Rep. Gr. 13 ; Cylinder Block, Belt Pulley Side; Ribbed Belt, Removing and Installing .
❑ Ribbed belt allocation (for 4- and 6-Cylinder vehicles). Refer to the Parts Catalog.
❑ A/C compressor drive unit, replacing (vehicles with 8-Cylinder FSI engine). Refer to
⇒ “3.1.2 Overview - A/C Compressor Power Unit, Vehicles with 8-Cylinder Engine”, page 290 (A/C
compressor, removing. Refer to ⇒ “3.5 A/C Compressor, Removing and Installing”, page 325 )
❑ Belt pulley with A/C Clutch - N25- , replacing. Applies to certain vehicles with a 4-Cylinder engine from
MY 2012 1). Refer to
⇒ “3.7.3 Belt Pulley, Removing and Installing, A/C Compressor with A/C Clutch N25 ”, page 379 .
Note
♦ There is an overload protection

installed between the belt pulley
and the A/C compressor input
shaft to protect the belt should
the A/C compressor get blocked
or be difficult to move.
♦ If the A/C compressor is runs
with resistance, the overload
safeguard interrupts the supply
of power to it.
♦ Rubber elements are installed
between belt pulley/drive unit
and the A/C compressor input
shaft, vibrations which may oc‐
cur during A/C compressor oper‐
ation may be dissipated via
these rubber elements (damper
function at torque fluctuations).
♦ There are different versions of
the pulley are installed depend‐
ing on the type of A/C compres‐
sor and engine. Refer to the
Parts Catalog and
⇒ “3 A/C Compressor”,
page 288 .


function.
4 - Oil Drain Plug

5 - Pressure Relief Valve
6 - Connection with Valve
7 - A/C Pressure/Temperature Sensor - G395- 1)
Note
♦ The A/C Pressure/Temperature

Sensor - G395- exchanges infor‐
mation with the Vehicle Electrical
via a local Data Bus. The Vehicle
ule - J519- transmits the data via
the Data Bus to the Climatronic
Control Module - J255- display
and control head. For this reason
a High Pressure Sensor - G65-
cannot be installed on this vehi‐
cle (it only delivers square-wave
signals). Refer to Parts Catalog.
♦ The temperature measured by
the A/C Pressure/Temperature
Sensor - G395- differs from the
actual refrigerant temperature in
the refrigerant circuit because of
Sensor - G395- design and its
component location. Because of
this, it is not currently evaluated
and is not used to regulate the A/
C system.
8 - Condenser

Note

Refer to
9 - Receiver/Dryer
❑ The receiver/dryer is mounted directly on the condenser. Refer to
⇒ “2.19 Receiver/Dryer, Removing and Installing”, page 267 (Receiver/Dryer, Removing and Installing)
WARNING
unlocked and opened
cuit is empty.
11 - Cap
❑ With a seal
❑ Always screw on
erant line differentiations. Refer to ⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ; A/C System General
the Parts Catalog.
❑ For the A/C service station to measure the pressures, discharge and fill the refrigerant circuit. Refer to
⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ; Refrigerant Circuit (Refrigerant R134a Servicing, Refrig‐
erant Circuit, Working with A/C Service Station) or ⇒ A/C Systems with Refrigerant R1234yf - General
❑ Depending on the engine version, it may be necessary to remove some components in order to be able
to connect to the service coupling.

Caution
erant circuit.
the body.
Only
♦ remove when the
nents .
Note

Service Station .
13 - Refrigerant Line with Inner Heat Exchanger

❑ In this refrigerant line, liquid warm refrigerant from the high pressure side is released into the low pressure
side as flowing vaporous refrigerant energy. This increases the cooing efficiency of the A/C system.
14 - Expansion Valve
15 - Evaporator
WARNING
unlocked and opened
cuit is empty.

17 - Sealing Cap
❑ With a seal
❑ Always screw on
the Parts Catalog.
erant line. For differentiations, refer to ⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ; A/C System General
the Parts Catalog.
❑ For the A/C service station to measure the pressures and discharge the refrigerant circuit. Refer to ⇒
Refrigerant R134a Servicing; Rep. Gr. 87 ; Refrigerant Circuit (Refrigerant R134a Servicing, Refrigerant
Circuit, Working with A/C Service Station) or ⇒ A/C Systems with Refrigerant R1234yf - General Infor‐
Caution
erant circuit.
the body.
Only
♦ remove when the
nents .

Note

Service Station .
2.1.2 System Overview - Refrigerant Circuit,

Not Opening the Refrigerant Circuit, Ve‐
hicles with High Voltage System
Note
For this model line, only vehicles with a high-voltage system were
manufactured that had the refrigerant circuit charged with refrig‐
erant R134a.
Read and follow all of the supplemental warnings for all work per‐
formed on vehicles with the high voltage system. Refer to
General Warnings .
WARNING

voltage system.

WARNING

connector.
DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.


1 - Electrically-Driven A/C
Compressor
❑ With A/C Compressor
and Electrical A/C Com‐
pressor - V470-
moving from bracket
and reinstalling, vehi‐
cles with 4-Cylinder en‐
gine. Refer to
⇒ “3.3.3 A/C Compres‐
sor, Removing and In‐
stalling on Bracket,
Electrically-Driven A/C
Compressor”,
page 304 1).
Note

♦ A/C compressors used as re‐
placement parts have different
oil capacities, therefore note the
amount of oil in the A/C com‐
ber. Refer to the Parts Catalog
and ⇒ Refrigerant R134a Serv‐
icing; Rep. Gr. 87 ; Refrigerant
R134a Capacities, Refrigerant
Oil and Approved Refrigerant
Oils (Refrigerant R134a, Servic‐
ing; Refrigerant R134a Capaci‐
ties, Refrigerant Oil and Ap‐
proved Refrigerant Oil).
little oil can result in lubrication
Refer to ⇒ Refrigerant R134a
erant R134a Capacities, Refrig‐
ant Oils (Refrigerant R134a,
Servicing; Refrigerant R134a
Approved Refrigerant Oil).

♦ When installing refrigerant lines

and the corresponding brackets,
make sure there is adequate dis‐
tance to the other components
(such as the belt, engine belt pul‐
ley, etc.).

Note

C system.
5 - Condenser
6 - Receiver/Dryer
❑ The receiver/dryer is mounted directly on the condenser. Refer to
⇒ “2.19 Receiver/Dryer, Removing and Installing”, page 267 (Receiver/Dryer, Removing and Installing)
7 - Cap
❑ With a seal
❑ Always screw on
❑ For the A/C service station used to measure the pressures and to empty and fill the refrigerant circuit.
Refer to ⇒ Refrigerant R134a, Servicing; Rep. Gr. 87 ; Refrigerant Circuit (Refrigerant R134a, Servicing;
Refrigerant Circuit, Using Service Station).

WARNING
Only remove the service
connections when the
ty. The connection does
not have a valve.
Note

necessary to remove the left addi‐
tional reinforcement on the tower
brace so that the service coupling of
the A/C service station can be con‐
nected. Refer to ⇒ Suspension,
Wheel, Steering; Rep. Gr. 40 ; Sus‐
pension Strut and Upper Control
Arm; Overview - Suspension Strut
and Upper Control Arm and ⇒ Re‐
frigerant R134a, Servicing; Rep. Gr.
87 ; Refrigerant Circuit (Refrigerant
R134a, Servicing; Refrigerant Cir‐
cuit, Using A/C Service Station).
9 - Connection to the Evaporator in the Battery Cooling Module

❑ High pressure side
WARNING
The
♦ bolts of the connec‐
tion point may only be
loosened when the refrig‐
erant circuit has been
emptied.
10 - Expansion Valve with Hybrid Battery Refrigerant Shut-Off Valve 2 - N517-

❑ On the evaporator in the battery cooling module
Note
The Hybrid Battery Refrigerant

Shut-Off Valve 2 - N517- is activated
when it is necessary to cool the bat‐
tery (closed without activation).
11 - Evaporator in the Battery Cooling Module

12 - Hybrid Battery Refrigerant Shut-Off Valve 1 - N516-
❑ Installed inside the engine compartment near the left suspension strut tower
Note

Shut-Off Valve 1 - N516- is activa‐
ted, for example, if it is necessary to
cool the battery and no cooling is
desired in the passenger compart‐
ment (open without activation).

WARNING
unlocked and opened
cuit is empty.
14 - Refrigerant Line with Inner Heat Exchanger

❑ In this refrigerant line, liquid warm refrigerant from the high pressure side is released into the low pressure
side as flowing vaporous refrigerant energy. This increases the cooing efficiency of the A/C system.
❑ For the evaporator in the A/C system
16 - Evaporator in the A/C System
WARNING
unlocked and opened
cuit is empty.

❑ Low pressure side
WARNING
The
emptied.
19 - Sealing Cap
❑ With a seal
❑ Always screw on
❑ For the A/C service station used to measure the pressures and to discharge the refrigerant circuit. Refer
to ⇒ Refrigerant R134a, Servicing; Rep. Gr. 87 ; Refrigerant Circuit (Refrigerant R134a, Servicing;
WARNING
not have a valve.

Note


Opening the Refrigerant Circuit, Vehi‐
cles without High Voltage System

1 - A/C Compressor Regulator

Valve - N280-
❑ Check the activation
and function. Refer to
Regulator Valve N280 ,
Checking Switch-On
Signal”, page 192 and
use the Vehicle Diag‐
nostic Tester .
Note

Valve - N280- is actuated by the
head via the Vehicle Electrical
System Control Module - J519- .
The A/C Compressor Regulator
Valve - N280- controls the pres‐
sure on the refrigerant circuit low
pressure side using the Vehicle
♦ Certain malfunctions at the A/C
N280- (for example, a stuck
valve or a short circuit in the coil)
can lead to a complaint regard‐
ing the A/C compressor (A/C
system is not cooling, the evap‐
orator ices over, etc.). If the A/C
N280- (and not the A/C compres‐
sor itself) is the cause, the A/C
compressor can be serviced by
replacing the A/C Compressor
Regulator Valve - N280- . Refer
to ⇒ Refrigerant R134a, Servic‐
ing; Rep. Gr. 87 ; Refrigerant
Circuit Components, Replacing
or ⇒ A/C Systems with Refriger‐
ant R1234yf - General Informa‐
tion; Rep. Gr. 87 ; Refrigerant
Circuit; Components, Replac‐
ing .
Valve - N280- is not available as
a replacement part for all A/C
compressors. If the A/C Com‐
pressor Regulator Valve - N280-
is not available as an individual
A/C compressor part (different
versions), then the entire A/C
2 - A/C Compressor
❑ A/C compressor, removing from bracket and reinstalling, 4-Cylinder and 6-Cylinder TDI engine. Refer to
⇒ “3.3 A/C Compressor, Removing and Installing on Bracket”, page 298 .
❑ A/C compressor refrigerant line, disconnecting and connecting. Refer to
⇒ “3.4 Refrigerant Lines, Disconnecting and Connecting at A/C Compressor”, page 312 .

Note
♦ When installing the refrigerant

lines and corresponding bracket,
make sure there is enough
space between the belt, the
bracket, the belt pulley and the
refrigerant lines.
♦ To protect the A/C compressor,
the engine should only be started
with the refrigerant circuit com‐
pletely assembled.
❑ Remove the ribbed belt. Refer to ⇒ Rep. Gr. 13 ; Cylinder Block, Belt Pulley Side; Ribbed Belt, Removing
and Installing .
❑ A/C compressor, removing and installing. Refer to
⇒ “3.5 A/C Compressor, Removing and Installing”, page 325 .
Note
♦ On vehicles with a 6-cylinder

gasoline engine or an 8-cylinder,
the A/C compressor can be re‐
moved and installed from the
bracket only when the refrigerant
circuit is evacuate. Refer to
♦ At start of production, compres‐
sors manufactured by
“Denso” (type “6 SEU 14”) on 4-
later time. Refer to
Capacities; Refrigerant Oil and
Approved Refrigerant Oils or ⇒
A/C Systems with Refrigerant
Rep. Gr. 00 ; Technical Data .
♦ Depending on the time period of
production and the engine, the
compressor construction type
may vary. Refer to the Parts Cat‐
alog.

♦ The A/C compressors are avail‐

able as replacement parts with
different oil capacities, therefore
note capacity on the A/C com‐
ber. Refer to
Approved Refrigerant Oils or ⇒
A/C Systems with Refrigerant
Rep. Gr. 00 ; Technical Data .
ties. Too much oil in the circuit
leads to higher pressures and re‐
duces the system cooling output.
Too little oil may lead to lubrica‐
tion problems in the A/C com‐
pressor. Refer to
page 112 , the Parts Catalog, ⇒
Refrigerant R134a Servicing;
Approved Refrigerant Oils (Re‐
frigerant R134a Servicing; Re‐
frigerant R134a, Refrigerant Oil
and Approved Refrigerant Oil
Capacities) or ⇒ A/C Systems
with Refrigerant R1234yf - Gen‐
eral Information; Rep. Gr. 00 ;
Technical Data .
running change on certain 4-cyl‐
er .
❑ If a new A/C compressor has been installed or new refrigerant oil has been added (for example, after
cleaning the refrigerant circuit), turn the A/C compressor by hand approximately 10 turns before using
for the first time after installing. This ensures that the compressor is not damaged when activated.

3 - Belt Pulley - A/C Compressor Drive Unit/Belt Pulley with A/C Clutch - N25-
❑ The A/C compressor belt pulley, replacing (4- and 6-Cylinder vehicles). Refer to
❑ Ribbed belt, removing and installing (vehicles with a 4- and 6-Cylinder engine). Refer to ⇒ Rep. Gr. 13 ;
Cylinder Block, Belt Pulley Side; Ribbed Belt, Removing and Installing .
❑ For the correct ribbed belt (4- and 6-Cylinder vehicles). Refer to the Parts Catalog
❑ A/C compressor drive unit (vehicles with an 8-Cylinder FSI engine). Refer to
⇒ “3.1.2 Overview - A/C Compressor Power Unit, Vehicles with 8-Cylinder Engine”, page 290 and
⇒ “3.5 A/C Compressor, Removing and Installing”, page 325 .
❑ Belt pulley with A/C Clutch - N25- , replacing. Applies to certain 4-Cylinder engine vehicles from MY 2012.
Refer to
⇒ “3.7.3 Belt Pulley, Removing and Installing, A/C Compressor with A/C Clutch N25 ”, page 379
Note
♦ There is an overload protection

installed between the belt pulley/
drive unit and the A/C compres‐
sor input shaft to protect the belt
should the A/C compressor get
blocked or be difficult to move.
♦ If the A/C compressor is runs
with resistance, the overload
safeguard interrupts the supply
of power to it.
♦ Rubber elements are installed
between belt pulley/drive unit
and A/C compressor input shaft,
vibrations which may occur dur‐
ing A/C compressor operation
may be dissipated via these rub‐
ber elements (damper function
at torque fluctuations).
♦ There are different versions of
the pulley are installed depend‐
ing on the type of A/C compres‐
sor and engine. Refer to the
Parts Catalog and
⇒ “3 A/C Compressor”,
page 288 .
function.
4 - Oil Drain Plug

❑ “Denso” A/C compressors have sealing ring installed, always replace
❑ “Denso” A/C compressor tightening specification: 30 Nm

❑ May only be removed to drain refrigerant oil with the A/C compressor removed. Rotate the A/C com‐
pressor via belt pulley to accelerate refrigerant oil flowing out. Refer to ⇒ Refrigerant R134a Servicing;
Rep. Gr. 87 ; Refrigerant Circuit Components, Replacing (Refrigerant R134a, Servicing; Refrigerant
Circuit Components, Replacing) or ⇒ A/C Systems with Refrigerant R1234yf - General Information; Rep.
Gr. 87 ; Refrigerant Circuit; Components, Replacing .
❑ Do not remove
❑ Tightening specification for the “Denso” A/C compressor: 10 Nm
❑ With O-ring “Denso” A/C compressor: 8.5 mm x 1.75 mm. Refer to
⇒ “3.13 Refrigerant Circuit Seals”, page 109 .
❑ To remove and install the valve insert when the refrigerant circuit is discharged, use, for example, an
adapter from the Refrigerant Sockets - T10364- .
WARNING
The valve insert may be
removed only when the
ty.
7 - A/C Pressure/Temperature Sensor - G395-

Note

mation via the Data Bus “LIN
Bus” with the Vehicle Electrical
The Vehicle Electrical System
Control Module - J519- then
transmits the data via the Data
Buss to the Climatronic Control
Module - J255- display and con‐
trol head. For this reason a High
Pressure Sensor - G65- cannot
be installed on this vehicle (it on‐
ly delivers square-wave signals).
Refer to Parts Catalog.
C system.
8 - Condenser
❑ Refrigerant lines, disconnecting and reconnecting. Refer to

Note

Refer to
9 - Receiver/Dryer
❑ Receiver/dryer is mounted directly on the condenser.
❑ Removing and installing. Refer to ⇒ “2.19 Receiver/Dryer, Removing and Installing”, page 267 .
Note

denser. Refer to
page 271 .
WARNING
unlocked and opened
cuit is empty.
❑ Refrigerant lines, disconnecting from the quick-coupling connections and connecting. Refer to
❑ For replacing the quick-coupling connection completely with the O-ring and support ring. Refer to. Refer
Note
The Audi RS 4 and on the Audi RS

5 has a block connector instead of
quick-release connector. Removing
and installing the block connector is
the same as removing and installing
the block connector on the condens‐
er. Refer to

11 - Sealing Cap
❑ With a seal
❑ Always screw on
the Parts Catalog.
Caution
erant circuit.
the body.
Only
♦ remove when the
nents .
the Parts Catalog.
❑ To remove and install the service connection or the valve insert when the refrigerant circuit is discharged,
use, for example, an adapter from the Refrigerant Sockets - T10364- .
❑ For the A/C service station to measure the pressures, discharge and fill the refrigerant circuit. Refer to
⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ; Refrigerant Circuit (Refrigerant R134a Servicing, Refrig‐
erant Circuit, Working with A/C Service Station) or ⇒ A/C Systems with Refrigerant R1234yf - General

Note
♦ Depending on the allocation of

the service connection to the re‐
frigerant line and vehicle version,
it may be necessary to remove
the left auxiliary reinforcement
on the tower brace so that the A/
C service station service cou‐
pling can be connected (for ex‐
ample, on the Audi Q5). Refer to
⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 40 ; Suspension
Strut, Upper Control Arm; Over‐
view - Suspension Strut, Upper
Control Arm and ⇒ Refrigerant
R134a Servicing; Rep. Gr. 87 ;
Refrigerant Circuit (Refrigerant
R134a Servicing, Working with
A/C Service Station) or ⇒ A/C
Systems with Refrigerant
Service Station .
vehicle, the service connections
may also be connected to the at‐
tached refrigerant line (for exam‐
ple, on the Audi RS 4 and Audi
RS 5) instead of to the refrigerant
line with an inner heat exchang‐
er.
♦ It may be necessary on the Audi
RS 4 and the Audi RS 5 to care‐
fully lift the refrigerant line and
then push it slightly to the side in
order to connect the service cou‐
pling.
13 - Refrigerant Pipe with Inner Heat Exchanger

❑ In this refrigerant pipe, the flowing fluid warm refrigerant on the high pressure side is delivered into the
low pressure side as flowing, vapor, cold refrigerant to increase the efficiency of the A/C system.
⇒ “2.14 Refrigerant Lines with Inner Heat Exchanger, Removing and Installing”, page 227 .
❑ Refrigerant line with inner heat exchanger, disconnecting and reconnecting. Refer to

Note
♦ After switching off the A/C com‐

pressor in this vehicle, it may
take a relatively long time for the
pressure on the high pressure
side to decrease. This is be‐
cause the expansion valve is
cold and the pressure on the low
pressure side increases quickly
after shutting the compressor off,
then the expansion valve closes
and the refrigerant flows slowly
to the low pressure side. If the A/
C compressor is switched on, the
pressure on the low pressure
side goes down, the expansion
valve open and the refrigerant
can flow of the low pressure side.
♦ From the start of production up to
evaporators approximately 40
mm wide (block depth) were in‐
stalled (A/C unit part number
“8K_ 820 005”). From MY 2012
as a running change, an evapo‐
rator with an approximately 50
mm width (block depth) is being
installed depending on the vehi‐
“8T_ 820 005”). Pay attention to
the correct allocation of the ex‐
pansion valve to the evaporator
(there are different versions).
15 - Evaporator
❑ A/C unit with evaporator, removing and installing. Refer to
❑ Evaporator with installed A/C unit, removing and installing. Refer to
⇒ “5.5 Evaporator, Removing and Installing”, page 475 .
Note

“8K_ 820 005”). From MY 2012

♦ For refrigerant R1234yf, there

must not be any separable con‐
nection points in the refrigerant
circuit in the vehicle interior (for
example, separating points on
the refrigerant lines to the evap‐
orator). Therefore the A/C unit
(with the evaporator housing)
must always be removed on
these vehicles and the evapora‐
tor with the refrigerant lines must
be completely replaced. Refer to
the Parts Catalog and
⇒ “5.11 Heater and A/C Unit, Re‐
moving and Installing”,
page 520 .
WARNING
unlocked and opened
cuit is empty.
17 - Sealing Cap
❑ With a seal
❑ Always screw on
the Parts Catalog.

Caution
erant circuit.
the body.
Only
♦ remove when the
nents .
the Parts Catalog.
❑ For the A/C service station to measure the pressures and discharge the refrigerant circuit. Refer to ⇒
Refrigerant R134a Servicing; Rep. Gr. 87 ; Refrigerant Circuit (Refrigerant R134a Servicing, Refrigerant
Circuit, Working with A/C Service Station) or ⇒ A/C Systems with Refrigerant R1234yf - General Infor‐
Note

the left auxiliary reinforcement
on the tower brace so that the A/
C service station service cou‐
pling can be connected (for ex‐
ample, on the Audi Q5). Refer to
⇒ Suspension, Wheels, Steer‐
Strut, Upper Control Arm; Over‐
view - Suspension Strut, Upper
Control Arm and ⇒ Refrigerant
R134a Servicing; Rep. Gr. 87 ;
Refrigerant Circuit (Refrigerant
R134a Servicing, Working with
A/C Service Station) or ⇒ A/C
Systems with Refrigerant
Service Station .


vehicle, the service connections
tached refrigerant line (for exam‐
ple, on the Audi RS 4 and Audi
RS 5) instead of to the refrigerant
line with an inner heat exchang‐
er.

Opening the Refrigerant Circuit, Vehi‐
cles with High Voltage System
Note
erant R134a.

General Warnings .
WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.

If it is necessary to perform work on the high voltage system com‐
ponents, de-energize the high voltage system. Refer to ⇒ Elec‐
trical System Hybrid; Rep. Gr. 93 ; High Voltage System, De-
Energizing and read and follow the “high voltage electrical system
general warnings” in ⇒ Electrical System Hybrid; Rep. Gr. 93 ;
High Voltage System General Warnings .
Note
Refer to ⇒ “2.3 Overview - Refrigerant Lines”, page 190


Compressor
pressor - V470-
moving and installing on
bracket, vehicles with 4-
Cylinder engine. Refer
to
Compressor”,
page 304 .
❑ A/C compressor refrig‐
erant line, disconnect‐
ing and connecting. Re‐
fer to
Lines, Disconnecting
and Connecting at A/C
Compressor”,
page 312 .
moving and installing.
Refer to
stalling, Vehicles with 4-
Cylinder Engine, Electri‐
cally-Driven A/C Com‐
pressor”, page 328 .
Note



ley, etc.).
♦ After the installation of the elec‐
trically-driven A/C compressor
and the subsequent filling of the
refrigerant circuit, start the A/C
compressor for the first time us‐
ing the “compressor intake” func‐
tion for the basic setting. The A/
C compressor may otherwise
become damaged if refrigerant
oil was improperly stored in the
A/C compressor compression
chamber before installation us‐
function.
♦ Only activate the electrically driv‐
en A/C compressor when the re‐
frigerant circuits are filled. If the
A/C compressor is running while
the refrigerant circuit is empty,
the A/C compressor may be‐
come damaged. Refer to ⇒ A/C
System with Refrigerant R134a;
Rep. Gr. 87 ; A/C System, Gen‐
eral Information (A/C System
with Refrigerant R134a, A/C
System, General Information)
ing" function.

❑ Do not remove
❑ Tightening specification for the “Denso” A/C compressor: 10 Nm
❑ With O-ring “Denso” A/C compressor: 8.5 mm x 1.75 mm. Refer to


❑ To remove and install the valve insert when the refrigerant circuit is discharged, use, for example, an
adapter from the Refrigerant Sockets - T10364- .
WARNING
The valve insert may be
removed only when the
ty.

Note

C system.
5 - Condenser
❑ Refrigerant lines, disconnecting and reconnecting. Refer to
Note
To remove the condenser from the

front end or to remove the radiator,
it may be necessary to drain the re‐
frigerant circuit and to remove the
refrigerant pipe from the condenser,
depending on the version of the ra‐
diator and of the condenser. Refer
to

6 - Receiver/Dryer
❑ Receiver/dryer is mounted directly on the condenser.
❑ Removing and installing. Refer to ⇒ “2.19 Receiver/Dryer, Removing and Installing”, page 267 .
Note

denser. Refer to
page 271 .
7 - Cap
❑ With a seal
❑ Always screw on
❑ For the A/C service station used to measure the pressures and to empty and fill the refrigerant circuit.
Refer to ⇒ Refrigerant R134a, Servicing; Rep. Gr. 87 ; Refrigerant Circuit (Refrigerant R134a, Servicing;
WARNING
not have a valve.
Note



❑ Refrigerant lines to battery cooling module on underbody (vehicle floor), removing and installing. Refer
to ⇒ “2.3 Overview - Refrigerant Lines”, page 190 .
❑ Refrigerant line pass-through in luggage compartment, removing and installing. Refer to
⇒ “2.11 Refrigerant Line Pass-Through in Luggage Compartment, Removing and Installing ”,
page 210 .
WARNING
The
discharged.

❑ Attached to the evaporator in the battery cooling module
❑ Expansion valve with Hybrid Battery Refrigerant Shut-Off Valve 2 - N517- , removing and installing. Refer
to
⇒ “2.16 Rear Expansion Valve with Hybrid Battery Refrigerant Shut-Off Valve 2 N517 , Removing and
❑ Refrigerant line pass-through in luggage compartment, removing and installing. Refer to
page 210 .
Note

Shut-Off Valve 2 - N517- is activated
when it is necessary to cool the bat‐
tery (closed without activation).
11 - Evaporator in the Battery Cooling Module

❑ Battery cooling module component
❑ Refrigerant Lines for Battery Cooling Module in Luggage Compartment, Removing and Installing. Refer
to
⇒ “2.12 Refrigerant Lines for Battery Cooling Module in Luggage Compartment, Removing and Instal‐
ling”, page 215
❑ Battery cooling module, removing and installing. Refer to
⇒ “10.12 Battery Cooling Module, Removing and Installing”, page 704 .
❑ Battery cooling module attachments, removing. Refer to
⇒ “10.3 Overview - Battery Cooling Module”, page 678 .
❑ Refer to ⇒ “10.11 Battery Cooling Module, Bringing into Service Position”, page 701
❑ Refer to ⇒ “2.3 Overview - Refrigerant Lines”, page 190
⇒ “10.6 Hybrid Battery Refrigerant Shut-Off Valve 1 N516 , Removing and Installing”, page 688 .
Note
♦ The Hybrid Battery Refrigerant

Shut-Off Valve 1 - N516- is acti‐
vated, for example, if it is neces‐
sary to cool the battery and no
cooling is desired in the passen‐
ger compartment (open without
activation).

♦ Union nut tightening specifica‐

tion. Refer to
⇒ “10.6 Hybrid Battery Refriger‐
ant Shut-Off Valve 1 N516 , Re‐
page 688 .
WARNING
unlocked and opened
cuit is empty.
14 - Refrigerant Line With Inner Heat Exchanger
❑ In this refrigerant pipe, the flowing fluid warm refrigerant on the high pressure side is delivered into the
low pressure side as flowing, vapor, cold refrigerant to increase the efficiency of the A/C system.
❑ For the evaporator in the A/C system
Note
♦ After switching off the A/C com‐

pressor in this vehicle, it may
take a relatively long time for the
pressure on the high pressure
side to decrease. This is be‐
cause the expansion valve is
cold and the pressure on the low
pressure side increases quickly
after shutting the compressor off,
then the expansion valve closes
and the refrigerant flows slowly
to the low pressure side. If the A/
C compressor is switched on, the
pressure on the low pressure
side goes down, the expansion
valve open and the refrigerant
can flow of the low pressure side.


“8K_ 820 005”). From MY 2012
16 - Evaporator in the A/C System

❑ A/C unit (with evaporator), removing and installing. Refer to
❑ Evaporator with installed A/C unit, removing and installing. Refer to
⇒ “5.5 Evaporator, Removing and Installing”, page 475 .
Note
From the start of production up to

evaporators approximately 40 mm
wide (block depth) were installed (A/
C unit part number “8K_ 820 005”).
From MY 2012 as a running change,
an evaporator with an approximate‐
ly 50 mm width (block depth) is be‐
ing installed depending on the vehi‐
“8T_ 820 005”). Pay attention to the
correct allocation of the expansion
valve to the evaporator (there are
different versions). Refer to the
Parts Catalog.
WARNING
unlocked and opened
cuit is empty.

WARNING
The
emptied.
19 - Sealing Cap
❑ With a seal
❑ Always screw on
❑ For the A/C service station used to measure the pressures and to discharge the refrigerant circuit. Refer
to ⇒ Refrigerant R134a, Servicing; Rep. Gr. 87 ; Refrigerant Circuit (Refrigerant R134a, Servicing;
WARNING
not have a valve.
Note

the left additional reinforcement
on the tower brace so that the
service coupling of the A/C serv‐
ice station can be connected (for
example, on the Audi Q5). Refer
to ⇒ Suspension, Wheel, Steer‐
Strut and Upper Control Arm;
Overview - Suspension Strut and
Upper Control Arm and ⇒ Re‐
frigerant R134a, Servicing; Rep.
Gr. 87 ; Refrigerant Circuit (Re‐
frigerant R134a, Servicing; Re‐
frigerant Circuit, Using A/C Serv‐
ice Station).
♦ Depending on the vehicle ver‐
sion, the service connections
tached refrigerant line instead of
the refrigerant line with an inner
heater core.

2.2 Overview - Refrigerant Line

Note
erant R134a.

General Warnings .
WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
WARNING
♦ The bolts of the connection point may only be loosened

when the refrigerant circuit has been discharged.

1 - Bolt
2 - Low Pressure Refrigerant
Line
❑ On the rear underbody
3 - O-Ring Seal
❑ Replacing
4 - Pass-Through for the Re‐
frigerant Lines in the Luggage
Compartment
❑ Removing and Instal‐
ling. Refer to
⇒ “2.11 Refrigerant Line
Pass-Through in Lug‐
gage Compartment, Re‐
moving and Installing ”,
page 210 .
5 - O-Ring Seal
❑ Replacing
6 - High Pressure Refrigerant
Line
7 - Bolt
8 - Bolt
Line
❑ On the front underbody
10 - O-Ring Seal
❑ Replacing
Line
12 - Bolt
13 - Low Pressure Refrigerant Line
14 - O-Ring Seal
❑ Replacing
16 - Bolt
18 - O-Ring Seal
❑ Replacing
❑ In the engine compartment
20 - Bolt
21 - High Pressure Refrigerant Line

22 - O-Ring Seal
❑ Replacing
❑ In the engine compartment
24 - Sheet Metal Nut
❑ On the underbody
❑ On the underbody
2.3 Overview - Refrigerant Lines
Note
erant R134a.
1 - High Pressure Side Refrig‐

erant Line
❑ Inside the engine com‐
partment
2 - O-Ring Seal
3 - Low Pressure Side Refrig‐
erant Line
❑ In the front on the floor
panel
ling. Refer to
⇒ “2.9 Refrigerant Lines
to Front Battery Cooling
Module, Removing and
Installing, on Vehicle
Floor”, page 201 .
4 - Bolt
❑ Tightening specifica‐
tion: 9 Nm (bolts with a
M6 thread) and 25 Nm
(bolts with a M8 thread).
5 - O-Ring Seal
6 - High Pressure Side Refrig‐
erant Line
❑ In the front on the floor
panel
ling. Refer to
⇒ “2.9 Refrigerant Lines
to Front Battery Cooling
Module, Removing and
Installing, on Vehicle
Floor”, page 201 .

7 - Bolt
❑ Tightening specification: 9 Nm (bolts with a M6 thread) and 25 Nm (bolts with a M8 thread).
8 - High Pressure Side Refrigerant Line
❑ In the rear on the floor panel
⇒ “2.10 Refrigerant Lines to Rear Battery Cooling Module, Removing and Installing, on Vehicle Floor”,
page 205 .
9 - O-Ring Seals
10 - Low Pressure Side Refrigerant Line
❑ In the rear on the floor panel
⇒ “2.10 Refrigerant Lines to Rear Battery Cooling Module, Removing and Installing, on Vehicle Floor”,
page 205 .
11 - Bolt
12 - Bolts
13 - O-Ring Seals
14 - Pass-Through for the Refrigerant Lines in the Luggage Compartment
page 210 .
15 - O-Ring Seals
16 - Bolts
17 - Nut
❑ Tightening specification 9 Nm.
❑ To the battery cooling module inside the luggage compartment
ling”, page 215 .
19 - Low Pressure Side Refrigerant Line
❑ To the battery cooling module inside the luggage compartment
ling”, page 215 .
20 - Bolt
21 - O-Ring Seals
22 - Bolt
23 - Sheet Metal Nut
❑ Tightening specification: 2.5 Nm
24 - Bolt

Note

Shut-Off Valve 1 - V516- is installed
in the high pressure side refrigerant
line. -item 1- ⇒ Item 1 (page 190)
and refer to
⇒ “10.6 Hybrid Battery Refrigerant
Shut-Off Valve 1 N516 , Removing
and Installing”, page 688 (it does
not have a number in this illustra‐
tion).
2.4 A/C Compressor Regulator Valve -

N280- , Checking Switch-On Signal
Note
♦ The following describes the test for an A/C compressor man‐

ufactured by “Denso” of type “6 SEU 14” without A/C Clutch -
N25- . The test is to be performed in the same way for vehicles
with a different compressor type or a different manufacturer.
♦ However, for an A/C compressor with an A/C Clutch - N25- ,
a 3-pin connector may be installed. Refer to ⇒ Wiring dia‐
grams, Troubleshooting & Component locations.
♦ The following describes checking a vehicle with a 6 cylinder
TDI engine; the procedure can vary on vehicles with a different
engine (4-, 6- or 8-cylinder engine).
♦ Not installed on an electrically-driven A/C compressor. Refer
to
⇒ “3.3.3 A/C Compressor, Removing and Installing on Brack‐
et, Electrically-Driven A/C Compressor”, page 304 .
♦ Certain malfunctions at the A/C Compressor Regulator Valve
- N280- (for example, a stuck valve or a short circuit in the coil)
can lead to a complaint regarding the A/C compressor (A/C
system is not cooling, the evaporator ices over, etc.). If the A/
C Compressor Regulator Valve - N280- (and not the A/C com‐
pressor itself) is the cause, the A/C compressor can be serv‐
iced by replacing the A/C Compressor Regulator Valve -
N280- . Refer to ⇒ Refrigerant R134a, Servicing; Rep. Gr.
87 ; Refrigerant Circuit Components, Replacing or ⇒ A/C Sys‐
tems with Refrigerant R1234yf - General Information; Rep. Gr.
87 ; Refrigerant Circuit; Components, Replacing .
♦ The A/C Compressor Regulator Valve - N280- is not available
as a replacement part for all A/C compressors. If the A/C
Compressor Regulator Valve - N280- is not available as an
individual A/C compressor part (different versions), then the
entire A/C compressor must be replaced if there is a complaint.
♦ To replace the A/C Compressor Regulator Valve - N280- on
an A/C compressor with an A/C Clutch - N25- , any connector
terminals must be removed from the connector housing on the
A/C Compressor Regulator Valve - N280- . Refer to ⇒ Re‐
Components, Replacing or ⇒ A/C Systems with Refrigerant
cuit; Components, Replacing .

Preliminary work
– Turn off the ignition.
– Remove the front noise insulation. Refer to ⇒ Body Exterior;
Rep. Gr. 66 ; Noise Insulation; Overview - Noise Insulation .
Test Sequence
– Disconnect the connector -B- from the A/C Compressor Reg‐
ulator Valve - N280- -A-.
– Using an adapter cable, re-establish the connection between
the connector -A- and the connector -B- on the A/C Compres‐
sor Regulator Valve - N280- .

Note
♦ Depending on the A/C compressor version (with or without the

A/C Clutch - N25- ), different adapter cables are to be used.
The Vehicle Diagnostic Tester - Test Adapter - 3 Pin -
VAS5257- is used, for example, on an A/C compressor without
an A/C Clutch - N25- and the Vehicle Diagnostic Tester - Test
Adapter - 2 Pin - VAS5256- is used on an A/C compressor with
an A/C Clutch - N25- . If no suitable adapter is available, the
connection between the connector -A- and the connector -B-
can be established using components from the Connector
Test Set - VAG1594D- .
♦ However an adapter cable can also be used for this test. To
do so, use, for example, one 2-pin connector each -A and B-
(part number 1J0 973 702 and 1J0 973 802 and related
terminal contacts), two commercially available sockets for ba‐
nana connectors -C- and two wires with 0.5 mm 2 diameter on
an A/C compressor with an A/C Clutch - N25- .
the Vehicle Electrical System Control Module - J519- at the
request of the Climatronic Control Module - J255- A/C display
and control head using the Vehicle Diagnostic Tester in the
"Guided Fault Finding" function. Refer to ⇒ Wiring diagrams,
♦ The above illustration shows an A/C compressor without A/C
Clutch - N25- where the 2-pin connector -A- leading to the ve‐
hicle wiring harness is attached directly to the A/C Compressor
Regulator Valve - N280- (connector -B-). Depending on the
version of the A/C compressor, the connector -B- may also
have a short wire.
♦ The A/C Compressor Regulator Valve - N280- activation is
displayed in the Vehicle Electrical System Control Module -
J519- measured values block. The maximum control current
depends on the version of the Climatronic Control Module -
J255- display and control head using the Vehicle Diagnostic
Tester in the "Guided Fault Finding" function. Refer to ⇒ Wiring
♦ The measured current that flows over the A/C Compressor
Regulator Valve - N280- is displayed in the measured values
block for the Climatronic Control Module - J255- A/C display
and control head and in the measured values block for the
Vehicle Electrical System Control Module - J519- using the
tion
♦ If the required actual current is not flowing over the A/C Com‐
pressor Regulator Valve - N280- , check the Vehicle Electrical
System Control Module - J519- positive and ground connec‐
tions and the wire connections between the Vehicle Electrical
System Control Module - J519- and the A/C Compressor Reg‐
ulator Valve - N280- for short circuit, contact resistance and
interchanged wires according to the wiring diagram. Refer to

– Connect the probe to the adapter cables.

– Measuring lead (signal wire) to terminal -2- of connector -B-
– Measuring lead (shielding, Ground) to terminal -1- of connec‐
tor -B-
Note
For an A/C compressor with a different connector (for example, a

3-pin connector on an A/C compressor with an A/C Clutch -
N25- ), note the connector assignment when connecting the
measuring cables. Refer to ⇒ Wiring diagrams, Troubleshooting
& Component locations.
– Select operating mode Test Instruments: DSO (Digital Storage

Oscilloscope) on the Vehicle Diagnostic Tester .
– Select 5 V/Div = 0.5 ms/Div (5 volts DC and 0.5 milliseconds
per unit)
– Set the temperature preset to maximum cooling output on the
head.
– Switch the activation of the A/C Compressor Regulator Valve
- N280- on and off by pressing the AC (or A/C ) button (with
an indicator lamp when the A/C compressor is on) on the Cli‐
matronic Control Module - J255- A/C display and control head
Shown on screen of oscilloscope, depending on setting of Clima‐
tronic Control Module - J255- A/C display and control head:
– There is no square-wave signal when “OFF” or “AC off” mode
is selected (indicator lamp in the “AC” or the A/C button does
not illuminate) (the A/C Compressor Regulator Valve - N280-
is not activated).

– In operating mode “Auto” and “AC on” (indicator lamps in but‐

tons come on) and temperature preselect for maximum cool‐
ing output, a square wave signal with an impulse width -A-
between 75% and 100% (the control valve is activated).
Note
♦ The illustration shows a signal with a duty cycle of approxi‐

mately 80%.
♦ The impulse width -A- depends on the desired cooling output,
electrical system voltage, etc. (over the width of region -A-, the
current is regulated via the A/C Compressor Regulator Valve
- N280- by the Vehicle Electrical System Control Module -
J519- based on the request from the Climatronic Control Mod‐
ule - J255- A/C display and control head).
♦ The signal distance -B- is always two milliseconds (corre‐
sponds to frequency of 500 Hertz).
♦ The duty cycle is determined by the ratio of impulse width
-A- and signal distance -B-.
– The impulse width of the square-wave signal changes de‐

pending on the Climatronic Control Module - J255- A/C display
and control head setting and the measured ambient influences
(duty cycle between 100% and larger than 30%; the A/C Com‐
pressor Regulator Valve - N280- is activated so the compres‐
sor output necessary to reach the specified temperatures is
achieved).
Note
♦ Whenever the mode is set to “Auto”, and “AC on” (the indicator
lamp in the buttons light up), and the temperature preset is set
to “Lo”, the A/C Compressor Regulator Valve - N280- is acti‐
vated so that the maximum permissible current of approxi‐
mately 0.65 A flows over the A/C Compressor Regulator Valve
- N280- (maximum A/C compressor output).
♦ In control mode, actuation time is governed by required cool‐
ing output and vehicle electrical system voltage, for example.
It is however always of sufficient duration to achieve a mean
current of 0.3 A.

2.5 A/C Compressor Regulator Valve -

N280- , Checking Activation
Note
♦ Perform an electrical test for the activation of the A/C Com‐

pressor Regulator Valve - N280- as it is described in the A/C
system Guided Fault Finding using the Vehicle Diagnostic
♦ The activation of the A/C Compressor Regulator Valve - N280-
occurs via the Vehicle Electrical System Control Module -
J519- . Refer to ⇒ Wiring diagrams, Troubleshooting &
Component locations. The request to activate the A/C Com‐
pressor Regulator Valve - N280- and the necessary current to
regulate the compressor output to reach the desired temper‐
ature at the evaporator. Sent via the Data Bus from the Cli‐
to the Vehicle Electrical System Control Module - J519- . The
Vehicle Electrical System Control Module - J519- then controls
the A/C Compressor Regulator Valve - N280- .
♦ If a fault in the A/C Compressor Regulator Valve - N280- is
detected, then it will be stored in the DTC memory for the Ve‐
hicle Electrical System Control Module - J519- and the Clima‐
tronic Control Module - J255- A/C display and control head. It
will be necessary to the check the Vehicle Electrical System
Control Module - J519- DTC memory when reading the DTC
memory for the Climatronic Control Module - J255- A/C display
and control head using the Vehicle Diagnostic Tester in the
♦ The activation of the A/C Compressor Regulator Valve - N280-
is displayed in the Vehicle Electrical System Control Module -
J519- measured values block using the Vehicle Diagnostic
2.6 A/C Pressure/Temperature Sensor -

G395- , Removing and Installing
Note
♦ The cooling output cannot be checked when the A/C Pressure/

Temperature Sensor - G395- is removed. The Climatronic
Control Module - J255- display and control head does not
switch on the A/C compressor.
♦ The refrigerant circuit remains closed, connection with valve.
♦ Only the A/C Pressure/Temperature Sensor - G395- may be
installed on this vehicle (the data exchange occurs via the LIN
Bus). Refer to the Parts Catalog.
♦ A High Pressure Sensor - G65- cannot be installed on this
vehicle (it only delivers square-wave signals). Refer to Parts
Catalog.
Removing
– Remove the upper lock carrier cover. Refer to ⇒ Body Exte‐
rior; Rep. Gr. 50 ; Lock Carrier; Overview - Lock Carrier .

– Disconnect the connector -A-.
– Disconnect the A/C Pressure/Temperature Sensor - G395-

-A- from the condenser connector -C-.
Installing
Installation is done is reverse order, observe the following:
– Replace the O-ring -B-. Refer to
⇒ “3.13 Refrigerant Circuit Seals”, page 109 . For the correct
allocation. Refer to the Parts Catalog.
– Tighten the A/C Pressure/Temperature Sensor - G395- -A-.
• Tightening specification: 5 Nm.
– Check the DTC memory for the Climatronic Control Module -
J255- display and control head and erase any displayed mal‐
functions, if necessary using the Vehicle Diagnostic Tester in

G395- , Checking
A/C Pressure/Temperature Sensor - G395- , checking the signal

Note
♦ The signal from the A/C Pressure/Temperature Sensor -

G395- is checked as described in Guided Fault Finding for the
A/C system using the Vehicle Diagnostic Tester in the "Guided
♦ The Vehicle Electrical System Control Module - J519- evalu‐
ates the A/C Pressure/Temperature Sensor - G395- signal. It
is transmitted via the Data Bus to the Climatronic Control Mod‐
ule - J255- A/C display and control head. Refer to ⇒ Wiring
♦ If a malfunction in the signal from the A/C Pressure/Temper‐
ature Sensor - G395- is detected, then the malfunction will be
entered in the DTC memory of the Vehicle Electrical System
Control Module - J519- and the Climatronic Control Module -
J255- A/C display and control head. It will be necessary to the
check the Vehicle Electrical System Control Module - J519-
DTC memory when reading the DTC memory for the Clima‐
tronic Control Module - J255- A/C display and control head
ing" function.
♦ The A/C Pressure/Temperature Sensor - G395- measured
values are displayed in the Vehicle Electrical System Control
Module - J519- measured values block using the Vehicle Di‐
agnostic Tester in the "Guided Fault Finding" function. The
displayed temperature value is currently not used by the Cli‐
matronic Control Module - J255- A/C display and control head.


G395- , Checking Pressure Signal
Note
♦ The cooling output cannot be checked when the A/C Pressure/

Temperature Sensor - G395- is removed. The Climatronic
Control Module - J255- display and control head does not
switch on the A/C compressor using the Vehicle Diagnostic
♦ To check the measured values for the A/C Pressure/Temper‐
ature Sensor - G395- using the Vehicle Diagnostic Tester in
♦ The A/C Pressure/Temperature Sensor - G395- exchanges
information with the Vehicle Electrical System Control Module
- J519- via a local Data Bus. The Vehicle Electrical System
Control Module - J519- transmits the data via the Data Bus to
the Climatronic Control Module - J255- display and control
head.
♦ The temperature measured by the A/C Pressure/Temperature
Sensor - G395- differs from the actual refrigerant temperature
because of the A/C Pressure/Temperature Sensor - G395-
design and its component location. Therefore it is not currently
evaluated and is not used to regulate the A/C system.
♦ Only the A/C Pressure/Temperature Sensor - G395- may be
installed for this vehicle. Refer to the Parts Catalog.
♦ After switching off the A/C compressor in this vehicle, it may
take a relatively long time for the pressure on the high pressure
side to decrease. This is because the expansion valve is “cold”
and the pressure on the low pressure side increases quickly
after shutting the compressor off, then the expansion valve
closes and the refrigerant flows slowly to the low pressure
side.
Preliminary Work


Routing for the 3-pin connector on the A/C Pressure/Temperature
Sensor - G395- -A-.
1- Ground
2- Signal output – via the local Data Bus to the Vehicle Elec‐
trical System Control Module - J519-
3- Terminal “75” (positive)
Test Sequence:
– Turn on the ignition.
– Check the ground and positive connection to the terminal
-A- .
– Check the connection and the function of the A/C Pressure/
Temperature Sensor - G395- using the Vehicle Diagnostic
Note
♦ The A/C compressor ( A/C Compressor Regulator Valve -

N280- ) is not actuated when the connector -A- is disconnec‐
ted.
♦ The A/C Pressure/Temperature Sensor - G395- is an elec‐
tronic control module over which exchanges information with
the Vehicle Electrical System Control Module - J519- via a lo‐
cal Data Bus using the Vehicle Diagnostic Tester in the "Gui‐
2.9 Refrigerant Lines to Front Battery Cool‐

ing Module, Removing and Installing, on
Vehicle Floor
♦ Pry Lever - 80-200-
Note
erant R134a.

General Warnings .

WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
Removing
– Discharge the refrigerant circuit. Refer to ⇒ Refrigerant
R134a, Servicing; Rep. Gr. 87 ; Refrigerant Circuit (Refriger‐
ant R134a, Servicing; Refrigerant Circuit, Using Service Sta‐
tion).
– Remove the aerodynamic trim panel on the left side. Refer to
⇒ Body Exterior; Rep. Gr. 66 ; Underbody Panel; Overview -
Underbody Panels .
– Free up the wire -1- using the Pry Lever - 80-200- -arrows-.
– Move the heat shield -2- slightly to the right.

– Free up the wiring harness -2-.

– Remove the nut -1- and bolts -3 and 5- and disconnect the
refrigerant lines -4 and 6-.
– Remove the nuts -arrows- and bolts -1 and 2- and disconnect

the refrigerant lines.
Note
Close all open lines and connections on the refrigerant line with
suitable caps (avoid dirt and moisture from entering the system).
– Remove the nuts -arrows- and the front refrigerant pipes.

Installing
Installation is carried out in the reverse order while observing the
following.
Note
♦ Follow the instructions for installing the O-rings. Refer to

♦ Following attachment, check routing of refrigerant lines. They
must be inserted in holders provided and not make contact
with other components.

– Replace the O-ring seals -4-. For the correct version. Refer to
the Parts Catalog.
– Clean the refrigerant line connections -3 and 5- and inspect
them for damage.
– Make sure the O-rings -4- sit correctly inside the grooves of
the respective mount.
– Check the alignment pin -2- (not present on all connections)
for damage and make sure that it is seated correctly.
– Tighten the bolts -1-.
– Install the remaining removed components.
– Electrical connections and routing. Refer to ⇒ Wiring dia‐
– Evacuate the refrigerant circuit and fill it. Refer to ⇒ Refriger‐
ant R134a, Servicing; Rep. Gr. 87 ; Refrigerant Circuit (Re‐
frigerant R134a, Servicing; Refrigerant Circuit, Using Service
Station).
fer to
Note
Observe the information regarding operating the A/C system after

filling. Refer to ⇒ Refrigerant R134a, Servicing; Rep. Gr. 87 ; A/
C System, General Information (Refrigerant R134a, Servicing; A/
C System, General Information). After charging the A/C system
before activating the A/C system.
2.10 Refrigerant Lines to Rear Battery Cool‐

ing Module, Removing and Installing, on
Vehicle Floor
Note
erant R134a.

General Warnings .


WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
Removing
tion).
– Remove the aerodynamic trim panel on the left side. Refer to
⇒ Body Exterior; Rep. Gr. 66 ; Underbody Panel; Overview -
Underbody Panels .
– Remove the EVAP canister. Refer to ⇒ Fuel Supply; Rep. Gr.
20 ; EVAP System; EVAP Canister, Removing and Installing .

– Open the retainer in direction of -arrow A-, pull it to the right in

direction of -arrow B- and free up the wire -1- on the bracket.
– Remove the nuts -arrows- and move the heat shield -1- slightly
downward.
– Remove the nut -arrow- from the bracket for the refrigerant
pipes.
– Remove the nuts -arrows- and bolts -1 and 2- and disconnect

the refrigerant lines.

– Remove the bolts -1 and 3-. Disconnect and remove the re‐
frigerant pipes -2 and 4-.
Note
Installing
following.
Note

the Parts Catalog.
them for damage.
Station).
fer to
Note


2.11 Refrigerant Line Pass-Through in Lug‐

gage Compartment, Removing and In‐
stalling
Note
erant R134a.

General Warnings .
WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
De-energize the high voltage system to perform the necessary

work on the high voltage system for the following procedure. Re‐
fer to. Refer to ⇒ Electrical System Hybrid; Rep. Gr. 93 ; High
Voltage System, De-Energizing and “read and follow the high
voltage electrical system general warnings” in ⇒ Electrical Sys‐
tem Hybrid; Rep. Gr. 93 ; High Voltage System General Warn‐
ings .
– De-energize the high voltage system. Refer to ⇒ Electrical
System Hybrid; Rep. Gr. 93 ; High Voltage System, De-En‐
ergizing .
High Voltage System,

DANGER!
Note

sequence:
♦ Body
Group 93)
Removing
tion).
– Remove the traction battery. Refer to ⇒ Electrical System;
Rep. Gr. 93 ; High Voltage Battery Unit; High Voltage Battery,
Removing and Installing .

– Remove the bolts -2 and 4- and the refrigerant lines

-1 and 3-.
– Remove the bolts -1 and 3-. Disconnect and remove the re‐
frigerant pipes -2 and 4-.
Note

– Remove the nuts -arrows- and remove the pass-through for

the refrigerant lines -1-.
Installing
following.
Note
♦ If the seal for the pass-through is damaged, seal the seal in

this spot with for example Silicone Adhesive - D 176 001 A3- .
Refer to Parts Catalog.
♦ The adhesive surface must be clean and free of grease when
applying the silicone adhesive.
– Install the rear refrigerant lines on the vehicle floor for the bat‐
tery cooling module. Refer to
⇒ “2.10 Refrigerant Lines to Rear Battery Cooling Module,
Removing and Installing, on Vehicle Floor”, page 205 .
– Install the refrigerant lines for the battery cooling module in the
luggage compartment. Refer to
⇒ “2.12 Refrigerant Lines for Battery Cooling Module in Lug‐
gage Compartment, Removing and Installing”, page 215 .
Station).
– Energize the power supply to the high voltage system. Refer
System, De-Energizing .
Restart the high voltage system
DANGER!
starts the vehicle.

Note

♦ Body

J255- display and control head and the A/C Compressor Con‐
trol Module - J842- and, if necessary, erase the displayed
faults using the Vehicle Diagnostic Tester in the "Guided Fault
Finding" function.
fer to
Note

2.12 Refrigerant Lines for Battery Cooling

Module in Luggage Compartment, Re‐
moving and Installing
Note
erant R134a.

General Warnings .


WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.

ings .

DANGER!
Note

sequence:
♦ Body
Group 93)
Removing
tion).
– Remove the high voltage battery. Refer to ⇒ Electrical Sys‐
tem; Rep. Gr. 93 ; High Voltage Battery Unit; High Voltage
Battery, Removing and Installing .


-1 and 4-.
– Remove the bolts -2 and 4- and disconnect and remove the

refrigerant pipes -1 and 3-.
Note
Installing
following.
Note


the Parts Catalog.
them for damage.
Station).
DANGER!
starts the vehicle.
Note

♦ Body


Finding" function.
fer to
Note

2.13 Refrigerant Lines, Disconnecting from

Quick-Release Couplings and Connect‐
ing
♦ Air Conditioner Couplings Release Tool - T40149-
♦ Air Conditioner Couplings Release Tool - T40149- (if the con‐
nections cannot be released with the Retaining Ring -
T40232- )
Removing
– Discharge the refrigerant circuit. Refer to ⇒ Refrigerant R134a
Servicing; Rep. Gr. 87 ; Refrigerant Circuit (Refrigerant R134a

Note
♦ Depending on the allocation of the service connection to the

refrigerant line and vehicle version, it may be necessary to re‐
move the left additional reinforcement on the tower brace so
that the service coupling of the A/C service station can be
connected (for example, on the Audi Q5). Refer to ⇒ Suspen‐
sion, Wheels, Steering; Rep. Gr. 40 ; Suspension Strut, Upper
Control Arm; Overview - Suspension Strut, Upper Control Arm
and ⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ; A/C System
C Service Station .
♦ There are different quick-release coupling versions
-A and D-. The refrigerant lines -C- can be unlocked and re‐
moved using the Air Conditioner Couplings Release Tool -
T40149/1- in the same manner with both quick-release
coupling versions.
♦ The check pins on the -B- quick-release couplings -A- installed
at the start of production are visible after installing the refrig‐
erant line -C-, when the locked refrigerant line -C- is pulled in
the direction of -arrow-.
♦ Beginning with MY 2010, as a running change, the quick-re‐
lease coupling -D- installed and the refrigerant line -C- are
being installed in the same manner as the quick-release cou‐
pling -A-. If the refrigerant line -C- is pulled in the direction of
-arrow- after assembling, the ring -E- will come out of the
quick-release coupling -D- and will show that the retaining ring
-F- is completely latched to the refrigerant line -C-. Then the
ring -E- can be removed from the refrigerant line -C-.
♦ If it is not possible to unlock the quick-couplings -A and B-
using the Air Conditioner Couplings Release Tool - T40149-
without damaging them, then unlock them -A and B- using
Disassembling Tool - T40232- -C- three times on the circum‐
ference and loosen the ring -D- on the quick-couplings
-A and B- and the refrigerant lines -E and F-. Remove the re‐
frigerant pipes -E and F- from the quick-couplings -A and B-.

– Clean the refrigerant lines -A and C- in the area of the quick-

release coupling connectors.
– Clean the refrigerant lines -A and C- in the area of the quick-
release coupling connectors with a silicone-free lubricant.
Note
♦ The refrigerant lines adhere to the O-ring with the A/C is used;
loosen the O-ring before mounting the release tool for air con‐
ditioner couplings, for example by pulling and pushing the
refrigerant lines; never twist the refrigerant lines.
♦ The Audi RS 4 and the Audi RS 5 have a block connector
instead of quick-release connector. Removing and installing
the block connector is same as removing and installing the
block connector on the condenser. Refer to
⇒ “2.17 Refrigerant Lines, Disconnecting and Connecting at
Condenser”, page 253 .
– Press the refrigerant lines -A and C- by hand all way into the
connecting piece -B- of the refrigerant line with the inner heat
exchanger.
– Connect the Air Conditioner Couplings Release Tool -
T40149/1- to the refrigerant line -A- all the way (the opening
of the retaining ring can be heard and felt). When doing this,
the retaining ring with will expand.
– Remove the refrigerant line -A- using the Air Conditioner Cou‐
plings Release Tool from the connecting piece -B- of the
refrigerant line with inner heat exchanger.
– Connect the Air Conditioner Couplings Release Tool -
T40149/2- to the refrigerant line -C- all the way (the opening
of the retaining ring can be heard and felt). When doing this,
the retaining ring with will expand.
– Remove the refrigerant line -C- using the Air Conditioner Cou‐
plings Release Tool from the connecting piece -B- of the
refrigerant line with inner heat exchanger.

Note
♦ If the refrigerant lines cannot be pulled out or pushed in, then

never twist them in the connector piece -C- .
♦ In this case, open (or cut) the quick-release couplings
-A or B- with, for example, the Retaining Ring - T40232- and
remove the retaining ring -D-.
♦ When cutting the coupling, make sure not to damage the con‐
nector piece -A- of the refrigerant lint with inner heat exchang‐
er.
Loosen the Connection on the Quick-Coupling Connections Us‐
ing the Retaining Ring - T40232- .
– Mount the disassembly tool -C- on the quick-couplings
-A or B- and separate the coupling 3 times.
Note
♦ Be careful not to damage the connection area on the inner heat

exchanger -G- and the refrigerant lines -E and F- when sepa‐
rating the quick-release coupling -A and B-.
♦ Insert the cutter on the removal tool -C- into the quick-release
coupling until the break at the cut location can be heard and
felt.
– Carefully bend open the cut quick-release coupling -A or B-

(being careful not to damage the refrigerant line) and remove
the retaining ring -D-.
– Spray the refrigerant lines near the opened quick-release cou‐
pling with a silicone-free lubricant.
Note
The refrigerant lines stick to the O-ring when the A/C system is
working. Pulling and pushing the refrigerant line after spraying the
lubricant can loosen the line from the O-ring making it easier to
remove. Never twist the refrigerant lines.
– Remove the refrigerant line -E and F- from the connection.

– Seal off the open lines and connections on the refrigerant line
with the inner heat exchanger with suitable caps (to keep dirt
and humidity from getting in).
Installing

Caution
Danger of leakage.
♦ The couplings -B and C- on the refrigerant line -D- with
inner heat exchanger must be replaced each time the re‐
frigerant line is opened.
– Pry the couplings -B and C- using a screwdriver -A- out of the

refrigerant line -D- with inner heat exchanger -arrow-.
– Thoroughly clean all parts of the refrigerant line connections

(for example, using Cleaning Solution - D 009 401 04- ).
– Check the connector -A- for the refrigerant line with inner heat
exchanger for damage.
– Replace the O-rings -B and G-, the support rings -C and F-
and the couplings -D and E-. Refer to the Parts Catalog.
Note
Follow the instructions for installing the O-rings. Refer to

– Coat the O-ring seals with refrigerant oil prior to installation.

Refer to ⇒ “3.13 Refrigerant Circuit Seals”, page 109 .
– Press on the couplings -D and E- until this audibly latch into
the refrigerant line with inner heat exchanger connector piece
-A- .
– Thoroughly clean the refrigerant lines -A and B- around the

connection area and check for damage.
– Install the refrigerant lines -A and B- all the way so that they
are free of tension.
Check for Correct Installation of the Refrigerant Lines.

• Try to disconnect the refrigerant lines -A and B- ; the stop must

be felt.
• The pins -B- on the retaining ring must be visible on the quick-
release coupling, version -A- (installed at SOP) when the
locked refrigerant line -C- is pulled in direction of -arrow-.
• On the quick-release coupling -D- (running change from MY
2010), the ring -E- must come out of the quick-release coupling
-D-, when, after assembling, the locked refrigerant line -C- is
pulled in direction of -arrow-. Then the ring -E- can be removed
from the refrigerant line -C-.
Note
♦ Install the refrigerant lines such that they are not strained.
♦ Check installation position of refrigerant lines to the quick-re‐
lease couplings (they should not come in contact with other
components).
– Evacuate and charge the refrigerant circuit. Refer to ⇒ Re‐

C Service Station .
- display and control head and erase any displayed malfunc‐
tions, if necessary using the Vehicle Diagnostic Tester in the
fer to
Note
Read the information for starting the A/C system after filling. Refer
to ⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ; A/C System
General Information or ⇒ A/C Systems with Refrigerant R1234yf
- General Information; Rep. Gr. 87 ; Working with A/C Service
Station; A/C System, Starting after Filling . After recharging, be‐
fore activating the A/C system.

2.14 Refrigerant Lines with Inner Heat Ex‐

changer, Removing and Installing
Audi Q5 Except Hybrid/RS 5
⇒ “2.14.1 Refrigerant Lines with Inner Heat Exchanger, Removing
RS 5
Q5 Hybrid
2.14.1 Refrigerant Lines with Inner Heat Ex‐

♦ Air Conditioner Couplings Release Tool - T40149- or Retain‐
ing Ring - T40232-
♦ Engine Bung Set - VAS6122-
Removing
Note
Depending on the allocation of the service connection to the re‐

frigerant line and vehicle version, it may be necessary to remove
the left auxiliary reinforcement on the tower brace so that the A/
C service station service coupling can be connected (for example,
on the Audi Q5). Refer to ⇒ Suspension, Wheels, Steering; Rep.
Gr. 40 ; Suspension Strut, Upper Control Arm; Overview - Sus‐
pension Strut, Upper Control Arm and ⇒ Refrigerant R134a
Servicing, Working with A/C Service Station) or ⇒ A/C Systems
– Remove the plenum chamber cover and/or the cowl panel trim
(different versions). Refer to ⇒ Body Exterior; Rep. Gr. 50 ;
– Disconnect the ground connection from the Battery - A- . Refer
to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery,
Disconnecting and Connecting .

Note
From MY 2010, refrigerant lines with an inner heat exchanger

-A- that have an additional weight (balance) -B- to reduce noise
are being installed on certain versions and depending on the en‐
gine. When installing refrigerant lines with an inner heat exchang‐
er -A- and the front wall of the plenum chamber, make sure the
weight -B- and the refrigerant lines -A- are not too close or touch‐
ing the other components.
– Remove the refrigerant line from the quick-release coupling

connections. Refer to
Couplings and Connecting”, page 221 .
Note
– Detach the plenum chamber front wall -A- from the vehicle.
Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Bulkhead; Overview
- Bulkhead .
Note
♦ On vehicles with a gasoline engine or a 4 cylinder TDI engine,

both coolant hoses to the heater core are routed through the
plenum chamber front wall -A- . On these vehicles, loosen the
grommet on both coolant hoses and move the plenum cham‐
ber front wall to the side (when doing this, the refrigerant circuit
must not be opened).
♦ When loosening the plenum chamber front wall, be careful not
to damage the brake booster vacuum line.
– For vehicles with a 6-Cylinder TDI engine, remove the plenum

chamber front wall -A-. Refer to ⇒ Body Exterior; Rep. Gr.
50 ; Bulkhead; Overview - Bulkhead .
– Disengage the catches in direction of -arrows A- and remove

the upper part of the line pass-through -2- upward in direction
of -arrow B-.
Note
Disregard item -1- .
– Loosen the wiring harness from the lower part of the line pass-
through -2- and remove the lower part.

– Remove the nut -C- on the suspension strut tower.

– Remove the bolts -A-.
– Disconnect the refrigerant line -B- with the inner heat ex‐
changer from the expansion valve.
Note
Seal the open connections on the refrigerant line and on the ex‐
pansion valve with suitable caps (to prevent dirt and moisture
from entering the system).
Installing
Note
Electrical connections and routing. Refer to ⇒ Wiring diagrams,

– Thoroughly clean all the connections in the expansion valve

-B- and in the refrigerant line -D- with the inner heat exchanger.
– Check the connections in the expansion valve -B- and on the
refrigerant line -D- for damage.
– Replace the quick-coupling connections on the refrigerant line
with inner heat exchanger. Refer to
– Replace the O-rings -A and C-. For the correct version. Refer
Note

– Coat the O-ring seals lightly with refrigerant oil before instal‐
ling. Refer to ⇒ “3.13 Refrigerant Circuit Seals”, page 109 .
– Make sure the O-rings fit properly inside the grooves on the
refrigerant line connections -D-.
– Tighten the bolts -E- for the refrigerant line connections -D-
with inner heat exchanger.
• Tightening specification -E-: 10 Nm.

– Tighten the nut -C- for the refrigerant line -B- .

– Install the plenum chamber front wall. Refer to ⇒ Body Exte‐
rior; Rep. Gr. 50 ; Bulkhead; Overview - Bulkhead .
Note
♦ Install refrigerant line such that it is not strained.

♦ Check installation position of refrigerant line to expansion
valve (it should not come in contact with other components).
– Install the refrigerant line on the quick-coupling connections.

Refer to
C Service Station .
fer to
Note

ing Ring - T40232-
Removing
tion).

– Remove the nut -6- and open the clamp -5-.

– Remove the refrigerant line -2- from the quick-coupling con‐
nection -1-. Refer to
– Remove the bolt -3- and remove the refrigerant line -4-.
– Seal the open lines and connections with clean plugs from the
Engine Bung Set - VAS6122- .

of -arrow B-.
– Loosen the wiring harness -1- from the lower part of the wire
pass-through and then remove the lower part.
- Bulkhead .
– Remove bolts -1-.

– Disconnect the refrigerant line -2- with the inner heat exchang‐
er from the expansion valve.
Engine Bung Set - VAS6122- .

Installing
Note


– Replace the quick-coupling connection on the refrigerant line
Couplings and Connecting”, page 221
Note

– Make sure the O-rings fit properly inside the grooves on the
refrigerant line connections -D-.
– Tighten the bolts -E- for the refrigerant line -D- with inner heat
exchanger.
Note
On certain versions, the refrigerant line with an inner heater core

-A- also has a weight (balance) -B- to reduce noise. When instal‐
ling the refrigerant lines with an inner heat exchanger and the
plenum chamber bulkhead, make sure the weight and the refrig‐
erant line are not too close to the other components or touching
them.

– Clean the connections on the refrigerant pipe and check for

damage.
– If applicable, inspect the alignment pin -4- for damage and
check that it is seated correctly.
– Inspect the guide ring -2- on the refrigerant line connection for
damage.
Note
♦ Coat the O-ring with refrigerant oil before installing. Refer to

♦ Make sure the O-ring fits correctly inside the groove in the re‐
frigerant pipe.
– Insert the O-ring seal -3- into the groove -arrow- on the refrig‐
erant line connection -1-.
– The cover -1- must sit correctly on the refrigerant pipe -2- as
illustrated.
– Make sure the rubber bushing -4- is seated in the mount.
– Install the refrigerant pipe -6- on the inner heater core and
tighten the bolt -5-.
– Attach the refrigerant line -3- to the quick-coupling connection.
Refer to
Note


Station).
fer to
– Check the DTC memory and erase any displayed entries using
the Vehicle Diagnostic Tester in the “Guided Fault Finding”
function.

ing Ring - T40232-

Note
erant R134a.
Removing
tion).
Note

the left additional reinforcement on the tower brace so that the
service coupling of the A/C service station can be connected (for
example, on the Audi Q5). Refer to ⇒ Suspension, Wheel, Steer‐
ing; Rep. Gr. 40 ; Suspension Strut and Upper Control Arm;
Overview - Suspension Strut and Upper Control Arm and ⇒ Re‐
frigerant R134a Servicing; Rep. Gr. 87 ; A/C System, General
Information (Refrigerant R134a, Servicing; A/C System General
Information).

General Warnings .
WARNING

voltage system.

WARNING

connector.
DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.



ings .
DANGER!
Note

sequence:
♦ Body
Group 93)

– Remove the rubber seal -A- and plenum chamber cover -B-
♦ Visually inspect the high voltage components -D- (here the
Electric Drive Power and Control Electronics - JX1- ) and the
high voltage cables -E- after removing the plenum chamber
cover -B-. Refer to
Voltage Components and Cables”, page 41 and ⇒ Electrical
System Hybrid; Rep. Gr. 93 ; High Voltage System General
Warnings .
Equipment; Rep. Gr. 93 ; High Voltage System, De-Energiz‐
ing .
cover -B-. Refer to
Warnings .
– Loosen the power distribution panel -1- and move it toward the
windshield with the wires. Refer to ⇒ Electrical Equipment;
Rep. Gr. 97 ; Relay Panels, Fuse Panels and E-Boxes; Over‐
view - Relay Panels, Fuse Panels and E-Boxes .
– Remove the high voltage cables to the Electric Drive Power
and Control Electronics - JX1- . Refer to ⇒ Electrical System
Hybrid; Rep. Gr. 93 ; High Voltage Cables; Overview - High
Voltage Cables .
– Cover the Electric Drive Power and Control Electronics - JX1-
and related wires to prevent them getting damaged and to
protect them from dirt. Refer to ⇒ Electrical System Hybrid;
Rep. Gr. 93 ; High Voltage System General Warnings .

Note
For example, use clean 20 mm bungs -B- from the Engine Bung
Set - VAS6122- to seal off the connections on the Electric Drive
Power and Control Electronics - JX1- -A-.
♦ Be careful not to damage any high voltage components -D- or

the high voltage cables -E-. Refer to ⇒ Electrical System Hy‐
brid; Rep. Gr. 93 ; High Voltage System General Warnings .
Note
♦ To remove and install the refrigerant line with the inner heat
exchanger, it may be necessary to remove the cowl panel trim
-C-. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Bulkhead; Plenum
Chamber Cover, Removing and Installing .
♦ From MY 2010, refrigerant lines with an inner heat exchanger
-A- that have an additional weight (balance) -B- to reduce
noise are being installed on certain versions and depending
on the engine. When installing refrigerant lines with an inner
heat exchanger -A- and the front wall of the plenum chamber,
make sure the weight -B- and the refrigerant lines -A- are not
too close or touching the other components.
– Remove the refrigerant line from the quick-release coupling

connections. Refer to
Note

- Bulkhead .
Note


of -arrow B-.
Note
Disregard item -1- .
– Loosen the wiring harness from the lower part of the line pass-
through -2- and remove the lower part.
– Remove the nut -C- on the suspension strut tower.

– Disconnect the refrigerant line -B- with the inner heat ex‐
changer from the expansion valve.
Note
Seal the open connections on the refrigerant line and on the ex‐
pansion valve with suitable caps (to prevent dirt and moisture
from entering the system).
Installing
Note



– Replace the quick-coupling connections on the refrigerant line
Note

– Make sure the O-rings fit properly in the grooves on the re‐
frigerant line refrigerant line connections -D-.
– Tighten the bolts -E- for the refrigerant line -D- with inner heat
exchanger.
– Tighten the nut -C- for the refrigerant line -B- .

– Install the plenum chamber front wall. Refer to ⇒ Body Exte‐
rior; Rep. Gr. 50 ; Bulkhead; Overview - Bulkhead .
Note

– Install the refrigerant line on the quick-coupling connections.

Refer to
Station).

Visually inspect the high voltage components -D- and high voltage
cables -E- after completing the work procedures and before in‐
stalling the plenum chamber cover -B-. Refer to ⇒ Electrical
Warnings .
DANGER!
starts the vehicle.
Note

♦ Body

fer to

Note

2.15 Expansion Valve, Removing and Instal‐

ling

Note
♦ After switching off the A/C compressor in this vehicle, it may

take a relatively long time for the pressure on the high pressure
side to decrease. This is because the expansion valve is cold
and the pressure on the low pressure side increases quickly
after shutting the compressor off, then the expansion valve
closes and the refrigerant flows slowly to the low pressure
side. If the A/C compressor is switched on, the pressure on
the low pressure side goes down, the expansion valve open
and the refrigerant can flow of the low pressure side.
♦ There are different versions of the expansion valve depending
on the refrigerant (R134a or R1234yf). Refer to Parts Catalog.
♦ From the start of production through the changeover from MY
-A- are being installed (air conditioner part number “8K_ 820
005”). From MY 2012, as a running change and depending on
the vehicle version, an approximately 50 mm wide evaporator
(block depth) -A- is being installed (A/C unit part number “8T_
820 005”). Pay attention to the correct allocation of the expan‐
sion valve to the evaporator (there are different versions).
Parts Catalog.
Removing
Note

Servicing; Rep. Gr. 87 ; A/C System General Information or ⇒
A/C Systems with Refrigerant R1234yf - General Information;
Rep. Gr. 87 ; Working with A/C Service Station .

General Warnings .


WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.

ings .
ing .
– Remove the refrigerant line with inner heat exchanger. Refer
to
⇒ “2.14 Refrigerant Lines with Inner Heat Exchanger, Remov‐

Note
To remove and install the expansion valve, it may be necessary

to remove the cowl panel trim -C-. Refer to ⇒ Body Exterior; Rep.
Gr. 50 ; Bulkhead; Plenum Chamber Cover, Removing and In‐
stalling .

Vehicles with a 6-Cylinder TDI engine:
– Remove the refrigerant line with inner heat exchanger. Refer
to
All vehicles except vehicles with a 6-Cylinder TDI engine:
– Loosen the refrigerant line with inner heat exchanger from the
expansion valve and vehicle and lay it to the side (do not re‐
move). Refer to
Note
♦ On vehicles with the 6-Cylinder TDI engine, the shape of the

front wall of the plenum chamber does not leave enough space
to move the refrigerant line to the side.
♦ On vehicles with a gasoline engine or a 4-Cylinder TDI engine,
the plenum chamber front wall must not be loosen or removed
from the vehicle (there is enough space).
All Vehicles

– Disconnect the expansion valve -B- from the refrigerant lines
leading to the evaporator.
Note
Seal all open lines and connections on evaporator with suitable

caps (avoid dirt and moisture from entering the system).

Installing
– Clean the connection pipes -C and E- leading to the evapora‐
tor and the expansion valve connections, and check for dam‐
age.
Note
♦ The expansion valve is available in different versions (same

housing but a different control characteristic). Therefore, to
ensure the exact allocation. Refer to the Parts Catalog.
on the refrigerant (R134a or R1234yf). Refer to Parts Catalog.
– Replace the O-ring seals -B and F-. For the correct version.
– Make sure the retaining plate -D- fits correctly on the connec‐
tion pipes -C and E- leading to the evaporator.
– Tighten the bolts -G-.
– Install the refrigerant line with inner heat exchanger. Refer to
C Service Station .

– Visually inspect the high voltage components -D- and high

voltage cables -E- after completing the work procedures and
before installing the plenum chamber cover -B-. Refer to ⇒
Electrical System Hybrid; Rep. Gr. 93 ; High Voltage System
General Warnings .
All Vehicles
fer to
Note
2.16 Rear Expansion Valve with Hybrid Bat‐

tery Refrigerant Shut-Off Valve 2 -
N517- , Removing and Installing
Note
erant R134a.

General Warnings .

WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
Removing
tion).
– Remove the luggage compartment floor covering. Refer to ⇒
Body Interior; Rep. Gr. 70 ; Luggage Compartment Trim Pan‐
els; Overview - Luggage Compartment Floor .


-1 and 4-.
– Disconnect and remove the connector -2- from the bracket.

– Remove bolts -1-.
– Remove the Hybrid Battery Refrigerant Shut-Off Valve 2 -
N517- -3- from the refrigerant lines to the evaporator.
Note

Installing
– Clean the connection pipe -C and E- leading to the evaporator
and the expansion valve connections and check for damage.
Note
♦ The expansion valve is available in different versions (same

housing but a different control characteristic). Therefore, to
ensure the exact allocation. Refer to the Parts Catalog.
on the refrigerant (R134a or R1234yf). Refer to the Parts Cat‐
alog.
– Replace the O-ring seals -B and F-. For the correct version.
– Make sure the retaining plate -D- fits correctly on the connec‐
tion pipes -C and E- leading to the evaporator.
– Tighten the bolts -G-.
Station).
– A/C System, Operating after Filling Refrigerant Circuit. Refer
to
Note


2.17 Refrigerant Lines, Disconnecting and

Connecting at Condenser
⇒ “2.17.1 Refrigerant Lines, Disconnecting and Connecting at
Condenser, Except RS Models”, page 253
Condenser, RS Models”, page 257
2.17.1 Refrigerant Lines, Disconnecting and

Connecting at Condenser, Except RS
Models
Note
♦ There are different versions of the condenser. Ensure the cor‐

rect version and allocation before installing. Refer to
⇒ “2.18.1 Condenser, Checking Version”, page 259 and the
Parts Catalog.
♦ To remove the condenser from the front end or to remove the
radiator, it may be necessary to drain the refrigerant circuit and
to remove the refrigerant pipe from the condenser, depending
on the version of the radiator and of the condenser. Refer to
⇒ “2.18 Condenser, Removing and Installing”, page 259 .
Removing
Note


– Remove the bolts (or clips) -1, 2, 3 and 5-. Refer to ⇒ Body
Exterior; Rep. Gr. 50 ; Lock Carrier; Overview - Lock Carrier .
– Lift the cover -4- on the lock carrier and disengage it on the
radiator grille. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Lock
Carrier; Overview - Lock Carrier .
– Remove the bolt -B-.

– Remove the refrigerant line -A- from the condenser.
– Release the clips in direction of -A arrows- and remove the left

air intake grille -1- in the lower part of the bumper cover in
direction of -arrow B-. Refer to ⇒ Body Exterior; Rep. Gr. 63 ;
Front Bumper; Overview - Bumper Cover .


Note
♦ If, for certain vehicles (for example, the Audi SQ5), the bolt
-B- is not accessible with the lower left bumper cover removed
(due to the bumper version), completely remove the bumper
cover. Refer to ⇒ Body Exterior; Rep. Gr. 63 ; Front Bumper;
Bumper Cover, Removing and Installing .
♦ Seal open pipes and connections at condenser with suitable
caps (to prevent ingress of dirt and moisture).
♦ The Audi Q5 has a refrigerant line made up of two pieces; do
not open the connections between both pieces to remove the
condenser (it is possible, but not necessary).
♦ If one piece of the refrigerant line on the Audi Q5 has to be
replaced, then the same tightening specification for the bolt on
the condenser connection applies to the bolt on the connec‐
tion.
Installing
– Clean the refrigerant line connections on the condenser and

on the refrigerant lines and check for damage.
– Replace the O-rings -C-. For the correct version. Refer to Parts
Catalog.

Note

♦ Following attachment, check routing of refrigerant lines on
condenser. They must be inserted in holders provided and not
make contact with other components.
♦ The refrigerant line -C- (from the condenser to the quick-re‐
lease coupling on the refrigerant line with the inner heat ex‐
changer) is secured by a clip -B- to the fender brace -A- from
MY 2008. The fender brace -A- has a hole -D- (diameter 6.5
mm). If the fender brace -A- does not have hole -D- (or a re‐
frigerant line -C- without a clip -B-), then secure the refrigerant
line -C- to the fender brace -A- with a cable tie. Wrap the re‐
frigerant line -C- on the contact surface with a piece of foam
(to protect against damage).
– Make sure the O-ring fits correctly inside the grooves
-arrows- on each mount.
– Check the fitting pin -A- (not installed on all connections) and
refrigerant line connections -B, E and F- for damage and prop‐
er seating.
– Tighten the bolts -D- .
• Tightening specification: 9 Nm
– Install the cover on the lock carrier. Refer to ⇒ Body Exterior;
Rep. Gr. 63 ; Front Bumper; Overview - Bumper Cover .
C Service Station .
fer to
Note


Connecting at Condenser, RS Models
Audi RS 4 and Audi RS 5
Note

Parts Catalog.
♦ It may be necessary to evacuate the refrigerant circuit and re‐
move the refrigerant pipes from the condenser in order to
remove the condenser from the front end or to remove the
radiator depending on the version of the radiator and the con‐
denser (for example, on the Audi RS 4 and the Audi RS 5).
Refer to
♦ On the Audi RS 4 and Audi RS 5, a different version of the
condenser is installed than as on other vehicles of this series
and the length of the refrigerant lines may also differ from other
vehicles. Pay attention to the correct allocation and refrigerant
R134a capacities. Refer to ⇒ “4 Technical Data”, page 110 or
⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ; Refrigerant
R134a Capacities, Refrigerant Oil and Approved Refrigerant
Oils and the Parts Catalog.
Removing
tion).
– Remove the air guide for the left auxiliary radiator. Refer to ⇒
Rep. Gr. 19 ; Radiator/Coolant Fan .

– Remove the bolt -1-.

– Remove the refrigerant pipe -2- from the condenser.
-VAS6122- .
Installing
– Replace the O-ring seals depending on the version. Refer to
the Parts Catalog.
– Check the alignment pin -A- (if equipped) for damage and
make sure it fits correctly.
– Check the guide ring -B- on the refrigerant line connection for
damage.
– Insert the O-ring -C- into the groove -arrow- in the refrigerant
pipe connection -E and F-.
Note
♦ Coat the O-ring with refrigerant oil before installing. Refer to

♦ Make sure the O-ring fits correctly inside the groove in the re‐
frigerant pipe.
– Tighten the bolts -D- .

Note
Following attachment, check routing of refrigerant lines on con‐

denser. They must be inserted in holders provided and not make
contact with other components.

Station).
fer to
function.

2.18 Condenser, Removing and Installing

⇒ “2.18.1 Condenser, Checking Version”, page 259
⇒ “2.18.2 Condenser, Removing and Installing, Except RS Mod‐
els”, page 261
⇒ “2.18.3 Condenser, Removing and Installing, RS Models”, page
265
2.18.1 Condenser, Checking Version
Note
♦ Depending on when the vehicle was manufactured, on the

version of the vehicle and on the engine, different condensers
are installed on these vehicles. Refer to the Parts Catalog.
These condensers different in their inner construction and vol‐
ume. The refrigerant circuit capacity depends on the condens‐
er. Always see which version of the condenser is installed
when determining the refrigerant capacity.
♦ Currently condensers made by different manufacturers are
being installed (“Denso” and “Showa/Keihin”). Each has spe‐
cific distinguishing marks.
♦ A condenser from one manufacturer can have a different con‐
struction but from the outside only the part number is different.
The construction (different flow distribution, different inner vol‐
ume) determines the refrigerant capacity for the refrigerant
circuit. Refer to ⇒ “4.1 Refrigerant Capacities”, page 110 .
Checking
Condenser Distinguishing Marks

Identifying a condenser made by “Denso” -A-

♦ The upper sealing strip -B- is U-shaped.
♦ Condenser manufacturer part number and manufacturer in‐
formation -C- (currently printed directly on it). For the correct
♦ Receiver/dryer -D- integrated on the condenser, dryer car‐
tridge with removed plastic screw (cover) replaceable. Refer
to
page 271 .
Note
♦ There are different versions of this condenser in its construc‐

tion, with different refrigerant R134a capacities (recognizable,
for example, by the part number 8K0 xxx xxx or 8T0 xxx xxx).
Refer to ⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ; Re‐
frigerant R134a Capacities, Refrigerant Oil and Approved Re‐
frigerant Oils ; for allocation. Refer to the Parts Catalog.
♦ Capacities and other information for refrigerant R1234yf. Re‐
fer to ⇒ “4 Technical Data”, page 110 and ⇒ A/C Systems with
Technical Data .
Identifying a condenser made by “Showa/Keihin” -A-

♦ The upper sealing strip -B- is flat.
♦ Condenser manufacturer part number and manufacturing in‐
formation -C- (currently on a label glued to it). For the correct
♦ Receiver/dryer -D- attached to the condenser (the receiver/
dryer can be replaced. Refer to
⇒ “2.19 Receiver/Dryer, Removing and Installing”,
page 267 ).
Note
♦ There are different versions of this condenser in its construc‐

tion, with different refrigerant R134a capacities (recognizable,
for example, by the part number 8K0 xxx xxx or 8T0 xxx xxx).
frigerant R134a Capacities, Refrigerant Oil and Approved Re‐
frigerant Oils ; for allocation. Refer to the Parts Catalog.
Technical Data .

2.18.2 Condenser, Removing and Installing,

Except RS Models
Note
♦ The radiator and condenser may have small indentations on

the fins even when installed correctly. It is not damage. Do not
replace the radiator or condenser because of those small in‐
dentations.
♦ Slight deformations on the side securing straps on the con‐
denser (for example, due to an accident), can result in an
unparallel flow from the condenser and radiator; this can be
resolved by pulling the straps back as long as the function/
condenser sealing is not impaired. The straps on the con‐
denser do not need to be replaced if there are small deforma‐
tions.
♦ A slight bending of the condenser (up to 4 mm) is permissible
as long as there is sufficient distance (minimum 4 mm) be‐
tween the condenser and the radiator and the function/sealing
of the condenser (of the refrigerant circuit) is not impaired. The
condenser does not have to be replaced if there are slight de‐
formations.
♦ Depending on the vehicle version, there are different con‐
denser versions. Refer to
Parts Catalog.
♦ To remove the condenser from the front end or to remove the
radiator, it may be necessary to drain the refrigerant circuit and
to remove the refrigerant pipe from the condenser, depending
on the version of the radiator and of the condenser. Refer to
Removing
Note

– Remove the refrigerant lines from the condenser. Refer to


– Remove the bolts -arrows-.

– Remove the air guide -1- on the intermediate flange -2- for the
air filter housing.
– Disconnect the connector -C- from the A/C Pressure/Temper‐

ature Sensor - G395- .
– Disconnect the connector -B- to the front parking aid sensors
and the connector to the Outside Air Temperature Sensor -
G17- -A- .
Note
Different installation locations of the Outside Air Temperature

Sensor - G17- (this illustration shows the location for vehicles of
MY 2008). Refer to
⇒ “9.5 Outside Air Temperature Sensor G17 , Removing and
– Remove the front bumper cover end plate (depending on the

vehicle version, for example, for the Audi Q5 it is currently not
always necessary). Refer to ⇒ Body Exterior; Rep. Gr. 63 ;
Front Bumper; Overview - Bumper Cover .
Note
On vehicles with a grille -A- (only specific vehicles with safety

feature against rocks and stone chips) the front bumper cover and
grille -A- must be removed in order to move and remove the air
duct -B-.

– Unlock the retaining straps in direction of -arrows A- (each two

straps, one on top and one below on the air guide) and move
the left and right air guide -1- toward the center of the vehicle
in direction of -arrow B-.
Vehicles with a Power Steering Oil Cooler:

– Unlock the retaining clamps in direction of -arrow A- and move
the power steering cooling coil -1- forward in direction of
-arrow B-.
– Remove the power steering oil cooler cooling coil from the
condenser and lay it on the engine.
Note
In the illustration the installation position is shown with the bumper

cover removed.

All:
– Unlock the retaining clamps -1- in direction of -arrow A- and
remove the condenser -2- upward and out of the brackets on
the radiator in direction of -arrows B-.
Note
In the illustration, with the bumper cover removed.
Installing
Note
♦ There is refrigerant oil in the removed condenser that must be

re-delivered to the refrigerant circuit (with new condenser).
frigerant Circuit Components, Replacing or ⇒ A/C Systems
Refrigerant Circuit; Components, Replacing .
Parts Catalog.
♦ The R134a refrigerant circuit capacity varies depending on
which version of the condenser is installed. Refer to
⇒ “4 Technical Data”, page 110 and ⇒ Refrigerant R134a,
Servicing; Rep. Gr. 87 ; Refrigerant R134a Capacities, Re‐
frigerant Oil and Approved Refrigerant Oils .
Technical Data .
– Install the refrigerant lines on the condenser. Refer to

Vehicles with a Power Steering Oil Cooler:
– Install the power steering oil cooler cooling coil. Refer to ⇒
Suspension, Wheels, Steering; Rep. Gr. 48 ; Power Steering
Hydraulics; Overview - Hydraulic Lines and Reservoir .
All:
Rep. Gr. 50 ; Lock Carrier; Overview - Lock Carrier .
C Service Station .

fer to
Note
2.18.3 Condenser, Removing and Installing,

RS Models
Audi RS 4 and Audi RS 5
Note
♦ The radiator and condenser may have small indentations on

the fins even when installed correctly. It is not damage. Do not
replace the radiator or condenser because of those small in‐
dentations.
♦ Slight deformations on the side securing straps on the con‐
denser (for example, due to an accident), can result in an
unparallel flow from the condenser and radiator; this can be
resolved by pulling the straps back as long as the function/
condenser sealing is not impaired. The straps on the con‐
denser do not need to be replaced if there are small deforma‐
tions.
♦ A slight bending of the condenser (up to 4 mm) is permissible
as long as there is sufficient distance (minimum 4 mm) be‐
tween the condenser and the radiator and the function/sealing
of the condenser (of the refrigerant circuit) is not impaired. The
condenser does not have to be replaced if there are slight de‐
formations.
♦ Depending on the vehicle version, there are different con‐
denser versions. Refer to
Parts Catalog.
♦ The Audi RS 4 and Audi RS 5 have a condenser version that
is not installed on other vehicles in this model line. For the
correct allocation and refrigerant capacity. Refer to, Parts Cat‐
alog and ⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ;
Refrigerant R134a Capacities, Refrigerant Oil and Approved
Refrigerant Oils (Refrigerant R134a, Servicing; Refrigerant
R134a Capacities, Refrigerant Oil and Approved Refrigerant
Oil).
♦ It may be necessary to evacuate the refrigerant circuit and re‐
move the refrigerant pipes from the condenser in order to
remove the condenser from the front end or to remove the
radiator depending on the version of the radiator and the con‐
denser (for example, on the Audi RS 4 and the Audi RS 5).
Refer to

Removing
tion).
– Remove the refrigerant lines from the condenser. Refer to
– Remove the left and right air guide -1- from the intermediate
flange -2- on the air filter housing.
– Unlock the retaining straps in direction of -arrows A- (each two

straps, one on top and one below on the air guide) and move
the left and right air guide -1- toward the center of the vehicle
in direction of -arrow B-.
Note
On vehicles with a grille -A- (only specific vehicles with safety

feature against rocks and stone chips) the front bumper cover and
grille -A- must be removed in order to move and remove the air
duct -B-.

– Unlock the retaining clamps -1- in direction of -arrow A- and

remove the condenser -2- upward and out of the brackets on
the radiator in direction of -arrows B-.
Installing
Note
The removed condenser contains refrigerant oil that must be re‐

turned to the refrigerant circuit (with the new condenser). Refer
to ⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ; Refrigerant Cir‐
cuit Components, Replacing (Refrigerant R134a, Servicing; Re‐
frigerant Circuit Components, Replacing).
– Install the refrigerant lines on the condenser. Refer to

Station).
fer to
function.
2.19 Receiver/Dryer, Removing and Instal‐

ling
Note
♦ There are different version of the receiver/dryer and condens‐

er. Allocation. Refer to
⇒ “2.18.1 Condenser, Checking Version”, page 259 and Parts
Catalog.
♦ The receiver/dryer may be attached to or integrated in the
condenser, depending on the version of the condenser. If the
condenser has an integrated receiver/dryer, replace the dryer
cartridge. Refer to
page 271 .
The removed receiver/dryer contains refrigerant oil which must

be returned to the refrigerant circuit (with the new receiver/dryer).
An oil quantity adjustment depends on the type of complaint. Re‐
fer to ⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ; Refrigerant
Circuit Components, Replacing or ⇒ A/C Systems with Refriger‐
ant R1234yf - General Information; Rep. Gr. 87 ; Refrigerant
Circuit; Components, Replacing
♦ If, for example, the receiver/dryer (or condenser) was dam‐
aged during an accident (no refrigerant has leaked out, no
moisture or dirt has gotten into the refrigerant circuit); drain the
refrigerant oil from the removed receiver/dryer (and the dam‐
aged condenser). Fill the refrigerant circuit with the amount of

refrigerant that drained plus 10 cm3 of fresh refrigerant oil. This

makes it easier to repair the circuit. Refer to ⇒ Refrigerant
R134a Servicing; Rep. Gr. 87 ; Refrigerant Circuit Compo‐
nents, Replacing or ⇒ A/C Systems with Refrigerant R1234yf
- General Information; Rep. Gr. 87 ; Refrigerant Circuit; Com‐
ponents, Replacing .
♦ If involved in a collision and an unknown amount of refrigerant
oil has leaked out or dirt and moisture has entered the refrig‐
erant circuit, the refrigerant circuit must be flushed. Refer to ⇒
Refrigerant R134a Servicing; Rep. Gr. 87 ; Refrigerant Circuit
(Refrigerant R134a Servicing; Refrigerant Circuit, Working
cuit; Refrigerant Circuit, Flushing .
Removing
Note



air filter housing.
Note
Depending on the vehicle version, it may be necessary to remove

the bumper cover in order to remove the front noise insulation (for
example, on the Audi A4 allroad). Refer to ⇒ Body Exterior; Rep.
Gr. 63 ; Front Bumper; Bumper Cover, Removing and Installing .
Vehicles with Charge Air Cooler or Engine Oil Cooler, Installed

under the Condenser:
– Remove the condenser. Refer to
All:

– Remove the bolt -C- and the bracket -D- upward.
– Remove the receiver/dryer -F- upward from the condenser
-E- -arrow-.
Note
♦ Be sure not to lose the rubber grommet -B- when removing the
receiver/dryer.
♦ Seal open connections on the receiver/dryer and condenser
with suitable caps (to prevent dirt and moisture from entering).
Installing
Note

♦ Keep the receiver/dryer closed as long as possible. Only re‐
move the cap immediately prior to installation (the receiver/
dryer contains a desiccant bag which quickly becomes satu‐
rated with moisture and unusable when the receiver/dryer is
open).

– Clean the condenser surface -C- .

– Check the connections on the condenser and on the receiver/
dryer for damage.
– Replace the seals -D- and the O-rings -E-. Refer to the Parts
Catalog.
– Make sure the O-ring fits correctly inside the grooves
-arrows- on each mount.
– Mount the receiver/dryer -B- on the condenser and tighten the
screws.
– Pull the protective sleeve -A- over the connection.
Vehicles with Charge Air Cooler, Installed under the Condenser:
– Install the condenser. Refer to
All:
– Install the front noise insulation. Refer to ⇒ Body Exterior;
Note

– Install the air guide on the intermediate flange for the air filter
housing. Refer to ⇒ Rep. Gr. 23 ; Air Filter; Overview - Air
Filter Housing (vehicle with diesel engine) or ⇒ Rep. Gr. 24 ;
Air Filter; Overview - Air Filter Housing (vehicle with gasoline
engine).
Rep. Gr. 50 ; Lock Carrier; Overview - Lock Carrier .
C Service Station .
fer to

Note
2.20 Dryer Bag/Dryer Cartridge, Removing

and Installing
⇒ “2.20.1 Dryer Bag/Dryer Cartridge, Removing and Installing,
Except RS Models”, page 271
⇒ “2.20.2 Dryer Bag/Dryer Cartridge, Removing and Installing,
RS Models”, page 275
2.20.1 Dryer Bag/Dryer Cartridge, Removing

and Installing, Except RS Models
Note
♦ There are different condenser versions and the dryer cartridge

installed inside them. Pay attention to the correct allocation.
Refer to ⇒ “2.18.1 Condenser, Checking Version”, page 259
condenser, depending on the version of the condenser. Re‐
place the attached receiver/dryer. Refer to
⇒ “2.19 Receiver/Dryer, Removing and Installing”, page 267 .
Removing
Note



air filter housing.
Note

– Remove the front bumper cover end plate (depending on the

vehicle version, for example, for the Audi Q5 it is currently not
necessary). Refer to ⇒ Body Exterior; Rep. Gr. 63 ; Front
Bumper; Overview - Bumper Cover .
Vehicles with Charge Air Cooler or Engine Oil Cooler, Installed
under the Condenser:
– Remove the condenser. Refer to

Vehicles, Where It Is Not Necessary to Remove the Condenser

in Order to Remove the Dryer Cartridge -D-:
WARNING
♦ Refrigerant must be extracted from refrigerant circuit be‐

fore removing sealing cap -A-. If the plastic screw -A- is
not removed within 10 minutes, pressure may form in the
refrigerant circuit due to evaporation. Extract the refriger‐
ant once more.
– Check the refrigerant circuit pressure with, for example, the

pressure gauge on an A/C service station. Refer to ⇒ Refrig‐
erant R134a Servicing; Rep. Gr. 87 ; Refrigerant Circuit
C Service Station .
WARNING
Only remove the plastic screw -A- when the pressure in the
refrigerant circuit is the same or less than the ambient pres‐
sure.
All:

– Remove the plastic screw -A- (with filter -C-) (tightening spec‐
ification: 2 Nm).
– Remove the dryer cartridge -D- downward and out of the con‐
denser.
Note
Seal the open connection on the condenser with the plastic screw
-A- to prevent dirt and moisture from getting in.
Installing
♦ Check the receiver/dryer on the condenser above the opening
-E- for dirt.
♦ Make sure the receiver/dryer thread -E- on the condenser is
not dirty or damaged.
♦ Replace the plastic screw -A- (with filter -C-), the dryer car‐
tridge -D- and the O-ring -B-.
♦ Coat the O-ring -C- lightly with refrigerant oil before installing.
♦ Make sure the O-ring -B- fits correctly inside the groove on the
plastic screw -A-.
♦ Keep the dryer cartridge -D- sealed in its air-tight package as
long as possible. Open the package just before installing the
dryer cartridge into the condenser. The dryer cartridge ab‐
sorbs moisture in a very short time and become unusable.
– Remove the dryer cartridge -D- from its original package.
– Insert the dryer cartridge -D- in the condenser receiver/dryer.
– Install the plastic screw -A- (with filter -C-) (tightening specifi‐
cation: 2 Nm).
– Install the condenser. Refer to
– Install the front bumper cover end plate, etc. (depending on
the vehicle version). Refer to ⇒ Body Exterior; Rep. Gr. 63 ;
Front Bumper; Overview - Bumper Cover
– Install the front noise insulation. Refer to ⇒ Body Exterior;
Note


C Service Station .
– Install remaining components.


fer to
Note
2.20.2 Dryer Bag/Dryer Cartridge, Removing

and Installing, RS Models
Note
♦ There are different condenser versions and the dryer cartridge

installed inside them. Pay attention to the correct allocation.
Refer to ⇒ “2.18.1 Condenser, Checking Version”, page 259
condenser, depending on the version of the condenser. Re‐
place the attached receiver/dryer. Refer to
⇒ “2.19 Receiver/Dryer, Removing and Installing”, page 267 .
Removing


– Remove the front oil cooler. Refer to ⇒ 6-Cylinder TDI Com‐
mon Rail 3.0L 4V Engine (Generation II); Rep. Gr. 17 ; Engine
Oil Cooler; Overview - Engine Oil Cooler .
– Remove the left and right air guide -1- from the intermediate
flange -2- on the air filter housing.
WARNING
♦ Refrigerant must be extracted from refrigerant circuit be‐

fore removing sealing cap -A-. If the plastic screw -A- is
not removed within 10 minutes, pressure may form in the
refrigerant circuit due to evaporation. Extract the refriger‐
ant once more.
– Check the refrigerant circuit pressure with, for example, the

pressure gauge on an A/C service station. Refer to ⇒ Refrig‐
erant R134a Servicing; Rep. Gr. 87 ; Refrigerant Circuit
C Service Station .
WARNING
Only remove the plastic screw -A- when the pressure in the
refrigerant circuit is the same or less than the ambient pres‐
sure.

– Remove the plastic screw -A- (with filter -C-).

– Remove the dryer cartridge -D- downward and out of the con‐
denser.
– Seal the open receiver/dryer with the plastic screw -A- to pre‐
vent dirt and moisture from getting in.
Installing
♦ Using the opening, inspect the receiver/dryer on the condens‐
er for dirt and damage on the threaded- and sealing surfaces.
♦ Replace the plastic screw -A- (with filter -C-), the dryer car‐
tridge -D- and the O-ring -B-.
♦ Coat the O-ring -C- lightly with refrigerant oil before installing.
♦ Make sure the O-ring -B- fits correctly inside the groove on the
plastic screw -A-.
♦ Keep the dryer cartridge -D- sealed in its air-tight package as
long as possible. Open the package just before installing the
dryer cartridge into the condenser. The dryer cartridge ab‐
sorbs moisture in a very short time and become unusable.
– Remove the dryer cartridge -D- from its original package.
– Insert the dryer cartridge -D- in the condenser receiver/dryer.
– Install the plastic screw -A- (with filter -C-) (tightening specifi‐
cation: 2 Nm).
C Service Station .
fer to
function.

2.21 Service Connection Differences, De‐

pending on Refrigerant (R134a or
R1234yf)
Note
♦ Only use valves and connections that are resistant to the re‐
spective refrigerant (R134a and/or R1234yf) and the corre‐
sponding refrigerant oil. Refer to the Parts Catalog.
♦ The service connections on the refrigerant circuits are de‐
signed so that only the service couplings provided for the
intended refrigerant (R134a or R1234yf) can be connected.
♦ These illustrations show service connections that have a
Schrader valve (needle valve or push pin) installed in them.
Depending on the vehicle version, the refrigerant, etc. service
connections with a primary sealing valve (ball valve) may also
be installed (other technology).
♦ Allocation in the vehicle and on the refrigerant circuit. Refer to
partment”, page 120 and
⇒ “2.1 Overview - Refrigerant Circuit”, page 150 .
♦ Different connections (outer diameter) for high pressure and
low pressure side.
♦ Before removing the valves or valve inserts, discharge the re‐
frigerant circuit. Refer to ⇒ Refrigerant R134a Servicing; Rep.
Gr. 87 ; Refrigerant Circuit or ⇒ A/C Systems with Refrigerant
C Service Station .
♦ Valve, Removing and Installing at Service Connection on Low
and High Pressure Side. Refer to
⇒ “2.22 Evacuating and Charging Valve, Removing and In‐
stalling, Low and High Pressure Side”, page 281 .
♦ Always install the closure caps with a seal.

Service Connections (Refrigerant R134a and R1234yf)
WARNING
First connect the A/C service station and evacuate the refrig‐
erant before removing the valves -B and E-. The refrigerant
circuit must be empty due to the risk of injury. Refer to ⇒ Re‐
frigerant R134a Servicing; Rep. Gr. 87 ; Refrigerant Circuit or
tion; Rep. Gr. 87 ; Working with A/C Service Station .
♦ High pressure side service connection closure cap -A- with

seal -G-
♦ High pressure side valve insert (version: Schrader or needle
valve) -B-
♦ High pressure side service connection -C-
♦ High pressure side service connection closure cap -D- with
seal -G-
♦ Low pressure side valve insert (version: Schrader or needle
valve) -E-
♦ Low pressure side service connection -F-

Note
♦ Depending on the manufacturer, there are different versions

of the service connections -C and F- for refrigerant R134a and
refrigerant R1234yf with different closure caps -A and D- and
valves -B and E-. Pay attention to the correct allocation. Refer
♦ The closure caps -A and D- for the service connections on the
R134a refrigerant circuit are currently black. The closure caps
for the service connections on the R1234yf refrigerant circuit
are currently gray. The type of refrigerant (such as “R1234yf”)
may also be imprinted on the closure caps.
♦ After connecting, carefully install the service coupling hand
wheel just far enough into the quick-release coupling adapter
until the valve -B and E- is securely opened in the service
connection (pay attention to the pressure gauge, do not put
too much pressure on the valve -B and E-).
♦ The service connections -C and F- on an R134a and R134yf
refrigerant circuit are designed so that only certain service
couplings can be connected for each of the refrigerants (dif‐
ferent dimensions. Refer to ⇒ page 280 ).
♦ For example, the service connections -C and F- are soldered
into a refrigerant line and therefore cannot be replaced sepa‐
rately.
♦ To remove and install the valves -B and E- (when the refrig‐
erant circuit is discharged), use, for example, an adapter from
the Refrigerant Sockets - T10364- . Refer to
stalling, Low and High Pressure Side”, page 281
♦ Due to the low tightening specification, only tighten the valves
-B and E- carefully. Refer to
stalling, Low and High Pressure Side”, page 281
♦ There are different versions of these valves, therefore the
tightening specifications are different. For a valve insert -C-
with a VG5 thread (5.2 x 0.7 mm, tire valve), the tightening
specification is 0.4 Nm. +- 0.1 Nm, on a valve insert with an
M6 x 0.75 mm thread, the tightening specification is 0.9 Nm
+- 0.1 Nm and on a valve insert with an M8 x 1.0 mm thread,
the tightening specification is 2.0 Nm +- 0.2 Nm. Refer to ⇒
A/C Systems with Refrigerant R1234yf - General Information;
Rep. Gr. 87 ; Refrigerant Circuit; General Description - Re‐
frigerant Circuit Components .
♦ There are different versions of these valve caps -A and D-,
which means there are different tightening specifications. A
valve cap with an M8 x 1mm or M10 x 1mm thread has a tight‐
ening specification of 0.4 Nm +- 0.1 Nm.
Service Connection Dimensions

♦ Valve insert -A- (different versions). Refer to ⇒ Refrigerant

R134a Servicing; Rep. Gr. 87 ; A/C System General Informa‐
tion and ⇒ A/C Systems with Refrigerant R1234yf - General
Information; Rep. Gr. 87 ; Refrigerant Circuit; Overview - Re‐
frigerant Circuit Components .
♦ Service connection -B- (depending on the refrigerant, there
are different versions on the high and low pressure side)
Service Connection Refrigerant R134a Refrigerant R1234yf
Dimensions -B- Service Connec‐ Service Connection
tion
High Low High Low
Pressure Pres‐ Pressure Pressure
Side sure Side Side
Side
Outer diameter -D1- 16.0 mm 13.0 17.0 mm 14.0 mm
mm
Outer diameter -D2- 14.0 mm 11.0 13.0 mm 12.0 mm
mm
Section -L1- 4.6 mm 6.15 9.0 mm 4.75 mm
mm
Section -L2- 8.16 mm 9.16 12.5 mm 7.2 mm
mm
Valve installation po‐ 6.1 - 7.1 6.1 - 7.1 8.3- 9.3 8.3- 9.3
sition (not actuated) mm mm mm mm
-C-
2.22 Evacuating and Charging Valve, Re‐

moving and Installing, Low and High
Pressure Side
♦ Refrigerant Sockets - T10364-
WARNING
Danger due to refrigerant coming out under pressure.

Danger of frost bite to skin and other parts of the body.
• Evacuate the refrigerant and immediately open the refrig‐
erant circuit afterward.
• If more than 10 minutes have elapsed since evacuating
the refrigerant and the refrigerant circuit was not opened,
evacuate the refrigerant again. Pressure in the refrigerant
circuit is caused by evaporation.

Note
♦ Certain tools are required to discharge the refrigerant circuit.

These work procedures may only be performed by trained
personnel. Refer to ⇒ Refrigerant R134a Servicing; Rep. Gr.
87 ; A/C System General Information or ⇒ A/C Systems with
Refrigerant R1234yf - General Information; Rep. Gr. 00 ; Le‐
gal Texts and Regulations .
♦ There are different versions depending on the refrigerant
(R134a or R1234yf). Refer to
⇒ “2.21 Service Connection Differences, Depending on Re‐
frigerant (R134a or R1234yf)”, page 278 or the Parts Catalog.
Removing
– Remove the closure caps (with seal) -1- or -2-.
– Remove the service connection -3- using the Refrigerant
Sockets - T10364- and a suitable adapter.
Note
There is additional information for the service connection. Refer

- General Information; Rep. Gr. 87 ; Refrigerant Circuit; General
Description - Refrigerant Circuit Components .
Installing
Install in reverse order of removal and note the following:
C Service Station .
Refer to
function.
2.23 A/C System, Starting Operation after

Filling Refrigerant Circuit
General Warnings .


WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
Caution
♦ After the installation of the electrically-driven A/C com‐

pressor and the subsequent filling of the refrigerant circuit,
start the A/C compressor for the first time using the “com‐
pressor intake” function for the basic setting. The A/C
compressor may otherwise become damaged if before in‐
stallation, refrigerant oil was improperly stored in the A/C
compressor compression chamber using the Vehicle Di‐
agnostic Tester in the "Guided Fault Finding" function
♦ Only activate the electrically driven A/C compressor when
the refrigerant circuits are filled. Damage to the A/C com‐
pressor may occur if the A/C compressor is running while
the refrigerant circuit is empty using the Vehicle Diagnos‐
tic Tester in the "Guided Fault Finding" function
♦ All removed parts are installed once again.

♦ The refrigerant circuit is filled. Refer to ⇒ Refrigerant R134a


– Operate the Electrical A/C Compressor - V470- via the “com‐
pressor cut-in” function using the Vehicle Diagnostic Tester in
Note

Note
♦ Only start engine after refrigerant circuit has been assembled.

♦ If possible start engine only with a filled refrigerant circuit.
♦ Do not start the engine while evacuating or when the refriger‐
ant circuit is evacuated (the A/C compressor could become
damaged). Refer to ⇒ Refrigerant R134a Servicing; Rep. Gr.
87 ; A/C System General Information or ⇒ A/C Systems with
Refer to
♦ The A/C compressor without A/C clutch - N25- is always driven
by the belt pulley or input shaft. To prevent damage when the
compressor is idling, it is lubricated by an “Internal oil circuit”.
♦ The compressor has an “Internal oil circuit” to ensure the A/C
compressor is not damaged when refrigerant circuit is empty.
Prerequisite for the internal lubrication is residual refrigerant
oil in A/C compressor.
♦ The engine may start when the refrigerant circuit is installed
correctly. For example; if the refrigerant lines are not connec‐
ted to A/C compressor, when the engine is running the A/C
compressor may heat up (via internal heat generation) so
much that the A/C compressor will be damaged.
♦ A/C Compressor Regulator Valve - N280- is not activated
when the refrigerant circuit is empty and the A/C compressor
idles with the engine. Since there is no refrigerant in the circuit,
the required refrigerant oil for lubricating the A/C compressor
is not supplied.
♦ All removed parts are installed once again.

♦ The refrigerant circuit is filled. Refer to ⇒ Refrigerant R134a
If it is necessary to start the engine with a discharged refrigerant
circuit:

♦ Refrigerant circuit must be fully assembled.

♦ There must be no vacuum in the refrigerant circuit.
♦ At least a quarter of the prescribed refrigerant oil must be in
the A/C compressor.
♦ Do not let the engine RPM go above 2,500.
♦ The engine should only run as long as is absolutely necessary.
Note the following when starting engine for first time after filling
refrigerant circuit:
– Start the engine with the A/C compressor switched off (“Econ”
mode set, indicator lamp in AC or A/C button does not light
up), and wait until engine idle speed has stabilized.
– Set the temperature preset on the Climatronic Control Module
- J255- A/C display and control head to “cold” (for the driver
and front passenger side).
– Press the AC or A/C button to switch on the A/C compressor
(“Auto” mode selected and the indicator lamp in the AC or A/
C button lights up) and let the A/C compressor idle with the
engine for at least five minutes.
Note

3 A/C Compressor
⇒ “3.1 Overview - A/C Compressor Power Unit”, page 288
⇒ “3.2 Overview - Belt Pulley”, page 291
⇒ “3.3 A/C Compressor, Removing and Installing on Bracket”,
page 298
⇒ “3.4 Refrigerant Lines, Disconnecting and Connecting at A/C
Compressor”, page 312
⇒ “3.5 A/C Compressor, Removing and Installing”, page 325
⇒ “3.6 Preliminary Work for Replacing Belt Pulley”, page 374
⇒ “3.7 Belt Pulley, Removing and Installing”, page 374
⇒ “3.8 A/C Compressor Input Shaft, Loosening and Tightening”,
page 382
⇒ “3.9 A/C Compressor Input Shaft, Removing and Installing”,
page 383
⇒ “3.10 Drive Plate with Overload Protection, Removing and In‐
stalling”, page 384
⇒ “3.11 Drive Plate with Overload Protection, Checking Run-Out
and Adjusting”, page 384
⇒ “3.12 A/C Compressor Drive Plate, Removing and Installing”,
page 384
⇒ “3.13 Drive Plate with Anti-Friction Bearing, Removing and In‐
3.1 Overview - A/C Compressor Power Unit

⇒ “3.1.1 Overview - A/C Compressor Power Unit, Electrically-
Driven A/C Compressor”, page 288
⇒ “3.1.2 Overview - A/C Compressor Power Unit, Vehicles with
8-Cylinder Engine”, page 290
3.1.1 Overview - A/C Compressor Power Unit, Electrically-Driven A/C Compres‐

sor
Note
♦ For this model line, only vehicles with a high-voltage system were manufactured that had the refrigerant
circuit charged with refrigerant R134a.
♦ With A/C Compressor Control Module - J842- and Electrical A/C Compressor - V470-
♦ If the A/C Compressor Control Module - J842- is faulty, the refrigerant oil quantity must be adapted in the
new A/C compressor. The refrigerant circuit must not be flushed with refrigerant R134a. Refer to ⇒ Refrig‐
erant R134a, Servicing; Rep. Gr. 87 ; A/C System, General Information (Refrigerant R134a, Servicing; A/
C System, General Information).
♦ For additional information regarding the A/C compressor. Refer to
⇒ “3.3.3 A/C Compressor, Removing and Installing on Bracket, Electrically-Driven A/C Compressor”, page
304 and ⇒ Refrigerant R134a, Servicing; Rep. Gr. 87 ; A/C System, General Information (Refrigerant
R134a, Servicing; A/C System, General Information).

Compressor
pressor - V470-
❑ Refer to
Compressor”,
page 304
❑ Refer to
stalling, Vehicles with 4-
Cylinder Engine, Electri‐
cally-Driven A/C Com‐
pressor”, page 328
2 - O-Ring Seal
❑ Replacing
3 - Refrigerant Line
4 - Bolt
tion: 9 Nm (bolts with a
M6 thread) and 25 Nm
(bolts with a M8 thread).
5 - High Voltage Cable to the
Electric Drive Power and Con‐
trol Electronics - JX1-
6 - O-Ring Seal
❑ Replacing
7 - Refrigerant Line
8 - Bolt
9 - Bolt
❑ Varying tightening specifications depending on bolt version. Refer to
⇒ “3.3.3 A/C Compressor, Removing and Installing on Bracket, Electrically-Driven A/C Compressor”,
page 304 .
3. A/C Compressor 289

3.1.2 Overview - A/C Compressor Power Unit, Vehicles with 8-Cylinder Engine
Note
If the drive plate overload protection triggers, check the A/C compressor for ease of motion before replacing
the drive unit. If the A/C compressor creates friction, replace it completely.
1 - A/C Compressor Input

Shaft
tion: 60 Nm
❑ The input shaft must be
seated free of play in
splines of engine drive
wheel with thread tight‐
ened. For checking. Re‐
fer to
Input Shaft, Removing
and Installing”,
page 383 .
❑ Loosening and tighten‐
ing. Refer to
Input Shaft, Loosening
and Tightening”,
page 382 .
ling. Refer to
Input Shaft, Removing
and Installing”,
page 383 .
❑ Grease the splines for
the engine drive wheel
with Grease - G 000
100- for example. Refer
2 - Hex Socket Bolt
tion: 10 Nm
3 - Drive Plate
❑ The overload protection
takes over when the tor‐

que is excessive (for example, if the A/C compressor runs with resistance) and the input shaft runs freely
without driving the A/C compressor.
❑ Run-out, checking and adjusting. Refer to
⇒ “3.11 Drive Plate with Overload Protection, Checking Run-Out and Adjusting”, page 384 .
⇒ “3.10 Drive Plate with Overload Protection, Removing and Installing”, page 384 .
4 - Drive Plate
❑ Tightening specification: 30 Nm
❑ Attached to the A/C compressor input shaft
❑ The overload protection takes over when the torque is excessive (for example, if the A/C compressor
runs with resistance) and the input shaft runs freely without driving the A/C compressor.
⇒ “3.12 A/C Compressor Drive Plate, Removing and Installing”, page 384 .
5 - Rubber Element
❑ When the drive unit de-couples, the vibrations and noises are dampened.
❑ When installing, coat the rubber elements B lightly using soapy water (as a lubricant).
⇒ “3.12 A/C Compressor Drive Plate, Removing and Installing”, page 384 .
6 - Spacer
❑ The original disc must be installed
❑ Dimensions: 17.5 x 10 x 3 mm
7 - Circlip
❑ Replace
❑ Install on correct side (flat side toward A/C compressor)
⇒ “3.13 Drive Plate with Anti-Friction Bearing, Removing and Installing”, page 385 .
8 - Drive Plate
❑ With roller bearing.
⇒ “3.13 Drive Plate with Anti-Friction Bearing, Removing and Installing”, page 385 .
❑ Clean the A/C compressor flange before installing the drive plate.
9 - A/C Compressor
❑ Different versions may be installed, depending on engine version and country version of vehicle. Refer
to the Parts Catalog
Note
There are different versions de‐

pending on the refrigerant (R134a
or R1234yf). Refer to the Parts Cat‐
alog.
3.2 Overview - Belt Pulley

⇒ “3.2.1 Overview - Belt Pulley, Denso A/C Compressor, Version
1 ”, page 291
⇒ “3.2.2 Overview - Belt Pulley, Denso A/C Compressor, Version
2 ”, page 293
⇒ “3.2.3 Overview - Belt Pulley, A/C Compressor with A/C Clutch
N25 ”, page 296
3.2.1 Overview - Belt Pulley, “Denso” A/C Compressor, Version “1”

A/C compressor without A/C Clutch - N25-

Note
♦ If overload protection of pulley triggers, check the A/C compressor for ease of motion before replacing the
pulley. If the A/C compressor creates friction, replace it completely.
♦ To remove the belt pulley, it is not always necessary to loosen the A/C compressor from the engine. Refer
to ⇒ “3.3 A/C Compressor, Removing and Installing on Bracket”, page 298 . However there may be not
enough space to remove the belt pulley depending on the engine version. If so, loosen or remove the A/C
compressor from the engine or loosen the lock carrier from the vehicle and pull it slightly forward to create
enough space (easier to perform depending on the vehicle version). Refer to ⇒ Body Exterior; Rep. Gr.
50 ; Lock Carrier; Service Position, Performing and Resetting .
♦ Different versions of the belt pulley (with different diameters) may be installed, depending on A/C compressor
construction type and engine version. Refer to the Parts Catalog.
♦ As a replacement part, the belt pulley with the drive plate and the cap is available under one part number.
The belt pulley and the drive plate are held together with one bolt (when the bolt is no longer needed, dispose
of it). When the bolt was manufactured, a predetermined amount of a specific grease was applied to the
threads in the drive plate; this amount is sufficient for bolting the drive plate to the compressor one time (a
drive plate, which has been removed, cannot be reused). Refer to the Parts Catalog.
♦ Belt pulley, removing and installing. Refer to
⇒ “3.7.1 Belt Pulley, Removing and Installing, Denso A/C Compressor, Version 1 ”, page 374 .
1 - Sealing Cap
2 - Drive Plate
tion: 30 Nm
❑ Always replace
❑ Bolted with the A/C
compressor input shaft,
clean the compressor
shaft thread before
mounting the drive
plate.
Note
The thread of the new drive plate

has already been greased with a
specific amount of a grease by the
manufacturer.
sions. Refer to the Parts
Catalog
que is excessive (for ex‐
ample, if the A/C com‐
pressor runs with resist‐
ance) and the belt pulley
runs freely without driv‐
ing the A/C compressor.
❑ With rubber elements
for decoupling belt pul‐
ley from A/C compres‐
sor input, dampens ra‐
tions and noise
❑ For installation, lightly
coat rubber elements,
for example with tire
mounting paste or a soap solution (as a lubricant)


3 - Circlip
❑ Always replace
4 - Belt Pulley
❑ The belt pulley is made of plastic and is sensitive to impact, therefore take special care when handling
it.
❑ There are different versions (depending, for example, on the type of engine). Refer to the Parts Catalog
5 - A/C Compressor
❑ Depending on engine version and the market, different versions may be installed. Refer to the Parts
Catalog
❑ Clean the A/C compressor flange before installing the pulley.
❑ Clean the compressor shaft thread and then coat the thread lightly with grease.
Note

alog.
3.2.2 Overview - Belt Pulley, “Denso” A/C Compressor, Version “2”


Note
♦ To remove the belt pulley, it depends on engine version if it is necessary to remove A/C compressor from
engine. Refer to ⇒ “3.3 A/C Compressor, Removing and Installing on Bracket”, page 298 .
♦ Different belt pulley versions may be installed, depending on A/C compressor type and engine version. Refer
♦ Belt pulley, removing and installing. Refer to
1 - Circlip with Rubber Disc

❑ Remove carefully using
a small screwdriver or
needle-nose pliers (es‐
pecially note belt pulley
when doing this).
ling. Refer to
⇒ “3.7.2 Belt Pulley, Re‐
moving and Installing,
Denso A/C Compres‐
sor, Version 2 ”,
page 376 .
❑ The rubber disc that is
vulcanized on serves as
noise insulation during
low compressor output
when engine is idling
2 - Drive Plate
tion: 35 Nm
❑ Attached to the A/C
compressor input shaft
Catalog
que is excessive (for ex‐
ample, if the A/C com‐
pressor runs with resist‐
ance) and the belt pulley
runs freely without driv‐
ing the A/C compressor.
ling. Refer to
⇒ “3.7.2 Belt Pulley, Re‐
moving and Installing, Denso A/C Compressor, Version 2 ”, page 376 .
3 - Circlip
❑ Always replace
4 - Spacer
❑ Dimensions: 17.5 x 10 x 3 mm

5 - Rubber Elements
❑ Quantity: 6, install on proper side. Refer to
❑ De-couples belt pulley from compressor drive axle, damps vibrations and noise.
❑ For installation, lightly coat rubber elements, for example with tire mounting paste or a soap solution (as
a lubricant)
6 - Belt Pulley
❑ The belt pulley is made of plastic and is sensitive to impact, therefore take special care when handling
it.
❑ There are different versions. Refer to the Parts Catalog
7 - A/C Compressor
❑ There are different versions depending on engine installed and the market. Refer to the Parts Catalog
❑ Clean the A/C compressor flange before installing the pulley
Note

alog.

3.2.3 Overview - Belt Pulley, A/C Compressor with A/C Clutch - N25-
Note
♦ To remove the belt pulley, it is not always necessary to loosen the A/C compressor from the engine. Refer
to ⇒ “3.3 A/C Compressor, Removing and Installing on Bracket”, page 298 . However there may be not
enough space to remove the belt pulley depending on the engine version. If so, loosen or remove the A/C
compressor from the engine or loosen the lock carrier from the vehicle and pull it slightly forward to create
enough space (easier to perform depending on the vehicle version). Refer to ⇒ Body Exterior; Rep. Gr.
♦ Different versions of the belt pulley (with different diameters) may be installed, depending on A/C compressor
construction type and engine version. Refer to the Parts Catalog.
♦ The replacement belt pulley with A/C clutch has a single part number. The belt pulley and the drive plate
are held together with one bolt (when the bolt is no longer needed, dispose of it). When the bolt was man‐
ufactured, a predetermined amount of a specific grease was applied to the threads in the drive plate; this
amount is sufficient for bolting the drive plate to the compressor one time (a drive plate, which has been
removed, cannot be reused). Refer to the Parts Catalog.
1 - Sealing Cap
❑ Not always present
2 - Clutch Plate
tion: 30 Nm
❑ Always replace
❑ Attached to the A/C
compressor input shaft
– Clean the contact surfa‐
ces on the clutch plate
and belt pulley before in‐
stalling.
– Clean the thread on the

A/C compressor shaft
before installing the
clutch plate.
– Check the gap dimen‐

sion between the belt
and clutch plates and
correct it if necessary
before tightening. Refer
to ⇒ , page 379 .
Note
The thread of the new clutch plate

has already been greased with a
specific amount of a grease by the
manufacturer.
Catalog
que is excessive (for example, if the A/C compressor runs with resistance) and the belt pulley runs freely
without driving the A/C compressor with the A/C Clutch - N25- switched on.
Removing and installing

– Hold the compressor shaft -C- tight and turn the clutch plate counter-clockwise in direction of -arrow-
with a suitable tool to remove as described for the drive plate on an A/C compressor without an A/C
clutch. Refer to
3 - Washer
4 - Spacer
❑ For adjusting the gap dimension between the clutch and belt pulley
❑ To check the gap dimension. Refer to ⇒ , page 381 .
5 - Circlip
❑ Always replace
❑ Be careful not to bend the circlip more than necessary when installing it.
– Insert circlip on correct side, the side with beveled insertion edge -C- faces away from A/C compressor
(install the flat side facing the A/C compressor).
6 - Belt Pulley
❑ The belt pulley is sensitive to impact. Be very careful when handling it.
❑ Clean the flange on the A/C compressor flange before installing the belt pulley.
❑ There are different versions (depending, for example, on the type of engine). Refer to the Parts Catalog.
❑ If it is not possible to remove the belt pulley from the flange on the A/C compressor by hand. Refer to
⇒ , page 380 .
7 - Circlip
❑ Always replace
❑ Be careful not to bend the circlip more than necessary when installing it.
– Insert circlip on correct side, the side with beveled insertion edge -C- faces away from A/C compressor
(install the flat side facing the A/C compressor).
8 - Solenoid Coil
❑ Make sure the bracket for the cable -B- is installed correctly.
❑ The connector -D- may be attached to the A/C compressor with a bracket, depending on the version.
9 - A/C Compressor
❑ Depending on engine version and the market, different versions may be installed. Refer to the Parts
Catalog.
❑ Clean the A/C compressor flange before installing the pulley.
❑ Clean the compressor shaft thread and then coat the thread lightly with grease.
Note

alog.

3.3 A/C Compressor, Removing and Instal‐

ling on Bracket
⇒ “3.3.1 A/C Compressor, Removing and Installing on Bracket,
Mechanically-Driven A/C Compressor, Vehicles with 4-Cylinder
Engine”, page 298
Mechanically-Driven A/C Compressor, Vehicles with 6-Cylinder
TDI Engine”, page 300
Electrically-Driven A/C Compressor”, page 304
3.3.1 A/C Compressor, Removing and Instal‐

ling on Bracket, Mechanically-Driven A/
C Compressor, Vehicles with 4-Cylinder
Engine
Note
♦ At the start of production, only A/C compressors manufactured

by “Denso” of type “6 SEU 14” are installed on vehicles with a
4- and 6-Cylinder engine. Depending on engine and period of
production, A/C compressors from other manufacturers or an‐
other version may be installed at a later time. Refer to the Parts
Catalog.
♦ It is possible to remove and re-install the A/C compressor at
the bracket on vehicles with a 4-Cylinder engine and 6-Cylin‐
der TDI engine without having to open the refrigerant lines.
♦ On vehicles with a 6-Cylinder gasoline engine or an 8-Cylin‐
der, the A/C compressor can be removed and installed from
the bracket only when the refrigerant circuit is open. Refer to
⇒ “3.5 A/C Compressor, Removing and Installing”,
page 325 and
⇒ “3.5.4 A/C Compressor, Removing and Installing, Vehicles
with 6-Cylinder Gasoline Engine”, page 343 .
♦ On vehicles with an 8-Cylinder FSI engine, the A/C compres‐
sor is driven by an input shaft, which can be removed and
replaced only if the A/C compressor has been removed. Refer
to
♦ The following describes the removal and installation of the A/
C compressor for a vehicle with a 4-Cylinder TDI engine and
a 6-Cylinder TDI engine with a “Denso” A/C compressor type
“6 SEU 14”. For vehicles with 4-Cylinder engine or another A/
C compressor, there may be differences (depending on en‐
gine, certain additional auxiliary components may need to be
removed or loosened).
♦ Do not discharge the refrigerant circuit to remove the bracket,
do not remove refrigerant hoses and lines from A/C compres‐
sor.
♦ Do not unfasten refrigerant lines and corresponding clamps.
♦ After removing the A/C compressor, tie it to the vehicle with
wire. Do not let is hang by the refrigerant lines.
♦ Before removing, mark direction of operation of ribbed belt
with chalk or felt-tipped pen. Running a used belt in the oppo‐
site direction could destroy it.

♦ Different A/C compressors may be installed depending on en‐

gine and country variant. Refer to the Parts Catalog.
Removing
Proceed as follows:
– Mark the running direction of the ribbed belt. Refer to ⇒ Rep.
Gr. 13 ; Cylinder Block, Belt Pulley Side; Ribbed Belt, Re‐
moving and Installing .
– Remove the ribbed belt -A-. Refer to ⇒ Rep. Gr. 13 ; Cylinder
Block, Belt Pulley Side; Ribbed Belt, Removing and Installing .
– Remove the A/C compressor bolt -B- .
– Remove the A/C compressor and move it away from the en‐
gine only far enough without bending or pulling off the refrig‐
erant hoses.
– Fasten the A/C compressor to the vehicle (for example, with a
wire) without pulling or bending the refrigerant pipes.
Caution
Risk of damaging refrigerant lines and hoses.

♦ Do not stretch, kink or bend refrigerant lines and hoses.
Note
♦ If the A/C compressor cannot be swiveled away enough from

the engine, then the A/C compressor must be removed. Refer
to
with 4-Cylinder Engine, Mechanically-Driven A/C Compres‐
sor”, page 325 .
♦ Depending on the engine (gasoline or diesel), the A/C Com‐
pressor either needs to be removed from the top or the bottom.
If the A/C Compressor is removed towards the top, then it may
be necessary to remove the coolant expansion tank from the
vehicle and loosen the coolant line from the bracket (do not
open the coolant circuit) and turn it slightly to the side. Refer
to ⇒ Engine; Rep. Gr. 19 ; Coolant Pipe
Installing

– Before tightening the A/C compressor, check seating of both

alignment bushings -A- in bracket or A/C compressor -B-.
Note
♦ The alignment sleeves -A- have different styles (different

lengths), make sure to use the correct style. Refer to the Parts
Catalog.
♦ Ensure bushings -A- are properly seated and contact surfaces
are clean. Bushings installed incorrectly and dirty or damaged
contact surfaces -C- on the bracket or A/C compressor can
lead to alignment irregularities between the A/C compressor
and engine. Alignment irregularities over operating time lead
to damage to the ribbed belt or A/C compressor.
– Install bolts -A, B, or C-.
Caution
Depending on the engine and when the vehicle was manufac‐

tured, the different bolts have different tightening specifica‐
tions.
♦ To ensure the correct allocation. Refer to the Parts Cata‐
log.
♦ Aluminum bolts (item -A-) only to be used once, replace.
♦ Tightening specification for aluminum bolts (item -A-) 8
Nm +180°
♦ Tightening specification for steel bolts (here -B and C-) 25
Nm
– Tighten the bolts -arrow-.

– Connect the connector -1- to the A/C Compressor Regulator
Valve - N280- .
– Mount the ribbed belt onto the ribbed belt pulley. Refer to ⇒
Rep. Gr. 13 ; Cylinder Block, Belt Pulley Side; Ribbed Belt,
Note
♦ After fastening the A/C compressor, check installation position

of refrigerant lines, lines must be engaged in bracket (if instal‐
led, depending on engine).
♦ Check refrigerant lines and their bracket to ensure there is
enough distance to the other components. Ensure there is also
enough distance between belts, bracket and pulley.


ling on Bracket, Mechanically-Driven A/

C Compressor, Vehicles with 6-Cylinder

TDI Engine
♦ Torx Socket - T60 - T40087-
Note
♦ At the start of production, only A/C compressors manufactured

by “Denso” of type “6 SEU 14” are installed on vehicles with a
4- and 6-Cylinder engine. Depending on engine and period of
production, A/C compressors from other manufacturers or an‐
other version may be installed at a later time. Refer to the Parts
Catalog.
the bracket on vehicles with a 4-Cylinder engine and 6-Cylin‐
der TDI engine without having to open the refrigerant lines.
♦ On vehicles with a 6-Cylinder gasoline engine or an 8-Cylin‐
der, the A/C compressor can be removed and installed from
the bracket only when the refrigerant circuit is open. Refer to
page 325 and
♦ On vehicles with an 8-Cylinder FSI engine, the A/C compres‐
sor is driven by an input shaft, which can be removed and
replaced only if the A/C compressor has been removed. Refer
to
♦ The following describes the removal and installation of the A/
C compressor for a vehicle with a 4-Cylinder TDI engine and
a 6-Cylinder TDI engine with a “Denso” A/C compressor type
“6 SEU 14”. For vehicles with 4-Cylinder engine or another A/
C compressor, there may be differences (depending on en‐
gine, certain additional auxiliary components may need to be
removed or loosened).
sor.
♦ Before removing, mark direction of operation of ribbed belt
with chalk or felt-tipped pen. Running a used belt in the oppo‐
site direction could destroy it.
Removing
Proceed as follows:

– Mark the running direction of the ribbed belt -A-. Refer to ⇒

– To release the tension on the ribbed belt, move the tensioner

using the Torx Socket - T60 - T40087- in direction of the
-arrow-. Refer to ⇒ Rep. Gr. 13 ; Cylinder Block, Belt Pulley
Side; Ribbed Belt, Removing and Installing .
– Remove the ribbed belt from the A/C compressor ribbed belt
pulley and release the tensioner. Refer to ⇒ Rep. Gr. 13 ;
Cylinder Block, Belt Pulley Side; Ribbed Belt, Removing and
Installing .
– Remove the left bolt -1- and the nut -3- and remove the longi‐
tudinal brace -2- .
– If equipped, loosen the power steering pump from the bracket
(not always necessary on vehicles with a flexible pressure line
to the power steering pump), move it to the side and then tie
it to the engine with wire, for example. Refer to ⇒ Suspension,
Wheels, Steering; Rep. Gr. 48 ; Power Steering Hydraulics;
Power Steering Pump, Removing and Installing .
Note
♦ Make sure not to twist, bend or pull the lines to the power
steering pump.
♦ There are different versions (stiff or flexible) of the power
steering pump pressure line.
♦ The pressure line and power steering pump are only installed
on vehicles without electromechanical power steering. Refer
to ⇒ Suspension, Wheels, Steering; Rep. Gr. 48 ; Power
Steering Hydraulics; Overview - Power Steering Pump .


– Remove the A/C compressor bolt -B- .
– Remove the A/C compressor and swivel it away from the en‐
gine without pulling or bending the refrigerant pipes
– Fasten the A/C compressor to the vehicle (for example, with a
wire) without pulling or bending the refrigerant pipes.
Caution

Note
♦ If the A/C compressor cannot be swiveled away enough from

the engine, then the A/C compressor must be removed. Refer
to
with 6-Cylinder TDI Engine”, page 335 .
♦ Depending on the engine type, it may also be necessary to
loosen the lock carrier from the vehicle and to pull it slightly
forward (to make space). Refer to ⇒ Body Exterior; Rep. Gr.
Installing

Note

Catalog.

– Install bolts -A-, -B- or -C-.
Caution

tions.
log.
Nm +180°
Nm

Valve - N280- .
– Mount the ribbed belt onto the ribbed belt pulley. Refer to ⇒
Note



ling on Bracket, Electrically-Driven A/C
Compressor
General Warnings .
WARNING

voltage system.

WARNING

connector.
DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.

Note
♦ With A/C Compressor Control Module - J842- and Electrical

A/C Compressor - V470-
♦ The electric motor for the A/C compressor is powered with
voltage from the Electric Drive Power and Control Electronics
- JX1- .
♦ The A/C Compressor Control Module - J842- integrated in the
A/C compressor regulates the speed and thereby the A/C
compressor output ( Electrical A/C Compressor - V470- ) ac‐
cording to request received via the Data Bus using the Vehicle
♦ There is no A/C Compressor Regulator Valve - N280- installed
in the electrically-driven A/C compressor. The A/C compressor
output is regulated externally via the A/C compressor speed
sensor. Refer to ⇒ Wiring diagrams, Troubleshooting & Com‐
ponent locations and using the Vehicle Diagnostic Tester in
♦ The electrically powered A/C compressor functions according
to the principle of a spiral charger (similar to a G-charger).
♦ The A/C Compressor Control Module - J842- and the Electrical
A/C Compressor - V470- are components and are currently
not able to be separated.

ings .
Note

the bracket on vehicles with a 4-Cylinder engine without hav‐
ing to open the refrigerant lines.
sor.
♦ The high voltage system line remains connected to the A/C
compressor. Do not release the high voltage system connec‐
tor from the A/C compressor.
Removing
ings .


System Hybrid; Rep. Gr. 93 ; High Voltage System, De-En‐
ergizing .
DANGER!
Note

sequence:
♦ Body
Group 93)
– Remove the engine cover. Refer to ⇒ Rep. Gr. 10 ; Engine

Cover; Engine Cover, Removing and Installing .

– Loosen the clamps -arrows- and remove the air guide hose.
Note
Ignore -1-.
– Free up the high voltage system connector -3- on the engine.

– Disconnect the connector -2- (for low voltage on the A/C com‐
pressor).
Note
Ignore -1 and 4-.
– Remove the bolts -arrows- from the A/C compressor.

– Remove the A/C compressor -A- and move it as far as possible

away from the engine on the left side in such a way that the
cable for the high voltage system -C- or the coolant hose are
not kinked or bent.
Caution
There is a risk of damaging the cable or the connector for the

high voltage system
♦ Do not bend or twist the connector for the high voltage
system -B-.
♦ Do not twist, stretch, kink, or bend the cable for the high
voltage system -C-.
– Secure the A/C compressor to the vehicle (for example, with

a wire) without pulling or bending the high voltage system ca‐
ble or the coolant hoses.
Caution
There is a risk of damaging the high voltage system cable or

the refrigerant lines and hoses.
Note
If the A/C compressor cannot be swiveled away enough from the

engine, then the A/C compressor must be removed. Refer to
⇒ “3.5.2 A/C Compressor, Removing and Installing, Vehicles with
4-Cylinder Engine, Electrically-Driven A/C Compressor”,
page 328 .
Installing
♦ Check the bolting points of the A/C compressor and the brack‐
et prior to installation. The contact surfaces must be clean and
rust and grease-free. Otherwise, repair the contact surfaces
with the Contact Surface Cleaning Set - VAS6410- . Refer to
⇒ Electrical Equipment General Information; Rep. Gr. 97 ;
Contact Surfaces, Cleaning .

Note
♦ After installing the A/C compressor and the subsequent filling

of the refrigerant circuit, start up the removed electrically-driv‐
en A/C compressor for the first time via the “compressor cut-
in” function for the basic setting. If the refrigerant oil was
improperly stored before installation in the A/C compressor
compression chamber, the A/C compressor may become
damaged. Refer to
with 4-Cylinder Engine, Electrically-Driven A/C Compressor”,
♦ Only activate the electrically driven A/C compressor when the
refrigerant circuits are filled. The A/C compressor may be‐
come damaged if the A/C compressor is run while the refrig‐
erant circuit is empty using the Vehicle Diagnostic Tester in
Caution

tions.
log.
Nm +180°
Nm

– Connect the connector to the electric system.
Note


– Secure the electric high voltage system cable to the designa‐

ted engine points.
– Secure the clip -1- to the engine -2- and cable holder -3- on
the wiring harness -4- as illustrated.
– Install the air guide hoses with the screw-type clamps. Refer
to ⇒ Rep. Gr. 21 ; Charge Air System; Overview - Charge Air
System .
DANGER!
starts the vehicle.
Note

♦ Body

Finding" function.

3.4 Refrigerant Lines, Disconnecting and

Connecting at A/C Compressor
⇒ “3.4.1 Refrigerant Lines, Disconnecting and Connecting at A/C
Compressor, Vehicles with 4-Cylinder Engine”, page 312
Compressor, Vehicles with 6-Cylinder Engine”, page 317
Compressor, Vehicles with 8-Cylinder FSI Engine”, page 321

Connecting at A/C Compressor, Vehi‐
cles with 4-Cylinder Engine
Note

Refer to
♦ Close open lines and connections on A/C compressor using
suitable caps (to prevent possible penetration of dirt and mois‐
ture).
Removing

Note


General Warnings .
WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.

– Remove the bolts -1 and 4-.

– Remove the refrigerant pipes.
♦ Remove the A/C Compressor from the bracket (only if the re‐
frigerant lines cannot be removed when the A/C Compressors
connected). Refer to
page 298 .
Note
♦ On vehicles with a 4-Cylinder engine, it is not always neces‐

sary to remove the A/C compressor from the bracket in order
to remove the refrigerant lines. Depending on the style of the
power steering vane pump, the refrigerant lines can be re‐
moved form the A/C compressor also when the A/C compres‐
sor is removed from the bracket.
♦ The power steering pump is only installed on vehicles without
electromechanical power steering. Refer to ⇒ Suspension,
Overview - Power Steering Pump .
♦ In vehicles with 4-Cylinder engines where the bolts on the re‐
frigerant line connection at the A/C compressor are not ac‐
cessible, remove the A/C compressor from the bracket. Refer
to
page 298 .
♦ If the refrigerant line on the low pressure side is to be removed
(from the refrigerant line with the inner heat exchanger to the
A/C compressor), then the components, which must be re‐
moved, depending on the routing of the refrigerant line (routing
is dependent on the engine).

– Remove the refrigerant lines -B and C- .
All Vehicles
Caution

Note
Seal open pipes and connections on the A/C compressor with

caps (to prevent dirt and moisture from getting in).
Installing
Installation is the reverse of removal, noting the following:

– Replace the O-rings seals -D and E-. For the correct version.
– Check the guide ring -F- on the connections for both refrigerant
lines -B and C- for damage.
– Clean the refrigerant line and A/C compressor connections
and check for damage.
– Coat the O-ring seals with refrigerant oil prior to installation.
– Insert the respective O-ring (-D and E-) into the groove -G- on
the connections for both refrigerant lines -B and C-.
Note
♦ Do not use the O-rings from the sealing caps that are installed
on the connections in the replacement compressor when in‐
stalling the lines.
♦ Make sure the O-rings fit correctly inside the groove -I- on each
refrigerant line.
– Insert both refrigerant lines -B and C- into the respective con‐

nection on the A/C compressor.
– Tighten the bolts -A- to 9 Nm (bolts with a M6 thread) and to
25 Nm (bolts with a M8 thread).
Note
Following attachment of refrigerant pipes to A/C compressor (and

installation of the A/C compressor) check routing of pipes. They
must be inserted in holders provided and not make contact with
other components.

C Service Station .
fer to
Note


cles with 6-Cylinder Engine
Note

ture).
♦ The following procedure describes removing and connecting
of the refrigerant lines on a vehicle equipped with a 6 cylinder
TDI engine. Vehicles with a 6-Cylinder gas engine, may have
a few differences, but the refrigerant lines are removed and
installed in the same manner.
Removing
Note

Working with A/C Service Station; A/C System, Starting after Fill‐
ing .

– Remove the engine cover in direction of -arrows-.
– Remove the oil dipstick -1- (if equipped).

– Remove the air guide hose and the hose clamp -3- .
– Disconnect the connector -4-.
– Remove the bolts -2- and then the Throttle Valve Control Mod‐
ule - J338- .
– Disconnect the connector -1- for the A/C Compressor Regu‐

lator Valve - N280- .
Caution

– Remove the bolts -2 and 3- and remove the refrigerant lines

from the compressor.
Note

ture).
♦ On vehicles with a gasoline engine and dynamic steering, de‐
pending on the installed position of the suction hose on the
power steering pump and on the work procedure, use a com‐
mercially available long socket (if available, best with a ball
head to loosen and tighten the bolt -2- on the refrigerant line.
Move the suction hose carefully to the side while doing this or
loosen the A/C compressor from the bracket to remove the
refrigerant lines. Refer to ⇒ Suspension, Wheels, Steering;
Rep. Gr. 48 ; Power Steering Hydraulics; Overview - Hydraulic
Lines and Reservoir and
Installing

Note
stalling the lines.
– Lightly coat the O-ring seals with refrigerant oil prior to instal‐
– Insert the respective O-ring -D and E- into the groove -G- on

– Insert both refrigerant lines into the respective connection on

the A/C compressor.
– Tighten bolts -2 and 3-.
• Tightening specification: 9 Nm (bolts with an M6 thread) and
25 Nm (bolts with an M8 thread).
Note
Following attachment of the refrigerant lines to A/C compressor

(and installation of the A/C compressor), check the routing of the
lines. They must be inserted in holders provided and not make

Valve - N280- .
C Service Station .
fer to
Note


cles with 8-Cylinder FSI Engine
Note

ture).
Removing
Note
♦ Depending on the allocation of the service connection to the

refrigerant line and vehicle version, it may be necessary to re‐
move the left auxiliary reinforcement on the tower brace so
that the A/C service station service coupling can be connected
(for example, on the Audi Q5). Refer to ⇒ Suspension,
Wheels, Steering; Rep. Gr. 40 ; Suspension Strut, Upper
Control Arm; Overview - Suspension Strut, Upper Control Arm
and ⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ; Refrigerant
Circuit (Refrigerant R134a Servicing, Working with A/C Serv‐
ice Station) or ⇒ A/C Systems with Refrigerant R1234yf -
General Information; Rep. Gr. 87 ; Working with A/C Service
Station .
♦ On the Audi RS 4 and Audi RS 5, it is not necessary to loosen
the coolant expansion tank to remove the A/C compressor, but
rather the left air filter must be removed. This is different from
the other vehicles. Refer to ⇒ Rep. Gr. 24 ; Air Filter; Overview
- Air Filter Housing .

– Remove the coolant hose -3- from the coolant expansion tank.
Refer to ⇒ Rep. Gr. 19 ; Coolant System/Coolant; Connection
Diagram - Coolant Hoses (not the Audi RS 4 and Audi RS 5).
– Remove the bolts -arrows- and then move the coolant expan‐
sion tank to the side with the coolant hoses -1 and 2- still
connected. Refer to ⇒ Rep. Gr. 19 ; Coolant System/Coolant;
Connection Diagram - Coolant Hoses (not for Audi RS 4 and
Audi RS 5).
– Completely remove the left air filter. Refer to ⇒ Rep. Gr. 24 ;
Air Filter; Overview - Air Filter Housing (only for Audi RS 4 and
Audi RS 5).
– Remove the left front wheel housing liner. Refer to ⇒ Body
Exterior; Rep. Gr. 66 ; Wheel Housing Liner; Overview - Front
Wheel Housing Liner .
– Disconnect the vacuum hose -1- and lay the hydraulic oil hose
to the side -arrow- .
– Remove the nuts -2- and remove the vacuum reservoir.
Caution

– Remove the bolt -2- and remove the refrigerant line from the
A/C compressor.
– Remove the bolt -1- and remove the refrigerant line from the
A/C compressor.
Note
Close open lines and connections on A/C compressor using suit‐

able caps (to prevent possible penetration of dirt and moisture).

Installing
Note
stalling the lines.
– Lightly coat the O-ring seals with refrigerant oil prior to instal‐
– Insert the respective O-ring -D and E- into the groove -G- on

– Insert both refrigerant lines into the respective connection on

the A/C compressor.
– Tighten the bolts -1 and 2-.
• Tightening specification: 9 Nm (bolts with an M6 thread) and
25 Nm (bolts with an M8 thread).
Note
Following attachment of the refrigerant lines to A/C compressor

(and installation of the A/C compressor), check the routing of the
lines. They must be inserted in holders provided and not make
– Install the left front wheel housing liner. Refer to ⇒ Body Ex‐
terior; Rep. Gr. 66 ; Wheel Housing Liner; Overview - Front
Wheel Housing Liner .
C Service Station .
fer to
Note

3.5 A/C Compressor, Removing and Instal‐

ling
4-Cylinder Engine, Mechanically-Driven A/C Compressor”,
page 325
4-Cylinder Engine, Electrically-Driven A/C Compressor”,
page 328
6-Cylinder TDI Engine”, page 335
6-Cylinder Gasoline Engine”, page 343
8-Cylinder FSI Engine, Except RS Models”, page 349
8-Cylinder FSI Engine, RS Models”, page 362

ling, Vehicles with 4-Cylinder Engine,
Mechanically-Driven A/C Compressor
Note
♦ Depending on time period of production and on engine, the

compressor type may vary. Refer to
⇒ “2.1 Overview - Refrigerant Circuit”, page 150 and the Parts
Catalog.
♦ At start of production, vehicles without a high-voltage system
have A/C compressors manufactured by “Denso” (type “6 SEU
14” on vehicles with a 4-cylinder or 6-cylinder engine, and type
“7 SEU 17” on vehicles with an 8-cylinder engine). A/C com‐
pressors from different manufacturers may also be installed at
a later time. Refer to the Parts Catalog and ⇒ Refrigerant
R134a Servicing; Rep. Gr. 87 ; Refrigerant R134a Capacities;
Refrigerant Oil and Approved Refrigerant Oils or
nical Data .
(R134a or R1234yf). Refer to the Parts Catalog.
with different oil capacities, therefore note the oil quantity in
the A/C compressor. Refer to
Oil and Approved Refrigerant Oils or ⇒ A/C Systems with Re‐
nical Data and for the correct part number, refer to the Parts
Catalog.
♦ Depending on A/C compressor type, different refrigerant oil
capacities are designated for the refrigerant circuit. The rea‐
son for the different oil capacities in the A/C compressor for
an otherwise identical refrigerant circuit lies in the design of
the A/C compressor itself, note these oil capacities. Too much
oil in the circuit leads to higher pressures and reduces cooling
performance of the system. Too little oil may lead to lubrication
problems in the compressor.

♦ If a new mechanically-driven A/C compressor has been in‐

stalled or new refrigerant oil has been put into these A/C
compressors (for example, after flushing refrigerant circuit),
the A/C compressor must be turned by hand approximately 10
turns. This ensures that the A/C compressor is not damaged
when activated. Refer to ⇒ Refrigerant R134a Servicing; Rep.
Gr. 87 ; A/C System General Information or ⇒ A/C Systems
Removing
Information; Rep. Gr. 87 ; Refrigerant Circuit; Refrigerant Cir‐
cuit, Flushing .
Note


– Remove the refrigerant lines from A/C compressor. Refer to
⇒ “3.4 Refrigerant Lines, Disconnecting and Connecting at A/
C Compressor”, page 312 .
Note
♦ The sequence is different and depends on the engine and the

power steering vane pump. Depending on the version of the
power steering pump, the A/C compressor must first be re‐
moved from the bracket before the refrigerant lines can be
removed.
♦ The power steering pump is only installed on vehicles without
electromechanical power steering. Refer to ⇒ Suspension,
Overview - Power Steering Pump .
♦ Depending on the engine (gasoline or diesel), the A/C Com‐
pressor either needs to be removed from the top or the bottom.
If the A/C Compressor is removed towards the top, then it may
be necessary to remove the coolant expansion tank from the
vehicle and loosen the coolant line from the bracket (do not
open the coolant circuit) and turn it slightly to the side. Refer
to ⇒ Engine; Rep. Gr. 19 ; Coolant Pipe
– Remove the A/C compressor from the bracket. Refer to

page 298 .

Installing
Install in reverse order of removal. Note the following:
Note
There is an unspecified amount of refrigerant oil in the removed

A/C compressor. Therefore observe the information on replacing
the A/C compressor. Refer to ⇒ Refrigerant R134a Servicing;
Rep. Gr. 87 ; Refrigerant Circuit Components, Replacing or ⇒ A/
C Systems with Refrigerant R1234yf - General Information; Rep.
Read the information before installing the A/C compressor. Refer

- General Information; Rep. Gr. 87 ; Refrigerant Circuit; Overview
- Refrigerant Circuit Components .
– Turn the A/C compressor by hand 10 rotations before installing
the ribbed belt on the pulley (to prevent damage to the com‐
pressor when it is first switched on).
– Install the A/C compressor on the bracket. Refer to
page 298 .
– Attach the refrigerant lines to the A/C compressor. Refer to
⇒ “3.4 Refrigerant Lines, Disconnecting and Connecting at A/
C Compressor”, page 312 .
Note
♦ Rotating will prevent damage to the A/C compressor when
starting the engine for the first from refrigerant oil that may be
located in the compression chamber.

C Service Station .
fer to

Note

ling, Vehicles with 4-Cylinder Engine,
Electrically-Driven A/C Compressor
Note
♦ For this model line, only vehicles with a high-voltage system

were manufactured that had the refrigerant circuit charged
with refrigerant R134a.
Catalog.
♦ After installing a new electrically-driven A/C compressor
( Electrical A/C Compressor - V470- ) or filling with new refrig‐
erant oil. Operate this A/C compressor via the “compressor
cut-in” function using the Vehicle Diagnostic Tester in the

General Warnings .
WARNING

voltage system.

WARNING

connector.
DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.



ings .
ing .
DANGER!
Note

sequence:
♦ Body
Group 93)
Removing
tion).

Note

the left additional reinforcement on the tower brace so that the
service coupling of the A/C service station can be connected. Re‐
fer to ⇒ Suspension, Wheel, Steering; Rep. Gr. 40 ; Suspension
Strut and Upper Control Arm; Overview - Suspension Strut and
Upper Control Arm and ⇒ Refrigerant R134a, Servicing; Rep. Gr.
87 ; Refrigerant Circuit (Refrigerant R134a, Servicing; Refrigerant
Circuit, Using A/C Service Station).
– Remove the engine cover in direction of -arrows-. Refer to ⇒

Rep. Gr. 10 ; Engine Cover; Engine Cover, Removing and
Installing .
– Free up the attaching points -1 and 3- for the high voltage

system cable on the engine -2- and electric wiring harness
-4-.
Unlock and disconnect the high voltage system connector -3- on
the A/C compressor.
Caution
♦ Do not bend the high voltage cable.

♦ Only remove the connector horizontally from the connec‐
tion after releasing it. Never turn the connector.
– Pull the locking mechanism in the direction of the -arrow-.

– Remove the connector from the A/C compressor horizontally
and without turning.
– Cover the high voltage cable connector and socket on the A/
C compressor (for example with a clean plug from the -
VAS6122- ) to protect them from debris and damage.

– Disconnect the connector -2- (for low voltage on the A/C com‐
pressor).
Note
Ignore -1 and 4-.

A/C Compressor, Vehicles with 4-Cylinder Engine”,
page 312 .

– Remove the A/C compressor from the bracket. Refer to

Installing
Before installing the A/C compressor. Refer to ⇒ Refrigerant
R134a Servicing; Rep. Gr. 87 ; A/C System, General Information
(Refrigerant R134a, Servicing; A/C System, General Informa‐
tion).
Note
There is a quantity of refrigerant oil in the removed A/C compres‐

sor, therefore observe the notes for replacing the A/C compres‐
sor. Refer to ⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ;
Refrigerant Circuit Components, Replacing (Refrigerant R134a,
Servicing; Refrigerant Circuit Components, Replacing).
– Install the A/C compressor on the bracket. Refer to

page 312 .
Note
♦ After the installation of the electrically driven A/C compressor
and the subsequent filling of the refrigerant circuit, start up the
A/C compressor for the first time using the “compressor cut-
in” function for the basic setting. The A/C compressor may
otherwise become damaged if before installation, refrigerant
oil was improperly stored in the A/C compressor compression
chamber using the Vehicle Diagnostic Tester in the "Guided
♦ Only activate the electrically driven A/C compressor when the
refrigerant circuits is filled. Damage to the A/C compressor
may occur if the A/C compressor is running while the refriger‐
ant circuit is empty using the Vehicle Diagnostic Tester in the

Station).

– Insert and secure the connector for the high voltage system
on the A/C compressor.
Caution
♦ Do not bend the high voltage cable.

♦ Only insert the connector in the designated position (con‐
nector coding) on the A/C compressor. Never turn the
connector.
– Inspect the connector for debris and damage.

– Plug the connector into the A/C compressor.
• The marks -1 and 2- on the connector and A/C compressor
must line up with each other.
– Secure the locking mechanism in the direction of the -arrow-.
– Install the remaining removed parts in the opposite order.
DANGER!
starts the vehicle.

– Operate the Electrical A/C Compressor - V470- via the “com‐
pressor cut-in” function using the Vehicle Diagnostic Tester in
fer to

Note

filling. Refer to ⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ; A/

ling, Vehicles with 6-Cylinder TDI En‐
gine

Note

Catalog.
nical Data .
nical Data and for the correct part number. Refer to the Parts
Catalog.
Refrigerant Circuit; Overview - Refrigerant Circuit Compo‐
nents .
Removing

Note

– Remove the oil dipstick -1- (if equipped).

– Remove the air guide hose and the hose clamp -3- .
– Remove the bolts -2- and then the Throttle Valve Control Mod‐
ule - J338- .
– Loosen the coolant expansion tank and tip to the side. Refer
to ⇒ Engine Mechanical; Rep. Gr. 19 ; Cooling System/Cool‐
ant; Connection Diagram - Coolant Hoses .


lator Valve - N280- .
Caution

– Remove the bolts -2 and 3- and remove the refrigerant lines

from the A/C compressor. Refer to
page 317 (removing and installing the refrigerant lines to the
A/C compressor)
Note


Note

Caution
Danger of destroying by reversed direction with a ribbed belt

already running.
♦ Before removing the ribbed belt, mark the running direc‐
tion with chalk or a marker.
– To remove the ribbed belt, swivel the tensioner using Torx

Socket - T60 - T40087- in the direction of -arrow-.
– Remove the ribbed belt from the ribbed belt pulley on the com‐
pressor and release the tensioner.

– Remove the left bolt -1- and the nut -3- and remove the longi‐
tudinal brace -2- .
– If equipped, loosen the power steering pump from the bracket
(not always necessary on vehicles with a flexible pressure line
to the power steering pump), move it to the side and then tie
it to the engine with wire, for example. Refer to ⇒ Suspension,
Power Steering Pump, Removing and Installing .
Note
♦ The pressure line to the power steering pump -C- is secured

to the A/C compressor by the bracket with the mounting bolt.
When removing the A/C compressor, make sure not to bend
the pressure line to the power steering pump -C- than abso‐
lutely necessary (maximum 5 mm).
♦ If it becomes necessary to remove the A/C compressor, do not
bend the pressure line for the power steering pump
-C and A- more than 5 mm. Loosen the power steering pump
with the bracket from the engine and pull it toward the front.
Move it to the side and secure it on the engine using, for ex‐
ample, wire. When moving the power steering pump to the
side, be sure not to bend, twist or pull the lines to the power
steering pump. Refer to ⇒ Suspension, Wheels, Steering;
Rep. Gr. 48 ; Power Steering Hydraulics; Power Steering
Pump, Removing and Installing .
♦ There are different versions (stiff or flexible) of the power
steering pump pressure line.
– Remove the bolts -arrows- and remove the A/C compressor.

Installing
Note

– If required, remove the alignment sleeves -A- from the A/C

compressor.
– Thoroughly clean the surfaces on the compressor.
– Install the alignment sleeves -A- in the A/C compressor.
Note
♦ Make sure the alignment sleeves are seated correctly and the
contact surfaces are clean. Alignment sleeves that are instal‐
led incorrectly and dirty or damaged contact surfaces can lead
to alignment irregularities between the compressor and en‐
gine. Alignment irregularities over operating time lead to dam‐
age to the ribbed belt input shaft or to the A/C compressor.
Catalog.
Caution

tions.
log.
Nm +180°
Nm

– Tighten the bolts -arrows- .
– Connect the refrigerant lines to the A/C compressor. For the

tightening specification for the bolts -B-), O-ring seal meas‐
urements -C- and additional information. Refer to

– To install the ribbed belt, move the tensioner using the Torx
Socket - T60 - T40087- in direction of the -arrow-. Refer to ⇒
– Install the Throttle Valve Control Module - J338- . Refer to ⇒
6-Cylinder TDI Common Rail 3.0L 4V Engine (Generation II);
Rep. Gr. 23 ; Intake Manifold; Throttle Valve Control Module
- J338- , Removing and Installing .
– Install the longitudinal brace. Refer to ⇒ Body Exterior; Rep.
Gr. 50 ; Lock Carrier; Overview - Lock Carrier .
Note
♦ Secure all hose connections with hose clamps used in series

production. Refer to the Parts Catalog.
♦ In order to be able to secure the charge air hoses to their con‐
nections, the screw clamps already used must be sprayed with
a rust remover before being installed.
♦ After fastening the A/C compressor and installing the refriger‐
ant line, check installation position of refrigerant lines, lines
must be engaged in bracket (if installed, depending on en‐
gine).

C Service Station .
fer to
Note


ling, Vehicles with 6-Cylinder Gasoline
Engine
Note

Catalog.
♦ On vehicles with a 6-Cylinder gasoline engine or an 8-Cylinder
FSI engine, the A/C compressor can only be removed and in‐
stalled at the bracket when the refrigerant circuit is discharged.
Refer to
(A/C Compressor, Removing and Installing).
nical Data .
Oil and Approved Refrigerant Oils or ⇒ Refrigerant R134a
Servicing; Rep. Gr. 87 ; Refrigerant R134a Capacities, Re‐
frigerant Oil and Approved Refrigerant Oils and for the correct
part number. Refer to the Parts Catalog.
nents .
Removing


Note


– Remove the bolts -1- and nuts -3- and remove the left longi‐
tudinal brace -2-. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Lock
– Remove the left front wheel and left front wheel housing liner.
Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner;
Overview - Front Wheel Housing Liner .
– Mark the running direction of the ribbed belt -A-. Refer to ⇒

– Remove the ribbed belt -A-. Refer to ⇒ Rep. Gr. 13 ; Cylinder
– If equipped, clamp off the supply line (suction hose) to the
power steering pump -B- using the Hose Clamps up to 25 mm
Diameter - 3094- . Refer to ⇒ Suspension, Wheels, Steering;
Lines and Reservoir .
– If necessary, remove the pressure line -C- from the power
steering pump -B-. Refer to ⇒ Suspension, Wheels, Steering;
Lines and Reservoir .

Note
♦ When moving the pressure line to the side, be sure not to bend,
twist or pull the line to the power steering pump.
♦ The power steering pump -B- is not loosened from the bracket
when removing the A/C compressor.
♦ The pressure line to the vane pump -C- (see illustration above)
is secured to the A/C compressor by the bracket with the bolt
-C- (see illustration below) .

page 317 .
Note
♦ The refrigerant lines are removed from the top.

♦ On vehicles with a gasoline engine and dynamic steering (de‐
pending on where the intake hose is installed on the power
steering pump), first loosen the A/C compressor from the
bracket and then remove the refrigerant lines from the A/C
compressor. Refer to
page 317 .


– Remove bolt -B- (and bolt -C-).
Note
♦ The bolt -C- was already removed on vehicles with a power

steering pump when the pressure line to the power steering
pump was loosened.
♦ This illustration shows the A/C compressor in a vehicle equip‐
ped with an After-Run Coolant Pump - V51- (not installed on
all versions). Depending on the vehicle equipment level, it may
be necessary to drain the coolant and remove the After-Run
Coolant Pump - V51- so that the A/C compressor can be re‐
moved (for draining the coolant and removing the After-Run
Coolant Pump - V51- . Refer to ⇒ Rep. Gr. 19 ; Coolant Pump/
Thermostat ).
♦ Depending on the version of the A/C compressor and of the
vehicle (different coolant fans, radiator and hoses to the After-
Run Coolant Pump - V51- ), it may also be necessary to bring
the lock carrier into the service position (so that the A/C com‐
pressor can be pivoted out downward). Refer to ⇒ Body
Exterior; Rep. Gr. 50 ; Lock Carrier; Service Position, Per‐
forming and Resetting .
Information for the service position of the lock carrier:
♦ When the bolts -A- are first removed, and after bolts -A- are
removed, mark the position of the lock carrier -B-, for example
with a water resistant marker on the longitudinal member -C-
(through the left and right hole) so that it can be installed
exactly in the same position.
♦ When both bolts -D- are removed and then longer bolts -E- (for
example bolts M10 x 100) are installed, the lock carried can
be moved approximately 60 mm forward after the bolts -F- are
removed.
♦ Using the sleeves -G- (or a suitable pad approximately 60 mm
long), secure the lock carrier -C- from sliding back.

– Remove the bracket -D- .

– Remove the bolt -E-.
– Remove the A/C compressor -F- from the bracket, pull it for‐
ward and remove it downward.
Installing
Note

Read the information before installing the A/C compressor. Refer

to ⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ; Refrigerant Cir‐
cuit Components, Replacing or ⇒ A/C Systems with Refrigerant
R1234yf - General Information; Rep. Gr. 87 ; Refrigerant Circuit;
Components, Replacing .

Note

Catalog.
Caution

tions.
log.
Nm +180°
Nm

– Tighten bolt -B-, -C- (and bolt -E-).

– Install the pressure line to the power steering pump. Refer to
⇒ Suspension, Wheels, Steering; Rep. Gr. 48 ; Power Steer‐
ing Hydraulics; Overview - Hydraulic Lines and Reservoir .

– Install the ribbed belt -A-. Refer to ⇒ Rep. Gr. 13 ; Cylinder

page 317 .
Note
♦ Rotating will prevent damage to the A/C compressor when
starting the engine for the first from refrigerant oil that may be
located in the compression chamber.
♦ After fastening the A/C compressor and installing the refriger‐
ant line, check installation position of refrigerant lines, lines
must be engaged in bracket (if installed, depending on en‐
gine).

C Service Station .
fer to
Note

ling, Vehicles with 8-Cylinder FSI En‐
gine, Except RS Models
S5 and S5 Cabriolet Only
♦ Engine Support Bridge - 10-222A-
♦ Engine Support - Supplement Kit - T40093A-
♦ Engine and Gearbox Jack - VAS6931-

Note

Catalog.
Refer to
nical Data .
Catalog.
Removing
– Turn the front wheels so that they are straight.

Caution
Danger of destroying electrical components.

♦ Observe the steps when disconnect the battery.
– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.

Gr. 27 ; Battery; Battery, Disconnecting and Connecting .
Note

– Remove the coolant hose -3- from the coolant expansion tank.
Diagram - Coolant Hoses .
– Remove the bolts -arrows- and move the coolant expansion
tank with the attached coolant hoses -1 and 2- to the side.
Diagram - Coolant Hoses .
– Drain the coolant. Refer to ⇒ Rep. Gr. 19 ; Coolant System/
Coolant; Coolant, Draining and Filling .
– Remove the plenum chamber front wall -A-. Refer to ⇒ Body

Exterior; Rep. Gr. 50 ; Bulkhead; Overview - Bulkhead .

– Disconnect the upper coolant hose -right arrow- from the en‐
gine.
Note
This coolant hose is removed with the coolant pipe.
– Remove the screw -2-.
– Remove the bolt -arrows-.

– Remove the guide tube -1- for the oil dipstick from the upper
part of the oil pan.
– Position the Engine Support Bridge - 10-222A- with the Engine

Support Brackets - T40093/6- on the left and right suspension
strut domed as shown.
– Engage the Engine Support Bridge - Spindles - 10-222A/11-
at the engine lifting eyes.
– Pretension the engine with the spindles slightly.
– Remove the left and right front wheels (to remove. Refer to ⇒
Suspension, Wheels, Steering; Rep. Gr. 44 ; Vehicle Align‐
ment ).
– Remove the left and right wheel housing liners. Refer to ⇒
Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner; Overview
- Front Wheel Housing Liner .
– Remove the left and right drive axles from the transmission
flange shafts. Refer to ⇒ Suspension, Wheel, Steering; Rep.
Gr. 40 ; Drive Axle; Drive Axle, Removing and Installing .

– Remove the bolt -arrow- for the power steering hydraulic line.
Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 48 ; Pow‐
er Steering Hydraulics; Overview - Hydraulic Lines and Res‐
ervoir .
Caution
Danger of damaging the airbag spring.

♦ Separate the universal joint from the steering gear only
with the front wheels in the straight position.
♦ Do not change the position of the steering and the steering
gear; secure the steering wheel with tape if necessary.
– Remove the bolt -arrow- for the universal joint. Refer to ⇒

Suspension, Wheel, Steering; Rep. Gr. 48 ; Steering Column;
Steering Intermediate Shaft, Removing and Installing .
– Remove the universal joint from the steering gear and push it
all the way up.
– Disconnect the vacuum hose -1- and free up the power steer‐
ing hydraulic fluid hose -arrow- at the bracket. Refer to ⇒
Suspension, Wheels, Steering; Rep. Gr. 48 ; Power Steering
Hydraulics; Overview - Hydraulic Lines and Reservoir .
– Remove the nuts -2- and remove the vacuum reservoir.
– Disconnect the connector -1- on the steering gear and free it

up.
Note
Ignore item -2-.
– Free up the left power steering hydraulic oil hose on the sub‐
frame.
– Free up the wires on the right side of the subframe.

– Disconnect the ground wires -arrow- from the right longitudinal

member.
– Remove the left and right bolts -1- and nuts -3- and remove
the longitudinal braces -2-. Refer to ⇒ Body Exterior; Rep. Gr.
50 ; Lock Carrier; Overview - Lock Carrier .
– Disconnect the connector on the Left Front Level Control Sys‐

tem Sensor - G78- and free up the wire -arrow-.
– Disconnect the connector -3- for the Left Electrohydraulic En‐

gine Mount Solenoid Valve - N144- .
– Remove the bolt -4- for the left engine mount.
Note
Ignore items -1 and 2- and -arrows-.

– Disconnect the connector -2- for the Right Electrohydraulic

Engine Mount Solenoid Valve - N145- .
– Remove the bolt -1- for the right engine mount. Refer to ⇒
Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 10 ;
Subframe Mount; Overview - Subframe Mount .
Note
Caution
Danger of accident if the subframe is not secured.

♦ Remove the subframe bolts only when the subframe is
supported.
– Support the subframe with the Engine and Gearbox Jack -

VAS6931- as shown. Refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 40 ; Subframe; Subframe, Removing and
Installing .
– Remove the left and right bolts -3- for the stabilizer bar. Refer
to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe;
Overview - Subframe .
– Remove the left and right nuts -1- and remove the bolts -2- for
the suspension strut. Refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 40 ; Subframe; Overview - Subframe .

– Remove the left and right bolts -1 through 3- in stages.
Caution
Danger of damaging chassis components.

♦ If the vehicle must be placed on its wheel, then the com‐
plete subframe, steering gear and the subframe support
must be correctly installed.
♦ Do not support the vehicle on the subframe or on the sub‐
frame support (for example, using a vehicle jack or some‐
thing similar).
– Carefully lower the subframe using the Engine and Gearbox

Jack - VAS6931- . While doing so, make sure there is enough
clearance for the left hydraulic hoses and the right wires. Refer
to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe;
Subframe, Removing and Installing .
– Let the subframe hang on the lower transverse link.
– Free up the wire on the lower left coolant pipe.

– Remove the bolt -1- (and if still not done, the bolt -2-) and re‐
move the left lower coolant pipe from the coolant hose
-left arrow- .
Note
Depending on the version of the left flange shaft bracket, it may

be necessary to loosen the bracket from the transmission and
then turn it (do not remove bracket) in order to remove the coolant
pipe. Refer to ⇒ Rep. Gr. 39 ; Seals .
– Remove the coolant pipe. Refer to ⇒ Rep. Gr. 19 ; Coolant

Pipes; Overview - Coolant Pipes .
– Remove the bolts -arrows- and remove the left engine support.
Note
Depending on the engine version, it may be necessary to use a

M12 socket (multi-point socket) with a ball head to remove the top
bolts on the engine support.
– Remove the left engine mount. Refer to ⇒ Engine Mechanical,

Fuel Injection and Ignition; Rep. Gr. 10 ; Subframe Mount;
Overview - Subframe Mount .

– Remove the coolant hose by loosening the spring clamp -3-

and pulling out the clip -2- slightly. Refer to ⇒ Rep. Gr. 19 ;
Coolant System/Coolant .
Note
Ignore items -1 and 4-.
Caution

– Remove the housing for the coolant pump. Refer to ⇒ Rep.

Gr. 19 ; Coolant Pump/Thermostat .
– Remove the bolts -1- and -2-. Refer to

A/C Compressor, Vehicles with 8-Cylinder FSI Engine”, page
321 (Refrigerant lines, removing and installing at A/C com‐
pressor).
– Remove refrigerant lines from A/C compressor.
Note

– Hold the A/C compressor input shaft -A- with a wrench and
turn the A/C compressor drive unit -B- in the direction of
-arrow C-.
Note
♦ Do not turn the A/C compressor input shaft -A-.

♦ The A/C compressor input shaft -A- can be slid into drive wheel
through boot -E- after loosening threaded connection.

– Mark the connector -1- for the A/C Compressor Regulator

Valve - N280- (to prevent confusing it with other connectors
which look identical).
Note
The connector to A/C Compressor Regulator Valve - N280- and

the connector to the electric engine mounts are identical in con‐
struction. If these connectors are interchanged, no entry appears
in the event memory. However, since the A/C compressor is con‐
tinuously activated, the evaporator may ice up.

lator Valve - N280- from the bracket.
– Carefully push the subframe downward and them remove the
A/C compressor to the rear (between the longitudinal member
and the subframe).
Installing
Note

– If necessary, install the A/C compressor input shaft -A- (in the
engine drive wheel) and check the grommet -E- seating.
Note
♦ A clamp on the power take-off flange keeps the grommet -E-

from sliding off. Refer to ⇒ Rep. Gr. 13 and to the Parts
Catalog.
♦ The illustration shows the location of the components on a ve‐
hicle with a power steering pump. The power steering pump
is only installed on vehicles without electromechanical power
steering. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr.
48 ; Power Steering Hydraulics; Overview - Power Steering
Pump .
– If necessary, remove the alignment sleeves -F- from the com‐

pressor.
– Thoroughly clean the A/C compressor and bracket surfaces.
– Install the alignment sleeves -F- in the bracket or in the A/C
compressor.


Note

Catalog.
are clean. Incorrectly installed bushings and dirty or damaged
and engine. Alignment irregularities over operating time can
lead to damage to the drive unit or the A/C compressor.
Caution

tions.
log.
Nm +180°
Nm

Valve - N280- .
– Check the A/C compressor connections and the refrigerant
lines for damage or dirt. Refer to
321 .


tightening specifications for the bolts -A-, measurements for
the O-rings -B- and -C- as well as additional information. Refer
to
321 and the Parts Catalog.
Note
Check refrigerant lines and their bracket for sufficient distances

to other components. Coat the O-ring seals lightly with refrigerant
oil prior to installation. Refer to

– To prevent damaging the compressor the first time is it switch‐

ed on, turn the A/C compressor drive unit -B- on the A/C
compressor by hand 10 rotations in the direction of the
-arrow C- before turning the A/C compressor input shaft -A- .
Note
By rotating, refrigerant oil which has accumulated in the com‐

pressor compression chamber in the removed A/C compressor
or after adding fresh refrigerant oil (for example, after blowing
through the refrigerant circuit) is forced out of the compression
chamber.
turn the compressor drive unit -B- in the direction of
-arrow D- .
Note
♦ Do not turn the A/C compressor input shaft -A- when tighten‐
ing.
♦ After installing, check installation position of grommet -E- on
drive wheel.
♦ After installing the input shaft -A-, check the boot -E- installa‐
tion position.
– Install the engine support with left engine mount. Refer to ⇒

– Install the lower left coolant pipe. Refer to ⇒ Rep. Gr. 19 ;
Coolant Pipes; Overview - Coolant Pipes .
– Install the subframe. Refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 40 ; Subframe; Subframe, Removing and In‐
stalling .
– Fasten the suspension strut onto the control arm. Refer to ⇒
Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe; Over‐
view - Subframe .
– Install the stabilizer bar. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 40 ; Subframe; Stabilizer Bar, Removing
and Installing .
– Attach the universal joint to the steering gear. Refer to ⇒ Sus‐
pension, Wheels, Steering; Rep. Gr. 48 ; Steering Column;
– Install the power steering hydraulic line. Refer to ⇒ Suspen‐
sion, Wheels, Steering; Rep. Gr. 48 ; Power Steering Hy‐
draulics; Overview - Hydraulic Lines and Reservoir .
– Install the longitudinal braces. Refer to ⇒ Body Exterior; Rep.
Note
Replace the seal; the self-locking nuts and the O-ring for the oil
dipstick guide tube.
– Install the oil dipstick tube. Refer to ⇒ Rep. Gr. 13 ; Crank‐

shaft; Overview - Crankshaft .

– Fill with coolant and bleed the coolant circuit. Refer to ⇒ Rep.
Gr. 19 ; Coolant System/Coolant; Coolant, Draining and Fill‐
ing .
C Service Station .
fer to
Note

ling, Vehicles with 8-Cylinder FSI En‐
gine, RS Models
RS 5 Only

Note

Catalog.
Refer to
nical Data .
Catalog.
nents .
Removing
– Turn the front wheels so that they are straight.

Caution
Danger of destroying electrical components.

♦ Observe the steps when disconnect the battery.
– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.

Gr. 27 ; Battery; Battery, Disconnecting and Connecting .
– Remove the left air filter housing. Refer to ⇒ Rep. Gr. 24 ; Air
Filter; Overview - Air Filter Housing .
– Remove the bolt -arrows-.

– Remove the oil dipstick tube -1-.
– Position the Engine Support Bridge - 10-222A- with the Engine

Support Brackets - T40093/6- on the left and right suspension
strut domed as shown.
– Engage the Engine Support Bridge - Spindles - 10-222A/11-
at the engine lifting eyes.
– Pretension the engine with the spindles slightly.

– Remove the noise insulation -1 and 2-. Refer to ⇒ Body Ex‐

terior; Rep. Gr. 66 ; Noise Insulation; Overview - Noise Insu‐
lation .
– Remove the left and right front wheels (to remove. Refer to ⇒
Suspension, Wheels, Steering; Rep. Gr. 44 ; Vehicle Align‐
ment ).
– Remove the left and right front wheel housing liners. Refer to
⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner; Overview
- Front Wheel Housing Liner .
– Remove the left and right drive axles from the transmission
flange shaft. Refer to ⇒ Suspension, Wheel, Steering; Rep.
Gr. 40 ; Drive Axle; Drive Axle, Removing and Installing .
– Drain the coolant. Refer to ⇒ Rep. Gr. 19 ; Coolant System/
Coolant; Coolant, Draining and Filling .
– Remove the left and right bolt -1- and nut -3- and then remove
the brace -2-.
– Remove the nut -arrow- from the right longitudinal member

and free up the ground cables.
– Disconnect the connector -1- from the Headlamp Range Con‐

trol Sensor 1 - G233- and free up the wire -arrow-.

– Remove the left and right bolt -1- from the stabilizer bar.
Note
Ignore -2 and 3-.
– Loosen the safety catch in direction of -arrow-, push the re‐

lease down and disconnect the connector -2- from the steering
gear.
– Free up the wiring harness.
– Remove the steering intermediate shaft from the steering gear

and push them upward. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 48 ; Steering Column; Steering Intermedi‐
ate Shaft, Removing and Installing .
– Remove the bolt -arrow- from the ATF pipes.

– Remove the left and right bolts -arrows- and leave the heat
shield -1- in its installed position.
– Disconnect the connector -3- for the Left Electrohydraulic En‐

gine Mount Solenoid Valve - N144- .
Note

– Remove the bolt -4- for the left engine mount.
Note
– Disconnect the connector -2- for the Right Electrohydraulic

Engine Mount Solenoid Valve - N145- .
– Remove the bolt -1- from the right engine mount.
Note
Caution
Danger of accident if the subframe is not secured.

♦ Remove the subframe bolts only when the subframe is
supported.

– Support the subframe with the Engine and Gearbox Jack -

VAS6931- as shown. Refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 40 ; Subframe; Subframe, Removing and
Installing .
– Remove the left and right bolts -1 through 3- in stages.
Caution
Danger of damaging chassis components.

♦ If the vehicle must be placed on its wheel, then the com‐
plete subframe, steering gear and the subframe support
must be correctly installed.
♦ Do not support the vehicle on the subframe or on the sub‐
frame support (for example, using a vehicle jack or some‐
thing similar).
– Carefully lower the subframe using the Engine and Gearbox

Jack - VAS6931- . While doing so, make sure there is enough
clearance for the left ATF lines and the right wires. Refer to ⇒
Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe; Sub‐
frame, Removing and Installing .
– Let the subframe hang on the lower transverse link.
– Remove the bolts -arrows- and remove the left engine support.
– Lift the clip -1- and loosen the clamp -2- to remove the coolant
hose.
– Move the coolant hose to the side.

– Loosen the clamps -1 and 2- to remove the coolant hoses.

– Move the coolant hoses to the side.
– Remove the housing for the coolant pump. Refer to ⇒ Rep.

Gr. 19 ; Coolant Pump/Thermostat
Caution

– Remove the bolts -1 and 2-. Refer to

321 (Refrigerant lines, removing and installing at A/C com‐
pressor).
– Remove refrigerant lines from A/C compressor.
Note

turn the A/C compressor drive unit -B- in the direction of
-arrow C-.
Note
♦ Do not turn the A/C compressor input shaft -A-.

♦ The A/C compressor input shaft -A- can be slid into drive wheel
through boot -E- after loosening threaded connection.

– Mark the connector -1- for the A/C Compressor Regulator

Valve - N280- (to prevent confusing it with other connectors
which look identical).
Note


lator Valve - N280- from the bracket.
– Carefully push the subframe downward and them remove the
A/C compressor to the rear (between the longitudinal member
and the subframe).
Installing
Note

– If necessary, install the A/C compressor input shaft -A- (in the
engine drive wheel) and check the grommet -E- seating.
Note
♦ A clamp on the power take-off flange keeps the grommet -E-

from sliding off. Refer to ⇒ Rep. Gr. 13 and to the Parts
Catalog.
♦ The illustration shows the location of the components on a ve‐
hicle with a power steering pump. The power steering pump
is only installed on vehicles without electromechanical power
steering. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr.
48 ; Power Steering Hydraulics; Overview - Power Steering
Pump .
– If necessary, remove the alignment sleeves -F- from the com‐

pressor.
– Thoroughly clean the A/C compressor and bracket surfaces.
– Install the alignment sleeves -F- in the bracket or in the A/C
compressor.


Note

Catalog.
are clean. Incorrectly installed bushings and dirty or damaged
and engine. Alignment irregularities over operating time can
lead to damage to the drive unit or the A/C compressor.
Caution

tions.
log.
Nm +180°
Nm

Valve - N280- .
– Check the A/C compressor connections and the refrigerant
lines for damage or dirt. Refer to
321 .


tightening specifications for the bolts -A-, measurements for
the O-rings -B- and -C- as well as additional information. Refer
to
321 and the Parts Catalog.
Note
Check refrigerant lines and their bracket for sufficient distances

to other components. Coat the O-ring seals lightly with refrigerant
oil prior to installation. Refer to

– To prevent damaging the compressor the first time is it switch‐

ed on, turn the A/C compressor drive unit -B- on the A/C
compressor by hand 10 rotations in the direction of the
-arrow C- before turning the A/C compressor input shaft -A- .
Note
By rotating, refrigerant oil which has accumulated in the com‐

pressor compression chamber in the removed A/C compressor
or after adding fresh refrigerant oil (for example, after blowing
through the refrigerant circuit) is forced out of the compression
chamber.
turn the compressor drive unit -B- in the direction of
-arrow D- .
Note
♦ Do not turn the A/C compressor input shaft -A- when tighten‐
ing.
♦ After installing, check installation position of grommet -E- on
drive wheel.
tion position.
– Install the engine support with left engine mount. Refer to ⇒

– Install the subframe. Refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 40 ; Subframe; Subframe, Removing and In‐
stalling .
– Install the stabilizer bar. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 40 ; Subframe; Stabilizer Bar, Removing
and Installing .
– Attach the universal joint to the steering gear. Refer to ⇒ Sus‐
pension, Wheels, Steering; Rep. Gr. 48 ; Steering Column;
– Install the ATF lines. Refer to ⇒ Automatic Transmission; Rep.
Gr. 37 ; ATF Circuit .
– Install the longitudinal braces. Refer to ⇒ Body Exterior; Rep.
Note
Replace the seal; the self-locking nuts and the O-ring for the oil
dipstick guide tube.
– Install the oil dipstick tube. Refer to ⇒ Rep. Gr. 13 ; Crank‐

shaft; Overview - Crankshaft .
– Fill with coolant and bleed the coolant circuit. Refer to ⇒ Rep.
ing .


C Service Station .
fer to
function.
3.6 Preliminary Work for Replacing Belt Pul‐

ley
– Mark the running direction of the ribbed belt (always refer to
the repair manual for the routing of the ribbed belt for each
engine). Refer to ⇒ Rep. Gr. 13 ; Cylinder Block, Belt Pulley
Side; Ribbed Belt, Removing and Installing .
– Release the tension on the ribbed belt and then remove it.
Refer to ⇒ Rep. Gr. 13 ; Cylinder Block, Belt Pulley Side;
Ribbed Belt, Removing and Installing .
Note
Mark direction of rotation of ribbed belt using chalk or felt-tip

marker before removing. Running a used belt in the opposite di‐
rection could destroy it.
3.7 Belt Pulley, Removing and Installing

⇒ “3.7.1 Belt Pulley, Removing and Installing, Denso A/C Com‐
pressor, Version 1 ”, page 374
⇒ “3.7.2 Belt Pulley, Removing and Installing, Denso A/C Com‐
pressor, Version 2 ”, page 376
with A/C Clutch N25 ”, page 379
3.7.1 Belt Pulley, Removing and Installing,

“Denso” A/C Compressor, Version “1”

Note
♦ Observe notes on replacing belt pulley -E-. Refer to

⇒ “3.2.1 Overview - Belt Pulley, Denso A/C Compressor, Ver‐
sion 1 ”, page 291 .
♦ Perform preparatory work as for removing belt pulley. Refer to
⇒ “3.6 Preliminary Work for Replacing Belt Pulley”,
page 374 .
♦ The belt pulley is made of plastic and is sensitive to impact,
therefore take special care when handling it.
♦ If the drive plate -C- overload protection activates, rotate the
pulley -E- using the outer part of the drive plate -C- so that the
compressor shaft -B- and the hexagon head on the drive plate
-D- (inner part of the drive plate -C-) do not rotate.
Removing
– Remove the cap -A-.

– Hold the A/C compressor input shaft -B- with a 7 mm wrench
and turn the drive plate -C- together with the pulley -E- in the
direction of the -arrow-.
Note
The torque to drive the A/C compressor is transferred to the drive

plate -C- via the threaded connection. If, while the A/C compres‐
sor is working, the drive plate -C- was attached to the A/C com‐
pressor shaft so tight, that it cannot be loosened (the 7 mm Allen
wrench -B- cannot transmit the necessary torque) then the A/C
– Remove the drive plate -C- .

– Remove the circlip -A-.

– Remove the pulley -B- .
Installing
Note
Replace circlip -A-.
Clean A/C compressor flange before installing pulley -B-.

When installing circlip -A-, note that it cannot be bent open more
than is necessary for installation.
– Install the pulley -B- .
– Insert circlip -A- on correct side, the side with beveled insertion
edge -C- faces away from A/C compressor (install flat side
facing A/C compressor).
– Clean the compressor shaft thread.
Note
The thread of the new drive plate has already been greased with
a specific amount of a grease by the manufacturer.
– When installing drive plate, coat the rubber element -D- lightly
e.g. with tire mounting paste or soap solution (as sliding com‐
pound).
– Insert rubber element -D- in belt pulley -B- according to illus‐
tration.
– Press the drive plate rubber element -C- far enough into the
pulley -E- until the drive plate -C- until it contacts A/C com‐
pressor shaft -B- .
– Attach the drive plate -C- to the compressor shaft -B- by turn‐
ing it contrary to the direction of the -arrow- .
– Hold the A/C compressor input shaft -B- for example, with a
standard 7 mm Allen wrench and turn the drive plate -C- to‐
gether with the belt pulley -E- opposite the direction of the
-arrow- (tightening specification 30 Nm).
3.7.2 Belt Pulley, Removing and Installing,

“Denso” A/C Compressor, Version “2”

Note
♦ Observe notes on replacing belt pulley. Refer to

sion 2 ”, page 293 .
♦ Perform preparatory work as for removing belt pulley. Refer to
page 374 .
♦ The belt pulley is made of plastic and is sensitive to impact,
therefore take special care when handling it.
♦ If overload safeguard of drive plate -C- has triggered, drive
plate can be pried off from belt pulley -D- after removing circlip
-A-
♦ To optimize noise reduction, a circlip -A- with a rubber disc
vulcanized on it is installed. Refer to
sion 2 ”, page 293 and the Parts Catalog.
Removing
– Using, for example, a small screwdriver or needle-nose pliers,

carefully remove the circlip -A- (with rubber disc vulcanized
onto it; refer to
sion 2 ”, page 293 ). Take extreme care not to damage belt
pulley when doing this.
– Hold the A/C compressor input shaft -B- securely with a stand‐
ard socket wrench and turn drive plate -C- with pulley -D- in
direction of -arrow E- (tightening torque 35 Nm).
– Remove drive plate -C-.
– Remove circlip -A-.

– Remove the belt pulley -B-.
Installing

Note
Replace circlip -A-.
Clean the A/C compressor flange before sliding on the belt pulley.
When installing the circlip -A-, note that it cannot be bent open
more than is necessary for installation.
– Install the belt pulley -B-.
– Insert circlip -A- on correct side, the side with beveled insertion
facing compressor).
– Insert rubber element -D- in belt pulley -B- according to illus‐
tration.
– When installing drive plate, coat rubber element -D- lightly for
example with tire mounting paste or soap solution (as sliding
compound).
– Insert the drive plate -C- far enough into rubber elements -D-
(see upper illustration) until it contacts A/C compressor shaft
-B-.
– Install the drive plate -C- on the compressor shaft -B- by ro‐
tating it in the direction of the -arrow F-.
– Tighten drive plate -C- (above pulley -D-) to 35 Nm by turning
with a standard band wrench (with webbing) in direction of
-arrow F-, hold compressor shaft -B- with a standard socket
wrench.
– Install circlip -A- (with rubber disc vulcanized on).

3.7.3 Belt Pulley, Removing and Installing, A/

C Compressor with A/C Clutch - N25-
Note
♦ To remove the belt pulley, it is not always necessary to loosen

the A/C compressor from the engine. Refer to
page 298 . However there may be not enough space to remove
the belt pulley depending on the engine version. If so, loosen
or remove the A/C compressor from the engine or loosen the
lock carrier from the vehicle and pull it slightly forward to create
enough space (easier to perform depending on the vehicle
version). Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Lock Carrier;
Service Position, Performing and Resetting .
♦ On vehicles with a 2.0L 4-cylinder TDI engine and a cross‐
member for the torque support, it is sensible to remove the A/
C compressor in order to remove the belt pulley, for example.
Refer to ⇒ 4-Cylinder TDI Common Rail 2.0L 4V Engine
(Generation II); Rep. Gr. 10 ; Subframe .
Clutch Plate, Removing and Installing. Refer to ⇒ , page 379 .

Belt Pulley, Removing. Refer to ⇒ , page 380 .
Gap Dimension between Belt and Clutch Plate, Checking. Refer
to ⇒ , page 381 .
Clutch Plate, Removing and Installing
Vehicles without a crossmember for the torque support
– Perform the preliminary work as for replacing the belt pulley.
Refer to
page 374 .
Vehicles with crossmember for the torque support (for example
on a 2.0L 4-cylinder TDI engine with a crossmember for the torque
support)
– Remove the A/C compressor. Refer to
page 325 .

All Vehicles
– Remove the closure cap -A-.
– Hold the A/C compressor input shaft -B- secure with a com‐
mercially available socket (7 mm) and turn the clutch plate
-C- in direction of -arrow-.
Note
The torque to drive the A/C compressor is transferred to the clutch

plate -C- via the threaded connection. If, while the A/C compres‐
sor is working, the clutch plate -C- was attached to the A/C
compressor shaft so tight, that it cannot be loosened (the 7 mm
Allen wrench -B- cannot transmit the necessary torque) then the
A/C compressor must be replaced.
Belt Pulley, Removing

Note
♦ Remove the belt pulley -A- as described below if it (after re‐

moving the locking ring) will not come off the A/C compressor
flange by hand (for example, due to dirt build-up).
♦ Mount the arms on the puller so that the outside of the belt
pulley does not get bent if the belt pulley -A- is going to be used
again.
– Remove the belt pulley -A- with a 3-arm puller -B-.
Note
♦ Do not support the puller spindle -B- on the A/C compressor

shaft when removing the belt pulley -A-.
♦ Use a sleeve -C- (for example, Sleeve VAG 1719/1 taken from
A/C Clutch Set - VAG1719- ) to support the spindle on the arm
puller -B- on the A/C compressor flange.
♦ Clean the flange on the A/C compressor thoroughly after re‐
moving the belt pulley -A-. It must possible to install the belt
pulley -A- by hand.
Gap Dimension Between Belt and Clutch Plate, Checking
Note
♦ The gap dimension must be within the permissible range over

the entire circumference.
♦ Gap dimension may also be measured with A/C compressor
installed.
♦ If the gap dimension is outside of the permissible range, first
remove the clutch plate and then remove or insert spacers to
get to attain the correct dimension.

– Perform the preliminary work as for replacing the belt pulley.
Refer to
page 374 .

• Tighten the clutch plate -C- on the A/C compressor shaft -E-
to 30 Nm.
– Measure the dimension “1” between the belt pulley -B- and the
clutch plate -C- with a depth gauge -F- at three places on the
clutch plate -C- circumference and then write down the meas‐
ured values.
– Apply 12 volts to the 1-pin connector -A-.
– Connect the ground to the compressor housing -D-.
– Measure the dimension “2” between the belt pulley -B- and the
clutch plate -C- with a depth gauge -F- at three places on the
clutch plate -C- circumference and then write down the meas‐
ured values.
– Calculate the gap dimension using dimensions “1” and “2”.
Gap dimension specified value: 0.4 to 0.6 mm (up to 0.8 mm on
an A/C clutch already used).
3.8 A/C Compressor Input Shaft, Loosening

and Tightening
Note
♦ Extensive preparatory work must be performed to be able to

loosen the A/C compressor input shaft. Refer to
(A/C Compressor, Removing and Installing, Vehicles with 8-
Cylinder FSI Engine).
♦ The input shaft can also be checked and tightened without
opening the refrigerant circuit. Refer to
Cylinder FSI engine).
Input Shaft, Loosening

– Remove any components that prevent access to the input
shaft. Refer to

– Hold the A/C compressor input shaft -A- in place using a

wrench and turn the drive unit -B- in direction of -arrow C-.
Note
♦ Do not turn the input shaft -A- .

♦ Input shaft -A- can be slid into drive wheel through the boot
-E- after loosening threaded connection.
tion position.
Input Shaft, Tightening

– Hold the A/C compressor input shaft -A- in place using a
wrench and turn the drive unit -B- in direction of -arrow D-
(tightening specification: 60 Nm).
– After tightening the A/C compressor input shaft, check the po‐
sition of the grommet -E-
3.9 A/C Compressor Input Shaft, Removing

and Installing
Removing the Input Shaft
page 325 .
– Remove the grommet -A-.
– Remove the input shaft -B- from splines of drive pinion -C-
Note
A clamp on the engine toothed drive gear flange -C- prevents the
boot -A- from slipping.
Installing the Input Shaft

– Check the input shaft -B-, splines must show no traces of wear
and must be seated free of play in splines of drive wheel -C-.
– Prior to installation, coat the input shaft splines -B-, for exam‐
ple, with Lubricating Grease - G 000 100- . Refer to the Parts
Catalog.
– Insert the input shaft -B- before installing A/C compressor and
slide it into drive wheel -C- up to stop.
– After installing A/C compressor, check the position of the
grommet -A-.
Note
A clamp on the power take-off flange keeps the grommet -A- from
sliding off. Refer to ⇒ Rep. Gr. 13 and to the Parts Catalog.

3.10 Drive Plate with Overload Protection,

Remove the Drive Plate
– Remove bolts -A-.
Note
Use a commercially available band wrench (with webbed band)

to counterhold at drive plate -C-.
Installing Drive Plate

– Position drive plate with overload protection -B- onto drive
plate -C-.
– Install the bolts -A- and tighten by hand.
– Check the drive plate run-out -B-. Refer to
⇒ “3.11 Drive Plate with Overload Protection, Checking Run-
Out and Adjusting”, page 384 .
– Tighten the bolts -A- (tightening specification: 10 Nm).
– Check the drive plate run-out -B- once more. Refer to
⇒ “3.11 Drive Plate with Overload Protection, Checking Run-
Out and Adjusting”, page 384 .
3.11 Drive Plate with Overload Protection,

Checking Run-Out and Adjusting
page 325 .
– Clean the drive plate flange -A- .
– Secure a dial gauge -B- using a dial gauge holder -C- (for ex‐
ample using Dial Gauge Holder - VW387- ) on A/C compres‐
sor.
– Set probe of dial gauge -D- on flange of drive plate -A- with a
pre-tension of approximately 1.0 mm.
– Turn the A/C compressor drive unit -E- a few turns.
Specified Value:
Run-out deviation is less than 0.21 mm (run-out of dial gauge,
difference between smallest and largest measured value 0.2 mm
maximum)
– If run-out deviation is greater than 0.2 mm, loosen bolts on
drive plate and re-adjust drive plate. Refer to
⇒ “3.10 Drive Plate with Overload Protection, Removing and
3.12 A/C Compressor Drive Plate, Removing

and Installing
– Remove the drive plate with overload protection. Refer to
⇒ “3.10 Drive Plate with Overload Protection, Removing and

Remove the Drive Plate

– Disconnect the drive plate -C- by turning using a conventional
band wrench (with webbed band) in direction of -arrow D-,
counterhold compressor shaft -A- using a retainer -B- on com‐
pressor shaft -A-.
Note
Depending on the version of the A/C compressor (the A/C com‐

pressor shafts are different), use a wrench or, for example, a
Extension with Counter Holder 2 - T10001/10- from the Shock
Absorber Set - T10001- or Counterhold - Shock Absorber - 3079-
to counterhold.
Connect the Drive Plate
– Lightly coat the rubber elements -B- with soapy water (as a
lubricant) to install.
– Insert rubber element -B- in the drive plate -A- according to
illustration.
– Insert drive plate -A- with rubber elements -B- onto drive plate
-C- according to illustration until it makes contact with A/C
compressor shaft.
Note
This illustration shows the rubber element -B- in version “1”. Rub‐
ber elements -B- of version “2” are joined to each other at top.
– Bolt the drive plate -C- onto compressor shaft -A- by rotating
in direction of -arrow E-.
– Tighten the drive plate -C- to 30 Nm by turning it in the direction
of -arrow E- using a conventional strap wrench (with cloth
tape); hold the compressor shaft -A- using a counter holder
-B- on the compressor shaft -A- .
Note
Depending on the version of the A/C compressor (the A/C com‐

pressor shafts are different), use a wrench or, for example, a
Extension with Counter Holder 2 - T10001/10- from the Shock
Absorber Set - T10001- or Counterhold - Shock Absorber - 3079-
to counterhold.
3.13 Drive Plate with Anti-Friction Bearing,

– Remove the drive plate from the compressor shaft. Refer to
⇒ “3.12 A/C Compressor Drive Plate, Removing and Instal‐
ling”, page 384 .

– Remove the circlip -A-.

– Remove the drive plate -B- .
Note
♦ Replace circlip -A-.

♦ Clean the A/C compressor flange before sliding on drive plate.
♦ When installing circlip -A-, note that it cannot be bent open
more than is necessary for installation.
♦ Insert circlip -A- on correct side, the side with beveled insertion
facing compressor).

4. Actuators 387
4 Actuators
⇒ “4.1 Overview - Front Actuators”, page 388
⇒ “4.2 Temperature Regulator Door Motor V68 / Rear Temper‐
ature Door Motor V137 , Removing and Installing”, page 404
⇒ “4.3 Airflow Door Motor V71 , Removing and Installing”,
page 408
⇒ “4.4 Center Vent Adjustment Motor V102 , Removing and In‐
⇒ “4.5 Defroster Door Motor V107 , Removing and Installing”,
page 412
⇒ “4.6 Left Footwell Door Motor V108 / Footwell Door Motor
V261 , Removing and Installing”, page 414
⇒ “4.7 Right Footwell Door Motor V109 , Removing and Instal‐
ling”, page 417
⇒ “4.8 Left Center Vent Motor V110 , Removing and Installing”,
page 419
⇒ “4.9 Right Center Vent Motor V111 , Removing and Installing”,
page 422
⇒ “4.10 Recirculation Door Motor V113 , Removing and Instal‐
ling”, page 424
⇒ “4.11 Left Temperature Door Motor V158 , Removing and In‐
⇒ “4.12 Right Temperature Door Motor V159 , Removing and
Q5 Hybrid
⇒ “4.13 Hybrid Battery Recirculation Door Positioning Motor 1
Q5 Hybrid
⇒ “4.14 Hybrid Battery Recirculation Door Positioning Motor 2
⇒ “4.15 Left Retaining Plate with Left Footwell Door Motor V108
and Left Center Vent Motor V110 , Removing and Installing ”,
page 438
⇒ “4.16 Right Retaining Plate with Right Footwell Door Motor
V109 and Right Center Vent Motor V111 , Removing and Instal‐
ling”, page 442
⇒ “4.17 Left Retaining Plate with Footwell Door Motor V261 , Re‐
moving and Installing”, page 444
⇒ “4.18 Left Retaining Plate with Left Footwell Door Motor V108
and Left Center Vent Motor V110 Disassembling and Assem‐
bling”, page 447
⇒ “4.19 Right Retaining Plate with the Right Footwell Door Motor
V109 and Right Center Vent Motor V111 , Disassembling and
Assembling”, page 448
⇒ “4.20 Left Retaining Plate with Footwell Door Motor V261 , Dis‐
assembling and Assembling”, page 449
4.1 Overview - Front Actuators

⇒ “4.1.1 Overview - Front Actuators, Basis Version”, page 388
⇒ “4.1.2 Overview - Front Actuators, Convenience Version”, page
398
4.1.1 Overview - Front Actuators, “Basis” Version

Note
Revised A/C units are gradually being installed from MY 2012 (use depends on the vehicle version) (A/C unit
part number “8T_ 820 005”). With the introduction of these A/C units, other actuators are also being installed.
The actuator different versions can currently be installed on both A/C unit versions (interchanging is currently
permitted). Refer to the Parts Catalog. Use the Vehicle Diagnostic Tester in the "Guided Fault Finding" function.
1 - Air Intake Housing

ling. Refer to
⇒ “5.12 Heater and A/C
Unit Air Intake Housing,
ling”, page 537 .
❑ Disassembling and As‐
sembling. Refer to
⇒ “5.3 Overview - Heat‐
er and A/C Unit Air In‐
take Housing”,
page 464 .
sions (with and without a
connection for the glove
compartment cooling)
❑ Glove compartment
cooling connection on
air intake housing. Refer
to
⇒ “6.14 Glove Compart‐
ment Cooling Connec‐
tion on Air Intake Hous‐
ing”, page 616 .
Note
♦ From 01/2008, A/C units which

have an additional connection
for the glove compartment cool‐
ing are being installed as a run‐
ning change. On vehicles with‐
out glove compartment cooling,
this connection is sealed with a
plug .
♦ From MY 2012 (use depends on
the vehicle version), a revised
Fresh Air Blower Control Module
- J126- (and Fresh Air Blower -
V2- , Climatronic Control Module
- J255- A/C display and control
head and A/C units with part
number “8T_ 820 005”) are grad‐
ually being used. The air intake
housing, along with the Fresh Air
Blower Control Module - J126-
and the A/C unit was also re‐
vised. Be sure to use the correct
version and allocation. Refer to
the Parts Catalog. Use the Vehi‐
4. Actuators 389
2 - A/C with Evaporator (“Basis” Version)

❑ May only be removed when refrigerant circuit has been discharged; bring vehicle to a workshop that has
the necessary tools and in which the work can be performed accordingly by qualified personnel. Refer
to ⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ; A/C System General Information or ⇒ A/C Systems
with Refrigerant R1234yf - General Information; Rep. Gr. 00 ; Legal Texts and Regulations .
❑ Evaporator, removing and installing with installed A/C unit (vehicles from start of production through MY
2012). Refer to ⇒ “5.5 Evaporator, Removing and Installing”, page 475 .
Note
♦ Revised A/C units and evapora‐

tors are gradually being installed
from MY 2012 (use depends on
the vehicle version) (A/C unit
part number “8T_ 820 005”). It is
not possible to replace the evap‐
orator on this A/C unit when the
A/C unit is installed. Before work‐
ing on the evaporator, check if it
is available as an installation kit
either without the evaporator
housing or only together with the
housing. Refer to the Parts Cat‐
alog. If the evaporator is availa‐
ble only together with the hous‐
ing, then it is necessary to
remove the A/C unit and replace
the evaporator with the evapora‐
tor housing. Refer to
⇒ “5.6 Evaporator Housing, Re‐
page 492 .
“8K_ 820 005”). From MY 2012
page 520 .
❑ Evaporator with evaporator housing, removing and installing. Refer to
⇒ “5.6 Evaporator Housing, Removing and Installing”, page 492 .


❑ A/C unit, disassembling and assembling. Refer to
⇒ “5.1 Overview - Attachments for Heater and A/C Unit and Air Intake Housing”, page 451 .
Note
Revised A/C units are gradually be‐

ing installed from MY 2012 (use de‐
pends on the vehicle version) (A/C
unit part number “8T_ 820 005”).
With the introduction of these A/C
units, other actuators are also being
installed. The actuator different ver‐
sions can currently be installed on
both A/C unit versions (interchang‐
ing is currently permitted). Refer to
the Parts Catalog. Use the Vehicle
3 - Recirculation Door Motor - V113-

⇒ “4.10 Recirculation Door Motor V113 , Removing and Installing”, page 424 .
4 - Airflow Door Motor - V71-
⇒ “4.3 Airflow Door Motor V71 , Removing and Installing”, page 408 .
5 - Coolant Pipes to Heater Core
6 - Expansion Valve
Note

“8K_ 820 005”). From MY 2012
pending on the refrigerant
(R134a or R1234yf). Refer to the
Parts Catalog.
7 - Grommet
❑ For sealing the opening through the plenum chamber rear wall for the refrigerant lines
8 - Cover for the Refrigerant Pipes Leading to the Evaporator
❑ Removing and installing. Refer to ⇒ “5.5 Evaporator, Removing and Installing”, page 475 .
4. Actuators 391
9 - Defroster Door Motor - V107-

⇒ “4.5 Defroster Door Motor V107 , Removing and Installing”, page 412 .
10 - Footwell Door Motor - V261-
⇒ “4.6 Left Footwell Door Motor V108 / Footwell Door Motor V261 , Removing and Installing”,
page 414 .
❑ Left retaining plate with the Footwell Door Motor - V261- , removing and installing. Refer to
⇒ “4.17 Left Retaining Plate with Footwell Door Motor V261 , Removing and Installing”, page 444 .
11 - Left Condensation Water Drain Connection (Driver Side)
❑ Condensation water drain hose, removing and installing. Refer to
❑ Check the condensation water drain. Refer to
⇒ “5.21 Condensation Water Drain, Checking”, page 578 .
12 - Temperature Regulator Door Motor - V68-
⇒ “4.2 Temperature Regulator Door Motor V68 / Rear Temperature Door Motor V137 , Removing and
13 - Footwell Vent Temperature Sensor - G192-
⇒ “9.7 Footwell Vent Temperature Sensor G192 / Left Footwell Vent Temperature Sensor G261 , Re‐
moving and Installing”, page 660 .
❑ The Footwell Vent Temperature Sensor - G192- is installed in the left footwell vent.
14 - Center Vent Temperature Sensor - G191-
⇒ “9.6 Center Vent Temperature Sensor G191 , Removing and Installing”, page 660 .
❑ The Center Vent Temperature Sensor - G191- is installed in the air guide channel to the instrument panel
vent.
15 - Connection to the Climatronic Control Module - J255- A/C Display and Control Head on the A/C Unit Wiring
Harness
16 - Fresh Air Blower Control Module - J126-
⇒ “5.17 Fresh Air Blower Control Module J126 , Removing and Installing”, page 560 .
❑ To check, use the Vehicle Diagnostic Tester in the "Guided Fault Finding" function.
Note
♦ As a running change in MY 2010,

gasoline engines that can run on
bioethanol (Flex Fuel vehicles)
were introduced, which currently
have an Auxiliary Heater Heating
Element - Z35- . Refer to
⇒ “5.8 Auxiliary Heater Heating
Element Z35 , Checking”,
page 506 .
♦ Currently an Auxiliary Heater
Heating Element - Z35- is also
installed on vehicles with a high
voltage system (hybrid vehicles)
and a gasoline engine. Refer to
page 506 .

♦ For vehicles with a gasoline en‐

gine, the electric auxiliary heater
(the Auxiliary Heater Heating El‐
ement - Z35- ) is activated by the
J255- display and control head
via the local Data Bus (activated
via the same outlet and also via
Module - J126- ) on the Auxiliary
Air Heater Control Module -
J604- . Also check the Auxiliary
J604- if there is a concern about
Module - J126- or the Fresh Air
Blower - V2- for these vehicles.
ponent locations.
♦ Check the Auxiliary Heater Heat‐
ing Element - Z35- function. Re‐
fer to
page 506 .
Parts Catalog. Use the Vehicle
4. Actuators 393
17 - Center Vent Adjustment Motor - V102-

⇒ “4.4 Center Vent Adjustment Motor V102 , Removing and Installing”, page 410 .
18 - Right Condensation Water Drain Connection (Passenger Side)
19 - Evaporator
Note
♦ Revised A/C units and evapora‐

tors are gradually being installed
from MY 2012 (use depends on
the vehicle version) (A/C unit
part number “8T_ 820 005”). It is
not possible to replace the evap‐
orator on this A/C unit when the
A/C unit is installed. Before work‐
ing on the evaporator, check if it
is available as an installation kit
either without the evaporator
housing or only together with the
housing. Refer to the Parts Cat‐
alog. If the evaporator is availa‐
ble only together with the hous‐
ing, then it is necessary to
remove the A/C unit and replace
the evaporator with the evapora‐
tor housing. Refer to
⇒ “5.6 Evaporator Housing, Re‐
page 492 .
“8K_ 820 005”). From MY 2012


page 520 .
20 - Heat Exchanger
❑ Heater exchanger with the A/C unit installed, removing and installing. Refer to
21 - Auxiliary Heater Heating Element - Z35- /Honeycomb
❑ The Auxiliary Heater Heating Element - Z35- is installed on vehicles with a diesel engine and on vehicles
with certain gasoline engines. Refer to
⇒ “5.8 Auxiliary Heater Heating Element Z35 , Checking”, page 506 .
❑ Vehicles with a gasoline engine and without an Auxiliary Heater Heating Element - Z35- have a honey‐
comb installed in the installation space as a place holder (this assures that current conditions in the A/C
unit with and without Auxiliary Heater Heating Element - Z35- are the same).
❑ If a parking heater (that is installed as optional equipment) is activated as an auxiliary heater on vehicles
with a diesel engine, there is no Auxiliary Heater Heating Element - Z35- , but rather a honeycomb is
installed (introduction open). Refer to
❑ Check the Auxiliary Heater Heating Element - Z35- function. Refer to
❑ Auxiliary Heater Heating Element - Z35- /Honeycomb with A/C unit installed, removing and installing.
Refer to ⇒ “5.9 Auxiliary Heater Heating Element Z35 , Removing and Installing”, page 511 .
Note
♦ In MY 2009, as a running
change, a new version of the
Auxiliary Heater Heating Ele‐
ment - Z35- is being installed (the
heating elements are a bit more
narrow); be sure to use the cor‐
rect version and note the alloca‐
tion. Refer to the Parts Catalog.
page 506 .
4. Actuators 395

page 506 .
22 - Fresh Air Blower - V2-

❑ Removing and installing. Refer to ⇒ “5.16 Fresh Air Blower V2 , Removing and Installing”, page 557 .
❑ To check, use the Vehicle Diagnostic Tester in the "Guided Fault Finding" function
Note
♦ There are different versions. Re‐

fer to
⇒ “5.16 Fresh Air Blower V2 ,
page 557 .
page 506 .
page 506 .
ponent locations.
fer to
page 506 .

♦ From MY 2012 (depending on

- J126- , Fresh Air Blower - V2- ,
number “8T_ 820 005” are grad‐
ually being used. Be sure to use
the correct version and alloca‐
function.
23 - Dust and Pollen Filter

❑ Different versions with and without activated charcoal filter element. Refer to
⇒ “3.11 Dust and Pollen Filter with Activated Charcoal Insert, Element Information”, page 107 and the
Parts Catalog.
24 - Evaporator Vent Temperature Sensor - G263-
⇒ “9.9 Evaporator Vent Temperature Sensor G263 , Removing and Installing”, page 662 .
4. Actuators 397
4.1.2 Overview - Front Actuators, “Convenience” Version
Note
From MY 2012 (introduction depending on the vehicle version), a revised Fresh Air Blower Control Module -
J126- (and Fresh Air Blower - V2- , Climatronic Control Module - J255- A/C display and control head, evaporator,
expansion valves, actuators and A/C units are being used. Refer to the Parts Catalog. Use the Vehicle Diag‐
nostic Tester in the "Guided Fault Finding" function. Read all the information regarding these components.
Refer to ⇒ “4.1.1 Overview - Front Actuators, Basis Version”, page 388 .

ling. Refer to
ling”, page 537 .
sembling. Refer to
take Housing”,
page 464 .
sions (with and without a
connection for the glove
compartment cooling)
❑ Glove Compartment
Cooling to Air Intake
Manifold Connection.
Refer to
⇒ “6.14 Glove Compart‐
ment Cooling Connec‐
tion on Air Intake Hous‐
ing”, page 616 .
Note
♦ From 01/2008, A/C units which

have an additional connection
for the glove compartment cool‐
ing are being installed as a run‐
ning change. On vehicles with‐
out glove compartment cooling,
this connection is sealed with a
plug .
♦ From MY 2012, a new version is
being used. Read all the infor‐
mation regarding this compo‐
nent. Refer to
⇒ “4.1.1 Overview - Front Actua‐
tors, Basis Version”, page 388 .
2 - A/C with Evaporator (“Convenience” Version)

❑ May only be removed when refrigerant circuit has been discharged; bring vehicle to a workshop that has
the necessary tools and in which the work can be performed accordingly by qualified personnel. Refer
to ⇒ Refrigerant R134a Servicing; Rep. Gr. 87 ; A/C System General Information or ⇒ A/C Systems
with Refrigerant R1234yf - General Information; Rep. Gr. 00 ; Legal Texts and Regulations .

Note
From MY 2012, a new version is be‐

ing used. Read all the information
regarding this component. Refer to
⇒ “4.1.1 Overview - Front Actuators,
Basis Version”, page 388 .
❑ A/C unit, disassembling and assembling. Refer to
⇒ “4.3 Airflow Door Motor V71 , Removing and Installing”, page 408 .
5 - Coolant Pipes to Heater Core
6 - Expansion Valve
❑ Refrigerant lines, disconnecting and connecting. Refer to
Note

nent. Refer to
pending on the refrigerant
(R134a or R1234yf). Refer to the
Parts Catalog.
7 - Grommet
8 - Left Temperature Door Motor - V158-
⇒ “4.11 Left Temperature Door Motor V158 , Removing and Installing”, page 426 .
9 - Cover for the Refrigerant Pipes Leading to the Evaporator
10 - Left Center Vent Motor - V110-
⇒ “4.8 Left Center Vent Motor V110 , Removing and Installing”, page 419 .
❑ Left retaining plate with the Left Footwell Door Motor - V108- and Left Center Vent Motor - V110- ,
removing and installing. Refer to
⇒ “4.15 Left Retaining Plate with Left Footwell Door Motor V108 and Left Center Vent Motor V110 ,
Removing and Installing ”, page 438 .
❑ Left Center Vent Motor - V110- , removing and installing. Refer to
4. Actuators 399

12 - Left Footwell Door Motor - V108-
page 414 .
13 - Left Condensation Water Drain Connection (Driver Side)
14 - Temperature Regulator Door Motor - V137-
15 - Left Footwell Vent Temperature Sensor - G261-
❑ The Left Footwell Vent Temperature Sensor - G261- is installed in the left footwell vent.
16 - Connection to the Climatronic Control Module - J255- A/C Display and Control Head on the A/C Unit Wiring
Harness
17 - Right Footwell Vent Temperature Sensor - G262-
⇒ “9.8 Right Footwell Vent Temperature Sensor G262 , Removing and Installing”, page 661 .
❑ The Right Footwell Vent Temperature Sensor - G262- is installed in the right footwell vent.
❑ To check using the Vehicle Diagnostic Tester in the "Guided Fault Finding" function.
Note

fer to
page 557 .
page 506 .


page 506 .
ponent locations.
fer to
page 506 .
nent. Refer to
19 - Evaporator
Note
From MY 2012, a new version is be‐

ing used. Read all the information
regarding this component. Refer to
⇒ “4.1.1 Overview - Front Actuators,
Basis Version”, page 388 .
20 - Right Condensation Water Drain Connection (Passenger Side)
4. Actuators 401
21 - Heat Exchanger
❑ Heater exchanger with the A/C unit installed, removing and installing. Refer to
The Auxiliary Heater Heating Element - Z35- is installed on vehicles with a diesel engine and on vehicles with
certain gasoline engines. Refer to ⇒ “5.8 Auxiliary Heater Heating Element Z35 , Checking”, page 506 .
Vehicles with a gasoline engine and without an Auxiliary Heater Heating Element - Z35- have a honeycomb
installed in the installation space as a place holder (this assures that current conditions in the A/C unit with and
without Auxiliary Heater Heating Element - Z35- are the same).
❑ Check the Auxiliary Heater Heating Element - Z35- function. Refer to
❑ Auxiliary Heater Heating Element - Z35- /Honeycomb with A/C unit installed, removing and installing.
Note
page 506 .
page 506 .
23 - Right Temperature Door Motor - V159-

⇒ “4.12 Right Temperature Door Motor V159 , Removing and Installing”, page 429 .
⇒ “4.9 Right Center Vent Motor V111 , Removing and Installing”, page 422 .
❑ Right retaining plate with the Right Footwell Door Motor - V109- and Right Center Vent Motor - V111- ,
⇒ “4.16 Right Retaining Plate with Right Footwell Door Motor V109 and Right Center Vent Motor V111 ,
Removing and Installing”, page 442 .
25 - Right Footwell Door Motor - V109-
⇒ “4.7 Right Footwell Door Motor V109 , Removing and Installing”, page 417 .

Note

fer to
page 557 .
nent. Refer to

❑ Follow the replacement intervals. Refer to Maintenance Tables
4. Actuators 403
4.2 Temperature Regulator Door Motor -

V68- / Rear Temperature Door Motor -
V137- , Removing and Installing
The Temperature Regulator Door Motor - V68- Is Installed on Ve‐
hicles Equipped with the “Basis” A/C System.
The Rear Temperature Door Motor - V137- Is Installed on Vehi‐
cles Equipped with the “Convenience” A/C System.
Note
♦ There are different designations and functions, depending on

the A/C version. Refer to ⇒ “6 Air Guide”, page 581 (air guide
in the A/C unit and in the vehicle).
♦ On a vehicle equipped with a “Convenience” A/C system, the
Rear Temperature Door Motor - V137- operates the temper‐
ature doors for the rear footwell vents and the rear center
console vents (not installed in the “Basis” A/C system).
♦ On a vehicle equipped with the “Basis” A/C system, the Tem‐
perature Regulator Door Motor - V68- operates the tempera‐
ture doors for the left and right side.
♦ Currently in this vehicle, all actuators are identical in construc‐
tion. During the basic setting, the actuators are assigned and
adapted corresponding to the switching sequence of the wir‐
ing. If this sequence does not conform the specification, the
adjustment motors will adapt incorrectly and the door control
will be wrong. Refer to
30 (A/C system actuators block diagram).
Removing
– Move the driver seat as far back as possible.
– Remove the storage compartment under the instrument panel
on the driver side. Refer to ⇒ Body Interior; Rep. Gr. 68 ;
Storage Compartments and Covers; Driver Side Instrument
Panel Cover, Removing and Installing .
Note
The actuator is installed on the left side, on the A/C unit, near the
center tunnel. Refer to ⇒ “4 Actuators”, page 388 .

– Remove the bolts -B-.

– Pull the actuator with its bracket -H- in the direction of the
-arrow- from the mounts -C and D-.
– Mark the connector -A- if necessary (to prevent confusing it
with other connectors, in the event several connectors are dis‐
connected at the same time).
– Loosen the connecting rod -E- from the toothed segment -F- .
– Remove the actuator with its bracket.
– Remove the bolts -G- and separate the actuator from the
bracket -H- .
– Loosen the toothed segment -A- from the actuator shaft -B- .
Installing
following.
– Install the actuator -B- in the bracket -D- .
– Install the bolts -G- .
– Attach the toothed segment -A- on the actuator shaft -B- as

shown in the illustration.
Note
The actuator does not have a stop, therefore the toothed segment
-A- can be mounted on the actuator shaft at any position. To as‐
sure the function, the toothed segment -A- must be in the correct
position to the marking on the bracket after assembling.
– Check the position of the toothed segment -A- ; the first tooth
must meet up with the marking -C- as shown.
4. Actuators 405
Note
♦ If a new actuator is delivered as a replacement part, the shaft

must always be positioned so that the toothed segment -A-
can be mounted as shown. If, when installing the toothed
segment -A- on the actuator shaft and the first tooth does not
meet up with the marking -C- as shown, (for example on an
actuator that was already once installed), then you must con‐
nect the actuator to the vehicle's electric system, and with the
ignition switched on, change the temperature setting on the
head so that the actuator changes its position and that the
toothed segment -A- moves into the correct position.
♦ Applying voltage does not make the actuator move; it moves
only if it is activated by the Climatronic Control Module - J255-
A/C display and control head.
♦ On the toothed segment -A- (see illustration above) mounted
on the actuator shaft, there is a larger tooth present; when in
use, this tooth must touch the lower tooth interval on the tooth‐
ed segment -D- which is on the temperature door shaft.
♦ There are different toothed segments -A- (different version of
the connecting element for the right temperature door con‐
necting rod), depending on the date of production. Refer to
⇒ , page 25 and the Parts Catalog
– Secure the temperature door toothed segment -D- with a pin

-A- (4 mm diameter) over the guide -B- and the mount -C-.

– Clip the connecting rod -E- to the toothed segment -F- .

– Connect the connector -A-.
– Slide the actuator with its bracket -H- opposite the direction of
the -arrow- into the mounts -C and D-.
– Install the wiring harness -A- so that it cannot come in contact
with any moving parts, for example, the actuating arm.
– Install the bolts -B-.
– Install the removed parts in the opposite order.
– Perform a basic setting and the output diagnostic test mode
for the A/C system using the Vehicle Diagnostic Tester in the
Note
♦ On this vehicle, the actuators are equipped with electronics.

During the basic setting, a new actuator learns its position on
the A/C unit and can then be activated by the Climatronic
Control Module - J255- A/C display and control head (currently
all actuators are identical) using the Vehicle Diagnostic Tester
♦ During the basic setting, the actuators are assigned and adap‐
ted corresponding to the switching sequence of the wiring. If
this sequence does not conform the specification, the adjust‐
ment motors will adapt incorrectly and the door control will be
wrong. Refer to

- A/C display and control head and erase any displayed mal‐
4. Actuators 407
4.3 Airflow Door Motor - V71- , Removing

and Installing
Note
♦ Perform the basic setting for the A/C system after installing the
actuator using the Vehicle Diagnostic Tester in the "Guided
♦ Via the functions “Output diagnostic test mode” and “Basic
setting”, the activation of A/C system electrical components
can be tested if necessary (for example, allocation test) using
function.
♦ After installing a new actuator, check the activation by the Cli‐
and check the function (correct position of recirculation door
and back pressure/fresh air door) using the Vehicle Diagnostic
♦ Airflow Door Motor - V71- function. Refer to ⇒ , page 409 .
Removing
– Move the passenger seats as far back as possible.
– Remove the air intake housing. Refer to
– Remove the air intake housing from the air intake manifold.
Refer to
⇒ “6.9 Air Intake Duct, Removing and Installing”, page 604 .


– Counter hold on the curved washer -A- and remove the ac‐
tuator -C- from the curved washer -A- .
Installing
following.
– Check the lever for the back pressure door -D- and for the fresh
air door -E- ; they must fit correctly in the curved washer -A- .
– Insert the actuator shaft -C- into the curved washer mount
-A- .
Note
The actuator does not have a stop; therefore, the actuator shaft
-C- can be inserted into the curved washer mount -A- in any po‐
sition.

Note

wrong. Refer to

Airflow Door Motor - V71- Function
♦ The position of the fresh air- and back pressure door is visible
via the air intake opening in the plenum chamber when the air
recirculation is closed (if necessary, remove the plenum cham‐
ber cover and cover over fresh air intake. Refer to
⇒ “6.8 Fresh Air Intake, Removing and Installing”,
page 600 ).
♦ For back pressure regulation, the fresh air intake duct is closed
partially via the back pressure door at a higher vehicle speed
(from approximately 80 km/h (50 mph)) by Climatronic Control
Module - J255- A/C display and control head (position of re‐
circulating air door is specified by the Climatronic Control
Module - J255- A/C display and control head).
4. Actuators 409
♦ To reduce the change in noise of the Fresh Air Blower - V2-

due to different air intake when switching from fresh air to
recirculating air mode or vice versa, the Airflow Door Motor -
V71- and the Recirculation Door Motor - V133- are activated
as follows:
– When switching from fresh air to recirculation mode, the re‐
circulation door is first opened, then the fresh air intake chan‐
nel is closed via the back pressure and fresh air door.
– When switching from recirculation to fresh air mode, the fresh
air intake channel is first closed by the back pressure/fresh air
door, then the recirculation door is closed.
– In partially air recirculation mode, the air recirculation door
-E- is opened and back pressure-/fresh air door is brought into
a center position by the Climatronic Control Module - J255- A/
C display and control head (fresh air and air recirculation air
intake duct are slightly opened simultaneously). This achieves
improved cool-off in certain temperature ranges and simulta‐
neously draws in a certain portion of fresh air as well.
4.4 Center Vent Adjustment Motor - V102- ,

Note
♦ The Center Vent Adjustment Motor - V102- is only installed on

vehicles equipped with the “Basis” A/C system.
Removing
– Remove the glove compartment. Refer to ⇒ Body Interior;
Rep. Gr. 68 ; Storage Compartments and Covers; Glove
Compartment, Removing and Installing .
– Remove the right footwell vent (front passenger side). Refer
to
⇒ “6.4 Front Passenger Side Footwell Vent, Removing and
– Remove the air guide channel -B- leading to the right instru‐
ment panel vent (passenger side).

– Mark the connector -A- if necessary (to rule out an interchange

in the event several connectors are disconnected at the same
time).
– Remove the shaft -D- of the actuator -C- from the center vent
door shaft -E- .
Installing
following.
– Insert the shaft -D- of the actuator -C- into the center vent door
shaft -E- .
Note
The actuator does not have a stop; therefore the actuator shaft
can be inserted into the center vent door shaft -E- in any position.

– Install the wiring harness so that it cannot come in contact with
any moving parts (for example, the actuating arm).
Note

wrong. Refer to

4. Actuators 411
4.5 Defroster Door Motor - V107- , Remov‐

ing and Installing
Note
Currently in this vehicle, all actuators are identical in construction.

During the basic setting, the actuators are assigned and adapted
corresponding to the switching sequence of the wiring. If this se‐
quence does not conform with the specification, the actuators will
adapt incorrectly and the door control will be wrong. Refer to
⇒ “1.10 Main Wiring Diagram for A/C System Actuators”,
page 30 .
Removing
– Remove the left footwell vent (driver side). Refer to
⇒ “6.3 Driver Side Footwell Vent, Removing and Installing”,
page 593 .
– Remove the accelerator pedal module. Refer to ⇒ Rep. Gr.
20 ; Accelerator Pedal Mechanism; Accelerator Pedal Position
Sensors -G79- / -G185- , Removing and Installing .

– Mark the connector -D- if necessary (to rule out an interchange

time).
– Disconnect the connector -D- .
– Remove the bolts -C-.
Note
To remove the bolt -C-, the Wrench - Special Ratchet - T40083-

may also be used.
– Loosen the shaft -A- (on the actuator -B-) from the actuating
arm -E- and remove the actuator.
Installing
following.
– Check the position of the actuating arm -E- in the guide on the
A/C unit -F-; when doing this, pay attention to both stops -G-.
– Insert the shaft -A- (on the actuator -B-) into the actuating arm
-E- .
Note
The actuator does not have a stop; therefore the shaft -A- can be
inserted into the actuating arm -E- in any position.
– Install the bolts -C-.

– Connect the connector -D- .
Note

wrong. Refer to
4. Actuators 413

4.6 Left Footwell Door Motor - V108- / Foot‐

well Door Motor - V261- , Removing and
Installing
The Footwell Door Motor - V261- Is Installed on Vehicles Equip‐
ped with the “Basis” A/C System.
The Left Footwell Door Motor - V108- Is Installed on Vehicles
Equipped with the “Convenience” A/C System.
Note
♦ There are different designations and functions, depending on

the A/C version. Refer to ⇒ “6 Air Guide”, page 581 (air guide
in the A/C unit and in the vehicle).
♦ On vehicles equipped with the “Convenience” A/C system, the
Left Footwell Door Motor - V108- operates the doors for the
left instrument panel vent, the left footwell vent and the left rear
footwell vent (under the driver seat).
♦ On vehicles with the “Basis” A/C system, the Footwell Door
Motor - V261- operates the doors for the left and right instru‐
ment panel vents, the left and right footwell vents and the left
and right rear footwell vents (under the front seats). The dif‐
ferent doors for the left and right side are connected with each
other in the A/C by connector rods.
♦ Left retaining plate with the Footwell Door Motor - V261- , re‐
moving and installing. Refer to
⇒ “4.17 Left Retaining Plate with Footwell Door Motor V261 ,
♦ Left retaining plate with the Left Footwell Door Motor - V108-
and Left Center Vent Motor - V110- , removing and installing.
Refer to
⇒ “4.15 Left Retaining Plate with Left Footwell Door Motor
V108 and Left Center Vent Motor V110 , Removing and In‐
stalling ”, page 438 .
Removing
page 593 .


4. Actuators 415

time).
Note

may also be used.
– Loosen the shaft -A- (on the actuator -B-) from the curved
washer -E- and remove the actuator.
Installing
following.
– Insert the shaft -A- (on the actuator -B-) into the curved washer
mount -E- .
Note
The actuator does not have a stop; therefore the shaft -A- can be
inserted into the curved washer mount -E- in any position.

Note

wrong. Refer to


4.7 Right Footwell Door Motor - V109- , Re‐

Note
♦ The Right Footwell Door Motor - V109- is only installed on ve‐

hicles equipped with the “Convenience” A/C system.
♦ Right retaining plate with the Right Footwell Door Motor -
V109- and Right Center Vent Motor - V111- , removing and
installing. Refer to
V109 and Right Center Vent Motor V111 , Removing and In‐
Removing
to
4. Actuators 417

time).
– Remove the shaft -D- of the actuator -C- from the curved
washer -E-.
Installing
following.
– Insert the shaft -D- of the actuator -C- into the curved washer
-E- .
Note
can be inserted into the curved washer -E- in any position.

Note

wrong. Refer to


4.8 Left Center Vent Motor - V110- , Re‐

Note
♦ The Left Center Vent Motor - V110- is only installed on vehicles

equipped with the “Convenience” A/C system.
♦ Left retaining plate with the Left Footwell Door Motor - V108-
and Left Center Vent Motor - V110- , removing and installing.
Refer to
to ⇒ , page 25 and Parts Catalog.
Removing
page 593 .
Note
♦ The following illustrations show the arrangement of the actua‐

tors and their retaining plates on the left side of the A/C unit
with the air channel leading to the left instrument panel vent
-A- removed for clarity.
♦ The air guide channel leading the left instrument panel vent
-A- is secured by an expanding clip or a screw -B- onto the
instrument panel crossmember -C-; the expanding clip or the
screw can only be removed when the outer instrument panel
shell is removed.
– Carefully loosen the air guide channel leading to the left in‐
strument panel vent -A- from the A/C unit vent.
4. Actuators 419

time).
Note

may also be used.
– Press the curved washer -E- toward the A/C unit and remove
the shaft -A- (of the actuator -B-) from the curved washer
-E- .
Note
♦ The Left Center Vent Motor - V110- operates the connector

rod -F- via the curved washer -E- (and with it the door for the
left indirect ventilation) and the door for the left center instru‐
ment panel vent via the lever -G-. If the lever pin -G- becomes
loosened out of the curved washer guiding groove -E- when
removing the actuator, the door for the left center instrument
panel vent will not actuate.
♦ In MY 2008, revised toothed gears -A- and a new bracket were
installed as a running change (a revised collar on the toothed
gear and a revised hole). Ensure the correct allocation of the
toothed gear to the bracket (these parts are supplied together
as a replacement part). Refer to the Parts Catalog.
♦ The connector rod -F- actuates the door in the left center vent.
Installing
following.

– Check the lever pin -G- and the connector rod pin -F- for proper
seating in the respective guiding groove in the curved washer
-E-.
– Insert the shaft -D- of the actuator -B- into the curved washer
-E-.
Note

– Connect the connector -D-.
Note

wrong. Refer to

4. Actuators 421
4.9 Right Center Vent Motor - V111- , Re‐

Note
♦ The Right Center Vent Motor - V111- is only installed on ve‐

hicles equipped with the “Convenience” A/C system.
V109- and Right Center Vent Motor - V111- , removing and
Removing


time).
– Remove the shaft -D- of the actuator -C- from the curved
washer -E-.
Installing
following.
– Insert the shaft -D- of the actuator -C- into the curved washer
-E- .
Note

Note

wrong. Refer to

4. Actuators 423
4.10 Recirculation Door Motor - V113- , Re‐

Note
♦ Perform the basic setting for the A/C system after installing the
actuator using the Vehicle Diagnostic Tester in the "Guided
♦ Via the functions “Output diagnostic test mode” and “Basic
setting”, the activation of A/C system electrical components
can be tested if necessary (for example, allocation test) using
function.
♦ In the event of problems with moisture in passenger compart‐
ment, additionally check recirculation door (must close com‐
pletely).
Removing

– Loosen the wiring harness -E- from the air intake housing.
– Disconnect the actuator shaft -C- from the air recirculation
door shaft -D-.
time).
Installing
following.
– Insert the actuator shaft -C- into the air recirculation door shaft
-D- .
Note
-C- can be inserted into the air recirculation door shaft -D- at any
position.

– Install the wiring harness -E- so that it cannot come in contact
with any moving parts (for example, the actuating arm).
Note

wrong. Refer to

4. Actuators 425
4.11 Left Temperature Door Motor - V158- ,

Note
♦ The Left Temperature Door Motor - V158- is only installed on

vehicles equipped with the “Convenience” A/C system.
ing. If this sequence does not conform with the specification,
the actuators will adapt incorrectly and the door control will be
wrong. Refer to
30 .
Removing
– Set the airflow direction to the footwell vents for both the driver
and front passenger side on the Climatronic Control Module -
Note
In the “air to the footwell vents” setting, the Defroster Door Motor
- V107- moves the connector rod -A- in a position in which the bolt
-B- is accessible. If the Defroster Door Motor - V107- does not
move the connector rod -A- into the desired position, remove the
actuator if necessary. Refer to
⇒ “4.5 Defroster Door Motor V107 , Removing and Installing”,
page 412 .

page 593 .
– Remove the steering column. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 48 ; Steering Column; Steering Column,
– Remove the pedal assembly and the accelerator pedal mod‐
ule. Refer to ⇒ Brake System; Rep. Gr. 46 ; Brake Pedal;
Mounting Bracket, Removing and Installing and ⇒ Rep. Gr.

– Remove the Left Center Vent Motor - V110- -B-. Refer to

⇒ “4.8 Left Center Vent Motor V110 , Removing and Instal‐
ling”, page 419 .
– Mark the connector -C- (to prevent confusing it with other con‐
nectors).
– Disconnect the connector -C-.
– Loosen the pin -D- (on the actuator bracket -E-) from the tooth‐
ed segment -F- (of the temperature door shaft) and remove
the bracket -E- (with the actuator) in the direction of the
-arrow-.
– Remove the bolts -A- and separate the actuator -B- from the
bracket -D- .
– Remove the toothed gear -C- from the actuator shaft -D- .
Installing
following.
– Mount the toothed gear -C- on the shaft -E- of the actuator
-B- .
Note
The actuator does not have a stop, therefore the toothed gear
-C- can be mounted on the actuator shaft at any position.
4. Actuators 427
– Bring the toothed gear -F- (in the temperature door shaft) all
the way to the stop into the shown position (by turning in the
direction of the -arrow-).
– Insert the guide -G- (on the bracket -E- with the actuator) into
the bracket -H- (on the A/C unit) .
– Slide the bracket -E- opposite the direction of the -arrow- to
the toothed segment -F- and insert the pin -D- (on the actuator
bracket -E-) into the toothed segment -F- (temperature door
shaft).
Note
The actuator and the toothed gear -J- do not have a stop; there‐
fore the toothed gear -J- can be joined to the toothed segment
-F- (temperature door shaft) in any position.

– Connect the connector -C-.
Note

wrong. Refer to

malfunctions, if necessary using the Vehicle Diagnostic Tester

4.12 Right Temperature Door Motor - V159- ,

Note
♦ The Right Temperature Door Motor - V159- is only installed on

Removing
– Set the airflow direction to the instrument panel vents for both
the driver and front passenger side on the Climatronic Control
Note
In the “air to the instrument panel vents” setting, the Right Center
Vent Motor - V111- -B- moves the curved washer -A- in a position
in which the bolt -C- is accessible. If the Right Center Vent Motor
- V111- -B- does not move the curved washer -A- into the desired
position, then remove the actuator if necessary and move the
curved washer by hand. Refer to
⇒ “4.9 Right Center Vent Motor V111 , Removing and Installing”,
page 422 .

– Mark the connector -D- (to prevent confusing it with other con‐
nectors).
– Remove the bolts -C and E- .
4. Actuators 429
– Loosen the pin -A- (on the actuator bracket -C-) from the tooth‐
ed segment -B- (temperature door shaft) and remove the
bracket -C- (with the actuator) in the direction of the -arrow-.
– Remove the bolts -A- and separate the actuator -B- from the
bracket -D- .
– Remove the toothed gear -C- from the actuator shaft -D- .
Installing
following.
– Mount the toothed gear -C- on the shaft -E- of the actuator
-B- .
Note
The actuator does not have a stop, therefore the toothed gear
-C- can be mounted on the actuator shaft at any position.
– Turn the toothed gear -B- (in the temperature door shaft) all
the way to the stop into the shown position (by turning in the
direction of the -arrow-).
– Insert the guide -D- (on the bracket -C- with the actuator) into
the mount -E- (on the A/C unit) .
– Slide the bracket -C- opposite the direction of the -arrow- to
the toothed segment -B- and insert the pin -A- (on the actuator
bracket) into the toothed segment -B- (temperature door
shaft) .
Note
The actuator and the toothed gear -C- do not have a stop; there‐
fore the toothed gear -C- can be joined to the toothed segment
-B- (temperature door shaft) in any position.

– Install the bolts -C and E-.

Note

wrong. Refer to

4.13 Hybrid Battery Recirculation Door Posi‐

tioning Motor 1 - V479- , Removing and
Installing
General Warnings .
age Components and Cables”, page 41 and ⇒ Electrical System
WARNING

voltage system.
4. Actuators 431
WARNING

connector.
DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.

Note
♦ For this vehicle, both actuators (for the Hybrid Battery Recir‐
culation Door Positioning Motor 1 - V479- and the Hybrid
Battery Recirculation Door Positioning Motor 2 - V480- ) on the
battery cooling module are activated by the Battery Regulation
Control Module - J840- via the data line. Both actuators are
connected the Battery Regulation Control Module - J840- via
the data line (LIN Bus). If an incorrect actuator is installed or
the actuators on the battery cooling module are switched,
there will be a malfunction at an actuator or in the wiring. This
malfunction may result in various DTC memory entries with
different malfunction types using the Vehicle Diagnostic Tester
in the "Guided Fault Finding" function. Refer to ⇒ Wiring dia‐
♦ The actuators on the battery cooling module are identical to
the actuators on the A/C unit, in that the Battery Regulation
Control Module - J840- cannot perform any addressing pro‐
cedure for the actuators. Only actuators which are already
addressed with the correct addresses may be installed on the
battery cooling module. When replacing, pay attention to the
correct version (part number) and when installing, the correct
component location using the Vehicle Diagnostic Tester in the
"Guided Fault Finding" function and the Parts Catalog.
♦ Note that in the vehicle diagnosis, various terms and defini‐
tions are used for the adjustment motors Hybrid Battery Re‐
circulation Door Positioning Motor 1 - V479- and hybrid battery
Recirculation Door Positioning Motor 2 - V480- : The Hybrid
Battery Recirculation Door Positioning Motor 1 - V479- is
marked as “valve 1 for the air guide for the hybrid battery”, the
Hybrid Battery Recirculation Door Positioning Motor 2 - V480-
as “valve 2 for the air guide for the hybrid battery”.
Caution
Make sure that the allocation for the actuator is correct.

♦ Both positioning motors ( Hybrid Battery Recirculation
Door Positioning Motor 1 - V479- and Hybrid Battery Re‐
circulation Door Positioning Motor 2 - V480- ) are identical.
They differ only by their electronically stored allocation
(assignment).
♦ If the actuators are switched during installation, the acti‐
vation of the doors in the battery cooling module will be
incorrect, resulting in a faulty air guide for the Traction
Battery - A2- .
♦ Mark the adjustment motor and the installed position on
the battery cooling module before removal.
♦ Pay attention to the markings when installing and, if nec‐
essary, check the part number of the actuator. Refer to the
Parts Catalog.
Note
Note the correct allocations: the Hybrid Battery Recirculation

Door Positioning Motor 1 - V479- has, for example, the part num‐
ber “8R0 820 504” at the start of production and the Hybrid Battery
Recirculation Door Positioning Motor 2 - V480- has, for example,
the part number “8R0 820 510”. Refer to the Parts Catalog.
4. Actuators 433
Removing
– Remove the bolts -arrows- and then remove the Hybrid Battery
Recirculation Door Positioning Motor 1 - V479- .
Installing
following.
– After installing, check the DTC memory for the Climatronic
Control Module - J255- display and control head and the Bat‐
tery Regulation Control Module - J840- and, if necessary,
erase the displayed faults using the Vehicle Diagnostic Tester
– Perform a function test and, if necessary, an output diagnostic
test for both of the actuators on the battery cooling module via
the Battery Regulation Control Module - J840- using the Ve‐
hicle Diagnostic Tester in the "Guided Fault Finding" function.
4.14 Hybrid Battery Recirculation Door Posi‐

tioning Motor 2 - V480- , Removing and
Installing
General Warnings .
WARNING

voltage system.

WARNING

connector.
DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
4. Actuators 435
Note
♦ For this vehicle, both actuators (for the Hybrid Battery Recir‐
culation Door Positioning Motor 1 - V479- and the Hybrid
Battery Recirculation Door Positioning Motor 2 - V480- ) on the
battery cooling module are activated by the Battery Regulation
Control Module - J840- via the data line. Both actuators are
connected the Battery Regulation Control Module - J840- via
the data line (LIN Bus). If an incorrect actuator is installed or
the actuators on the battery cooling module are switched,
there will be a malfunction at an actuator or in the wiring. This
malfunction may result in various DTC memory entries with
different malfunction types using the Vehicle Diagnostic Tester
in the "Guided Fault Finding" function. Refer to ⇒ Wiring dia‐
♦ The actuators on the battery cooling module are identical to
the actuators on the A/C unit, in that the Battery Regulation
Control Module - J840- cannot perform any addressing pro‐
cedure for the actuators. Only actuators which are already
addressed with the correct addresses may be installed on the
battery cooling module. When replacing, pay attention to the
correct version (part number) and when installing, the correct
component location using the Vehicle Diagnostic Tester in the
"Guided Fault Finding" function and the Parts Catalog.
♦ Note that in the vehicle diagnosis, various terms and defini‐
tions are used for the actuators Hybrid Battery Recirculation
Door Positioning Motor 1 - V479- and Hybrid Battery Recircu‐
lation Door Positioning Motor 2 - V480- : The Hybrid Battery
Recirculation Door Positioning Motor 1 - V479- is marked as
“valve 1 for the air guide for the hybrid battery”, the Hybrid
Battery Recirculation Door Positioning Motor 2 - V480- as
“valve 2 for the air guide for the hybrid battery”.
Caution
Make sure that the allocation for the actuator is correct.

♦ Both positioning motors ( Hybrid Battery Recirculation
Door Positioning Motor 1 - V479- and Hybrid Battery Re‐
circulation Door Positioning Motor 2 - V480- ) are identical.
They differ only by their electronically stored allocation
(assignment).
♦ If the actuators are switched during installation, the acti‐
vation of the doors in the battery cooling module will be
incorrect, resulting in a faulty air guide for the Traction
Battery - A2- .
♦ Mark the actuator and the installed position on the battery
cooling module before removal.
♦ Pay attention to the markings when installing and, if nec‐
essary, check the part number of the adjustment motor.
Note
Note the correct allocations. The Hybrid Battery Recirculation

Door Positioning Motor 1 - V479- has the part number “8R0 820
504” at the start of production for example and the Hybrid Battery
Recirculation Door Positioning Motor 2 - V480- has the part num‐
ber “8R0 820 510”. Refer to the Parts Catalog.

Removing
– Remove the Hybrid Battery Recirculation Door Positioning
Motor 2 - V480- and disconnect the connector -1-.
Installing
following.
– Perform a function test and, if necessary, an output diagnostic
test for both of the actuators on the battery cooling module via
the Battery Regulation Control Module - J840- using the Ve‐
4. Actuators 437
4.15 Left Retaining Plate with Left Footwell

Door Motor - V108- and Left Center Vent
Motor - V110- , Removing and Installing
The Left Footwell Door Motor - V108- and the Left Center Vent
Motor - V110- Are Installed in the “Convenience” A/C System.
Note
♦ The retaining plate with the Left Footwell Door Motor - V108-
and the Left Center Vent Motor - V110- is only installed on
♦ Retaining plate with Left Footwell Door Motor - V108- and Left
Center Vent Motor - V110- disassembling and assembling.
Refer to
V108 and Left Center Vent Motor V110 Disassembling and
Assembling”, page 447 .
wrong. Refer to
30 .
♦ On right-hand drive vehicles, the curved washer is not directly
driven via the actuator shaft; on these vehicles, the curved
washer is operated by two additional toothed gears. Refer to
⇒ “4.8 Left Center Vent Motor V110 , Removing and Instal‐
ling”, page 419 .
Removing
page 593 .

Note
♦ The following illustrations show the arrangement of the actua‐

tors and their retaining plates on the left side of the A/C unit
with the air channel leading to the left instrument panel vent
-A- removed for clarity.
♦ The air guide channel leading the left instrument panel vent
-A- is secured by an expanding clip or a screw -B- onto the
instrument panel crossmember -C-; the expanding clip or the
screw can only be removed when the outer instrument panel
shell is removed.
– Mark the connector -A- (to the Left Center Vent Motor - V110- ),
-B- (to the Defroster Door Motor - V107- ), -C- (to the Left
Footwell Door Motor - V108- ) and -D- (to the Rear Tempera‐
ture Door Motor - V137- ) (to prevent from using them).
– Disconnect the connectors -A- up to -D-.
– Loosen the wiring -E- from the mounting points on the retaining
plate -F- .
– Carefully disconnect the connector rods -A through D- from

the levers on each door.
Note
♦ The connecting rods -A through D- are clipped on to the levers;

unclip them carefully so that the lever does not get damaged.
– Remove bolts -E-.

– Remove the retaining plate -F- (together with the actuators,
the levers, the curved washers and the connector rods) from
the A/C unit.
Installing
following.
– Lightly coat the curved washer guides as well as the pins at
the door levers with grease (for example, Lubricant - G 000
150- . Refer to the Parts Catalog.
4. Actuators 439
– Make sure the levers, curved washers and retaining plate con‐
necting rods -A- are assembled correctly. Refer to
V108 and Left Center Vent Motor V110 Disassembling and
Assembling”, page 447 .
– When installing the retaining plate -A-, insert the retaining
plate pins -B- into the mounts -C- and the curved washer pins
-D and F- into the mounts -E- .
– When installing the retaining plate -A-, insert the pins on the
lever -G- into the guiding groove on the curved washers -F- .
Note
♦ When inserting, make sure that the curved washer stop -C- is
not installed in the area -F- (between both stops on the A/C
unit -D and E-).
♦ The curved washer -A- actuates the door for the left indirect
ventilation (driver side) via the lever -B-.
– Install the bolts -E-.

– Carefully connect the various connector rods -A through D- to
the lever of each door.

– Route the wiring harness -E- as shown and secure it at the

mounting points to the retaining plate -F- .
– Connect the connectors -A through D- according to the mark‐
ings.
– Check the wiring harness routing -E- so that it cannot come in
contact with any moving parts (for example, levers).
Note

wrong. Refer to

– Direct the airflow direction via the various settings on the Cli‐
to the different vents and check whether the air coming out at
the vents actually changes according to the setting.
4. Actuators 441
4.16 Right Retaining Plate with Right Foot‐

well Door Motor - V109- and Right Cen‐
ter Vent Motor - V111- , Removing and
Installing
Note
♦ The retaining plate with the Right Footwell Door Motor - V10-
and the Right Center Vent Motor - V111- is only installed on
V109- and Right Center Vent Motor - V111- , disassembling
and assembling. Refer to
⇒ “4.19 Right Retaining Plate with the Right Footwell Door
Motor V109 and Right Center Vent Motor V111 , Disassem‐
bling and Assembling”, page 448 .
Removing
– Loosen the air guide to the right instrument panel vent from
the instrument panel crossmember (there are different ver‐
sions). Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instrument
Panel Central Tube .
Note
The air guide from the air guide channel -B- is attached to the right
instrument panel vent with two bolts. To loosen, remove the bolt
which is installed at the bottom and is accessible.

– Mark the connector -A- (to the Right Center Vent Motor -
V111- ) and -B- ( Right Footwell Door Motor - V109- ) (to
prevent confusion).
– Disconnect the connector -A and B-.
– Remove the connector from the Evaporator Vent Temperature
Sensor - G263- . Refer to
– Loosen the wiring -D- from the mounting points on the retain‐
ing plate -J-.
– Carefully loosen the different connecting rods (from -E to H-)
from each door.
Note
♦ The connecting rods (from -E through H-) are clipped on to the

levers; unclip them carefully so that the lever does not get
damaged.

– Remove the retaining plate -J- (together with the control mo‐
tors, the lever, the curved washers and the connecting rods)
from the A/C unit.
Installing
following.
necting rods -J- are assembled correctly. Refer to
⇒ “4.19 Right Retaining Plate with the Right Footwell Door
Motor V109 and Right Center Vent Motor V111 , Disassem‐
bling and Assembling”, page 448 .
– When installing the retaining plate -J-, pay attention to the lev‐
er pin -K- and the curved washer guide -L- .
Note
Make sure the curved washer stop -M- is inserted between both
stops on the A/C unit -N and O- (the curved washer must be able
to move across the area marked with the arrow).

– Connect the connector -A and B- according to the markings.
– Mount the wiring harness -D- into the mounting points on the
retaining plate -J- .
– Install the wiring harness -D- so that it cannot come in contact
with any moving parts (for example, the actuating arm).
– Install the removed parts in the opposite order
4. Actuators 443

Note

wrong. Refer to

4.17 Left Retaining Plate with Footwell Door

Motor - V261- , Removing and Installing
The Footwell Door Motor - V261- Is Installed on Vehicles Equip‐
ped with the “Basis” A/C System.
Note
♦ The retaining plate with the Footwell Door Motor - V261- is only
installed on vehicles equipped with the “Basis” A/C system.
♦ Retaining plate with the Footwell Door Motor - V261- , disas‐
sembling and assembling. Refer to
Disassembling and Assembling”, page 449 .
wrong. Refer to
30 .
Removing


page 593 .
– Mark the connector -A- (to the Defroster Door Motor - V107- ),
-B- ( Footwell Door Motor - V261- ) and -C- ( Temperature
Regulator Door Motor - V68- ) (to prevent confusion).
– Disconnect the connectors -A through C-.
– Loosen the wiring harness -D- from the mounting points on the
mounting plate -E- .
– Carefully disconnect the connector rods -A through C- from

the levers on each door.
Note
♦ The connecting rods (-A through C-) are clipped on to the lev‐
ers; unclip them carefully so that the lever does not get dam‐
aged.
– Remove the bolts -D-.

– Remove the retaining plate -E- (together with the actuator
-F-, the lever, the curved washers and the connecting rods)
from the A/C unit.
Installing
following.
necting rods -A- are assembled correctly. Refer to
Disassembling and Assembling”, page 449 .
4. Actuators 445
– When installing the retaining plate -A-, correctly insert the pins
for the retaining plate -B- and the curved washer -C- into the
A/C unit mounts.
– Install the bolts -D-.

– Connect the various connector rods -A through C- from the
levers on each door.
– Connect the connector -A through C- according to the mark‐

ings.
– Mount the wiring harness -D- into the mounting points on the
retaining plate -E- .
– Check the wiring harness routing -D- so that it cannot come in
contact with any moving parts (for example, levers).
Note

wrong. Refer to


4.18 Left Retaining Plate with Left Footwell Door Motor - V108- and Left Center
Vent Motor - V110- Disassembling and Assembling
– Remove the retaining plate together with the Left Footwell
Door Motor - V108- and the Left Center Vent Motor - V110- .
Refer to
Note
♦ The retaining plate with the Left Footwell Door Motor - V108- and the Left Center Vent Motor - V110- is only
installed on vehicles equipped with the “Convenience” A/C system.
♦ Currently in this vehicle, all actuators are identical in construction. During the basic setting, the actuators
are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not
conform with the specification, the actuators will adapt incorrectly and the door control will be wrong. Refer
to ⇒ “1.10 Main Wiring Diagram for A/C System Actuators”, page 30 .
♦ The actuator shaft does not have a stop; therefore the shaft of these actuators can be inserted into the
curved washer in any position.
♦ On right-hand drive vehicles, the curved washer -item 10- ⇒ Item 10 (page 448) is not directly driven via
the actuator shaft; on these vehicles, the curved washer is operated by two additional toothed gears. Refer
to ⇒ “4.8 Left Center Vent Motor V110 , Removing and Installing”, page 419 .
♦ Depending on the production date, there are different versions of the levers and connecting elements on
the A/C unit. Refer to ⇒ , page 25 and the Parts Catalog.
4. Actuators 447
1 - Bolt
2 - Left Center Vent Motor -
V110-
3 - Retaining Plate
4 - Left Footwell Door Motor -
V108-
5 - Connecting Rod
❑ To the door for the left
center vent
6 - Connecting Rod
instrument panel vent
7 - Actuating Lever
8 - Connecting Rod
❑ To the left rear footwell
vent door
9 - Connecting Rod
front footwell
10 - Curved Washer
❑ On the Left Center Vent
Motor - V110-
11 - Actuating Lever
13 - Curved Washer
❑ On the Left Footwell
Door Motor - V108-
14 - Curved Washer Stop
❑ When reassembling,
pay attention to the correct position of the curved washer. Refer to ⇒ page 439 .
4.19 Right Retaining Plate with the Right Footwell Door Motor - V109- and Right
Center Vent Motor - V111- , Disassembling and Assembling
– Remove the retaining plate with the Right Footwell Door Motor
- V109- and Right Center Vent Motor - V111- . Refer to

Note
♦ The retaining plate with the Right Footwell Door Motor - V10- and the Right Center Vent Motor - V111- is
only installed on vehicles equipped with the “Convenience” A/C system.
conform the specification, the adjustment motors will adapt incorrectly and the door control will be wrong.
Refer to ⇒ “1.10 Main Wiring Diagram for A/C System Actuators”, page 30 (A/C system actuators block
diagram).
1 - Bolt
2 - Center Vent Adjustment
Motor - V111-
3 - Retaining Plate
4 - Right Footwell Door Motor -
V109-
5 - Connecting Rod
❑ To the right center vent
door
6 - Connecting Rod
❑ To the right dash panel
vent door
7 - Actuating Lever
8 - Connecting Rod
❑ To the right rear footwell
vent door
9 - Connecting Rod
❑ To the right front foot‐
well vent door
10 - Curved Washer
❑ On the Right Center
Vent Motor - V111-
13 - Curved Washer
❑ On the Right Footwell
Door Motor - V109-
4.20 Left Retaining Plate with Footwell Door Motor - V261- , Disassembling and
Assembling
– Remove the left retaining plate with the Footwell Door Motor -
V261- . Refer to
4. Actuators 449
Note
♦ The retaining plate with the Footwell Door Motor - V261- is only installed on vehicles equipped with the
“Basis” A/C system.
conform the specification, the adjustment motors will adapt incorrectly and the door control will be wrong.
Refer to ⇒ “1.10 Main Wiring Diagram for A/C System Actuators”, page 30 (A/C system actuators block
diagram).
1 - Bolt
2 - Footwell Door Motor - V261-
3 - Retaining Plate
4 - Connecting Rod
❑ To the doors for the left
and right instrument
panel vents
5 - Actuating Lever
6 - Curved Washer
❑ On the Footwell Door
Motor - V261-
7 - Actuating Lever
8 - Connecting Rod
❑ To the flaps for the rear
footwell vents
9 - Connecting Rod
❑ To the doors for the front
footwell vents

5 Front Heater and A/C Unit

⇒ “5.1 Overview - Attachments for Heater and A/C Unit and Air
Intake Housing”, page 451
⇒ “5.2 Overview - Air Distribution Housing Doors and Partitions”,
page 461
⇒ “5.3 Overview - Heater and A/C Unit Air Intake Housing”, page
464
⇒ “5.4 Overview - Evaporator Housing”, page 470
⇒ “5.5 Evaporator, Removing and Installing”, page 475
⇒ “5.6 Evaporator Housing, Removing and Installing”,
page 492
⇒ “5.7 Evaporator, Cleaning”, page 496
page 506
⇒ “5.10 A/C System Temperature Door Heat Output Activation,
Checking”, page 514
page 520
⇒ “5.12 Heater and A/C Unit Air Intake Housing, Removing and
⇒ “5.13 Left Radiator Housing with Temperature Doors, Remov‐
ing and Installing ”, page 541
⇒ “5.14 Right Radiator Housing, Removing and Installing (with
Temperature Doors)”, page 545
⇒ “5.15 Dust and Pollen Filter, Removing and Installing”,
page 556
⇒ “5.16 Fresh Air Blower V2 , Removing and Installing”,
page 557
⇒ “5.17 Fresh Air Blower Control Module J126 , Removing and
⇒ “5.18 Heater Core, Preparing for Removal”, page 562
⇒ “5.19 Heater Core, Removing and Installing”, page 567
⇒ “5.20 Condensation Water Drain, Removing and Installing”,
page 577
⇒ “5.21 Condensation Water Drain, Checking”, page 578
5.1 Overview - Attachments for Heater and

A/C Unit and Air Intake Housing
⇒ “5.1.1 Overview - Attachments for Heater and A/C Unit and Air
Intake Housing, Basis Version”, page 451
⇒ “5.1.2 Overview - Attachments for Heater and A/C Unit and Air
Intake Housing, Convenience Version”, page 456
5.1.1 Overview - Attachments for Heater and A/C Unit and Air Intake Housing,
“Basis” Version
– Remove the A/C unit. Refer to
page 520 .
5. Front Heater and A/C Unit 451

1 - Bolt
❑ 1 Nm
2 - Bracket for Coolant Pipes
3 - Evaporator Housing
❑ For disassembling and
assembling. Refer to
⇒ “5.4 Overview - Evap‐
orator Housing”,
page 470 .
sions based on the man‐
ufacturing date and on
the vehicle version. Re‐
fer to
orator Housing”,
page 470 and to the
Parts Catalog
❑ Evaporator housing, re‐
moving from A/C unit
⇒ “5.6 Evaporator Hous‐
ing, Removing and In‐
4 - Coolant Pipe
❑ Removing from the
heater core and instal‐
ling. Refer to
⇒ “5.19 Heater Core,
ling”, page 567 .
❑ For the coolant supply
from the engine
5 - Coolant Pipe
ling. Refer to ⇒ “5.19 Heater Core, Removing and Installing”, page 567 .
❑ For coolant return to engine
6 - O-Ring
❑ Always replace
❑ Coat lightly with coolant before installing. Refer to
7 - Clamp
❑ These clamps are installed by the manufacturer; they hold the coolant pipes in the heater core installed
by the manufacturer -item 8- ⇒ Item 8 (page 452) .
8 - Heat Exchanger
❑ This version is installed by the manufacturer.
❑ Removing and installing. Refer to ⇒ “5.19 Heater Core, Removing and Installing”, page 567 .
9 - Bracket for Coolant Pipes in Replacement Heater Core
❑ Included with the replacement heater core. Refer to the Parts Catalog
10 - Washer
11 - Bolt
❑ 2.5 Nm

12 - Replacement Heat Exchanger
❑ With the A/C unit installed, removing and installing. Refer to
❑ This version is a replacement part. Refer to the Parts Catalog
❑ Included with the replacement heater core -item 6- ⇒ Item 6 (page 452) , and -item 9-
⇒ Item 9 (page 452) through -item 12- ⇒ Item 12 (page 453) . Refer to the Parts Catalog
❑ Cover the heater core according to the version of the A/C system installed in the vehicle with foam seals.
Refer to ⇒ “5.19 Heater Core, Removing and Installing”, page 567 (Heater Core, Removing and Instal‐
ling)
13 - Honeycomb
❑ Designed for gasoline and diesel engines equipped with an optional parking heater that is activated like
an auxiliary heater (there is no Auxiliary Heater Heating Element - Z35- installed). Refer to
⇒ “5.9 Auxiliary Heater Heating Element Z35 , Removing and Installing”, page 511 .
❑ Cover the honeycomb with foam seals according to the version of the A/C system. Refer to
⇒ “5.9 Auxiliary Heater Heating Element Z35 , Removing and Installing”, page 511 ( Auxiliary Heater
Heating Element - Z35- , Removing and Installing).
14 - Auxiliary Heater Heating Element - Z35-
❑ On vehicles with a diesel engine (and also on vehicles which have a parking heater installed as an
optional equipment that also functions as an auxiliary heater) and on certain gasoline engines. Refer to
❑ Checking function. Refer to ⇒ “5.8 Auxiliary Heater Heating Element Z35 , Checking”, page 506 .
❑ Cover the Auxiliary Heater Heating Element - Z35- with foam seals according to the version of the A/C
system. Refer to ⇒ “5.9 Auxiliary Heater Heating Element Z35 , Removing and Installing”, page 511
( Auxiliary Heater Heating Element - Z35- , Removing and Installing).
Note
In MY 2009, as a running change, a

new version of the Auxiliary Heater
Heating Element - Z35- is being in‐
stalled (the heating elements are a
bit more narrow); be sure to use the
correct version and note the alloca‐
15 - Bracket
16 - Left Radiator Housing (with the Temperature Doors)
❑ The activation of the temperature doors and with it the left radiator housing is different between vehicles
equipped with “Convenience” and “Basis” A/C systems. On the “Basis” A/C system, both temperature
doors (for the left instrument panel vents and the left footwell vents) are controlled by the same shaft.
Refer to ⇒ “5.2 Overview - Air Distribution Housing Doors and Partitions”, page 461 and the Parts Cat‐
alog.
❑ Different versions (with one or two lower attaching points. Refer to
⇒ “5.13 Left Radiator Housing with Temperature Doors, Removing and Installing ”, page 541 and the
Parts Catalog)
⇒ “5.13 Left Radiator Housing with Temperature Doors, Removing and Installing ”, page 541 .
❑ Lightly coat the curved washer guides, the shaft bearings, the toothed segments as well as to the pins
on the door levers with lubricant (for example, with Lubricant - G 000 150- . Refer to Parts Catalog)

18 - Left Retaining Plate with the Footwell Door Motor - V261-

❑ With curved washer, actuating arms and connecting rods
❑ Footwell Door Motor - V261- , removing and installing. Refer to
page 414 .
❑ Left retaining plate with the Footwell Door Motor - V261- , removing and installing. Refer to
⇒ “4.17 Left Retaining Plate with Footwell Door Motor V261 , Removing and Installing”, page 444 .
❑ Retaining plate with the Footwell Door Motor - V261- , disassembling and assembling. Refer to
⇒ “4.20 Left Retaining Plate with Footwell Door Motor V261 , Disassembling and Assembling”,
page 449 .
❑ The actuation of the temperature doors differs between vehicles equipped with the “Basis” A/C system
and the “Convenience” A/C system On the “Basis” A/C system, the doors (for the left and right instrument
panel vents and the left and right front footwells) are connected to each other by connecting rods in the
air distribution housing. The doors for the left and right rear footwell vents are connected to each other
by a shaft. These doors are all actuated by the Footwell Door Motor - V261- . Refer to
⇒ “5.2 Overview - Air Distribution Housing Doors and Partitions”, page 461 .
❑ Lightly coat the curved washer guides, the shaft bearings as well as to the pins on the door levers with
lubricant (for example, with Lubricant - G 000 150- . Refer to Parts Catalog).
19 - Toothed Segment
20 - Retaining Plate with the Temperature Regulator Door Motor - V68-
❑ Removing and installing the retaining plate with the Temperature Regulator Door Motor - V68- ; removing
the actuator from the retaining plate. Refer to
❑ The actuation of the left and right temperature doors differs between vehicles equipped with the “Basis”
A/C system and the “Convenience” A/C system On the “Basis” A/C system, the shaft for the left tem‐
perature doors are actuated by the Temperature Regulator Door Motor - V68- via a toothed segment
-item 19- ⇒ Item 19 (page 454) . The right temperature door is also actuated by the Temperature Reg‐
ulator Door Motor - V68- via the connecting rod -item 23- ⇒ Item 23 (page 454) which engaged in this
toothed segment. Refer to ⇒ “5.2 Overview - Air Distribution Housing Doors and Partitions”, page 461 .
❑ Lightly coat the shaft bearings, the toothed segments as well as to the pins on the door levers with
Lubricant - G 000 150- . Refer to Parts Catalog).
21 - Connecting Rod to the Defroster Door
22 - Actuating Arm to Defroster Door Motor - V107-
23 - Connecting Rod for the Temperature Doors
Note
There are different connecting rods

-A- (different version of the connect‐
ing element to the toothed segment
and to the right temperature doors),
depending on the date of produc‐
tion. Refer to ⇒ , page 25 and the
Parts Catalog.
24 - Footwell Vent Temperature Sensor - G192-

❑ The Footwell Vent Temperature Sensor - G192- is installed in the left footwell vent.
25 - Center Vent Temperature Sensor - G191-
❑ The Center Vent Temperature Sensor - G191- is installed in the air guide channel to the instrument panel
vent.
26 - Wiring Harness, “Basis” Version

❑ Mark the allocation before disconnecting the connectors (danger of interchange, connectors of same
shape for different motors and temperature sensor).
❑ Secure wiring harness to mounting points provided on housing (using cable ties -item 27-
⇒ Item 27 (page 455) , or on mounts) so that it does not come into contact with moving components.
27 - Cable Ties
28 - A/C System Air Distribution Housing, “Basis” Version
❑ Do not disassemble further
❑ Different versions between vehicles equipped with the “Convenience” A/C system and the “Basis” A/C
system. Refer to the Parts Catalog
on the door levers with lubricant (for example, with Lubricant - G 000 150- . Refer to Parts Catalog).
Note
On the “Basis” version, the various

doors (for example, for the left and
right vents) are connected to each
other by connecting rods; they are
actuated by only one actuator. Refer
to
⇒ “5.2 Overview - Air Distribution
Housing Doors and Partitions”,
page 461 .
29 - Right Radiator Housing (with the Temperature Doors)

❑ The activation of the temperature doors and with it the right radiator housing is different between vehicles
equipped with “Convenience” and “Basis” A/C systems. On the “Basis” A/C system, both temperature
doors (for the right instrument panel vents and the right footwell vents) are operated together via the
shaft. Refer to ⇒ “5.2 Overview - Air Distribution Housing Doors and Partitions”, page 461 and the Parts
Catalog.
Parts Catalog).
⇒ “5.14 Right Radiator Housing, Removing and Installing (with Temperature Doors)”, page 545 .
⇒ “4.4 Center Vent Adjustment Motor V102 , Removing and Installing”, page 410 .

5.1.2 Overview - Attachments for Heater and A/C Unit and Air Intake Housing,
“Convenience” Version
page 520 .
1 - Bolt
❑ 1 Nm
2 - Bracket for Coolant Pipes
3 - Evaporator Housing
❑ For disassembling and
assembling. Refer to
orator Housing”,
page 470 .
sions based on the man‐
ufacturing date and on
the vehicle version. Re‐
fer to
orator Housing”,
page 470 and to the
Parts Catalog.
❑ Evaporator housing, re‐
moving from A/C unit
⇒ “5.6 Evaporator Hous‐
ing, Removing and In‐
4 - Coolant Pipe
ling. Refer to
⇒ “5.19 Heater Core,
ling”, page 567 .
❑ For the coolant supply
from the engine
5 - Coolant Pipe
ling. Refer to ⇒ “5.19 Heater Core, Removing and Installing”, page 567 .
❑ For coolant return to engine
6 - O-Ring
❑ Replacing
❑ Coat lightly with coolant before installing. Refer to
7 - Clamp
❑ These clamps are installed by the manufacturer; they hold the coolant pipes in the heater core installed
by the manufacturer -item 8- ⇒ Item 8 (page 452) .
8 - Heat Exchanger
9 - Bracket for Coolant Pipes in Replacement Heater Core
❑ Included with the replacement heater core. Refer to the Parts Catalog.

10 - Washer
11 - Bolt
❑ 2.5 Nm
12 - Replacement Heat Exchanger
❑ This version is a replacement part. Refer to the Parts Catalog.
❑ Included with the replacement heater core -item 6- ⇒ Item 6 (page 456) , and -item 9-
⇒ Item 9 (page 456) through -item 12- ⇒ Item 12 (page 457) . Refer to the Parts Catalog.
❑ Cover the heater core according to the version of the A/C system installed in the vehicle with foam seals.
Refer to ⇒ “5.19 Heater Core, Removing and Installing”, page 567 (Heater Core, Removing and Instal‐
ling)
13 - Honeycomb
❑ Designed for vehicles with a gasoline engine without an Auxiliary Heater Heating Element - Z35- and for
vehicles with a diesel engine equipped with an optional parking heater that also serves as an auxiliary
heater (there is no Auxiliary Heater Heating Element - Z35- installed). Refer to
❑ Cover the honeycomb with foam seals according to the version of the A/C system. Refer to
⇒ “5.9 Auxiliary Heater Heating Element Z35 , Removing and Installing”, page 511 ( Auxiliary Heater
Heating Element - Z35- , Removing and Installing).
14 - Auxiliary Heater Heating Element - Z35-
❑ On vehicles with a diesel engine (and also on vehicles which have a parking heater installed as an
optional equipment that also functions as an auxiliary heater) and on certain gasoline engines. Refer to
❑ Checking function. Refer to ⇒ “5.8 Auxiliary Heater Heating Element Z35 , Checking”, page 506 .
❑ Cover the Auxiliary Heater Heating Element - Z35- with foam seals according to the version of the A/C
system. Refer to ⇒ “5.9 Auxiliary Heater Heating Element Z35 , Removing and Installing”, page 511
( Auxiliary Heater Heating Element - Z35- , Removing and Installing).
Note

15 - Bracket
16 - Retaining Plate with the Left Temperature Door Motor - V158-
❑ Removing and installing, disassembling and assembling. Refer to
⇒ “4.11 Left Temperature Door Motor V158 , Removing and Installing”, page 426 .
18 - Left Retaining Plate with the Left Footwell Door Motor - V108- and the Left Center Vent Motor - V110-
❑ With curved washers, actuating arms and connecting rods.

❑ Left Footwell Door Motor - V108- , removing and installing. Refer to

page 414 .
❑ Left Center Vent Motor - V110- , removing and installing. Refer to
❑ Retaining plate with Left Footwell Door Motor - V108- and Left Center Vent Motor - V110- , disassembling
and assembling. Refer to
⇒ “4.18 Left Retaining Plate with Left Footwell Door Motor V108 and Left Center Vent Motor V110 Dis‐
assembling and Assembling”, page 447 .
19 - Left Radiator Housing (with the Temperature Doors)
❑ The activation of the temperature doors and with it the left radiator housing is different between vehicles
equipped with “Convenience” and “Basis” A/C systems. On the “Convenience” A/C system, the temper‐
ature doors (for the left front and the rear) are operated by various actuators. Refer to
⇒ “5.2 Overview - Air Distribution Housing Doors and Partitions”, page 461 and the Parts Catalog.
Parts Catalog).
⇒ “5.13 Left Radiator Housing with Temperature Doors, Removing and Installing ”, page 541 .
20 - Toothed Segment
21 - Retaining Plate with the Rear Temperature Door Motor - V137-
❑ Removing and installing the retaining plate with the Rear Temperature Door Motor - V137- ; removing
the actuator from the retaining plate. Refer to
❑ The actuation of the left and right temperature doors differs between vehicles equipped with the “Basis”
A/C system and the “Convenience” A/C system On the “Convenience” A/C system, the shaft for the left
rear temperature doors are actuated by the Rear Temperature Door Motor - V137- via a toothed segment
-item 20- ⇒ Item 20 (page 458) . The right rear temperature door is also actuated by the Rear Temperature
Door Motor - V137- via the connecting rod -item 24- ⇒ Item 24 (page 458) which engaged in this toothed
segment. Refer to ⇒ “5.2 Overview - Air Distribution Housing Doors and Partitions”, page 461 .
❑ Lightly coat the shaft bearings, the toothed segments as well as to the pins on the door levers with
Lubricant - G 000 150- . Refer to Parts Catalog).
22 - Connecting Rod to the Defroster Door
23 - Actuating Arm to Defroster Door Motor - V107-
24 - Connector Rod for the Rear Temperature Doors
25 - Air Distribution Housing, “Convenience” A/C System
❑ Do not disassemble further
❑ Different versions between vehicles equipped with the “Convenience” A/C system and the “Basis” A/C
system. Refer to the Parts Catalog

Note
♦ On the “Convenience” A/C sys‐

tem, there is a separator wall in‐
stalled (to partition the left and
right as well as front and rear). In
addition, each left and right vent
for indirect ventilation and the air
guide to the rear left and right
vent in the rear center console
has a door installed. The differ‐
ent doors (for example, for the
instrument panel vents and the
left and right footwell vents) are
each actuated by one actuator.
The doors for the center instru‐
ment panel vents and the air
guide to the vents in the left and
right rear center console are con‐
nected to each other by a con‐
necting rod and are operated by
the Left Center Vent Motor -
V110- and the Right Center Vent
Motor - V111- .
♦ From 08/2007 as a running
change, an A/C unit with an air
distribution housing with opti‐
mized air flow will be introduced
(versions “1” and “2”). Refer to
⇒ , page 25 .
26 - Left Footwell Vent Temperature Sensor - G261-

❑ The Left Footwell Vent Temperature Sensor - G261- is installed in the left footwell vent.
27 - A/C System Wiring Harness, “Convenience” Version
❑ Mark the allocation before disconnecting the connectors (danger of interchange, connectors of same
shape for different motors and temperature sensor).
❑ Attach the wiring harness to the attaching point on the housing or attach it to the mounts with cable ties
so that it cannot come into contact with moving parts -item 29- ⇒ Item 29 (page 459) .
28 - Right Footwell Vent Temperature Sensor - G262-
⇒ “9.8 Right Footwell Vent Temperature Sensor G262 , Removing and Installing”, page 661 .
❑ The Right Footwell Vent Temperature Sensor - G262- is installed in the right footwell vent.
29 - Cable Ties
30 - Right Radiator Housing (with the Temperature Doors)
❑ The activation of the temperature doors and with it the right radiator housing is different between vehicles
equipped with “Convenience” and “Basis” A/C systems. On the “Convenience” A/C system, the temper‐
ature doors (for the right front and the right rear) are actuated by various actuators. Refer to
⇒ “5.2 Overview - Air Distribution Housing Doors and Partitions”, page 461 and the Parts Catalog
Parts Catalog).
⇒ “5.14 Right Radiator Housing, Removing and Installing (with Temperature Doors)”, page 545 .

31 - Right Retaining Plate with the Right Footwell Door Motor - V109- and the Right Center Vent Motor - V111-
❑ With curved washers, actuating arms and connecting rods.
❑ Right Footwell Door Motor - V109- , removing and installing. Refer to
⇒ “4.7 Right Footwell Door Motor V109 , Removing and Installing”, page 417 .
❑ Right Center Vent Motor - V111- , removing and installing. Refer to
⇒ “4.9 Right Center Vent Motor V111 , Removing and Installing”, page 422 .
disassembling and assembling. Refer to
⇒ “4.19 Right Retaining Plate with the Right Footwell Door Motor V109 and Right Center Vent Motor
V111 , Disassembling and Assembling”, page 448 .
32 - Retaining Plate with the Right Temperature Door Motor - V159-
❑ Removing and installing, disassembling and assembling. Refer to
⇒ “4.12 Right Temperature Door Motor V159 , Removing and Installing”, page 429 .

5.2 Overview - Air Distribution Housing

Doors and Partitions
⇒ “5.2.1 Overview - Air Distribution Housing Doors and Partitions,
Basis Version”, page 461
⇒ “5.2.2 Overview - Air Distribution Housing Doors and Partitions,
Convenience Version”, page 462
5.2.1 Overview - Air Distribution Housing Doors and Partitions, “Basis” Version
Note
♦ The air distribution housing is not disassembled. Refer to the Parts Catalog.
♦ There are different versions of the air distribution housing depending on which A/C system is installed in the
vehicle, “Convenience” or “Basis”. Refer to the Parts Catalog.
1 - Air Distribution Housing

“Basis” A/C System
❑ Complete, do not disas‐
semble
2 - Left Housing Half
3 - Right Housing Half
4 - Lever
5 - Door in the “Defrost” Vent
6 - Shaft
7 - Connecting Rod
8 - Door in the Vent Leading to
the Center Instrument Panel
Vents
9 - Vent Door Leading to the
Left Instrument Panel Vent
10 - Connecting Rod
Right Instrument Panel Vent
Front Left Footwell Vent
13 - Connecting Rod
Front Right Footwell Vent
15 - Lever
16 - Lever
17 - Lever
Rear Left Footwell Vent
19 - Shaft
20 - Vent Door Leading to the Rear Right Footwell Vent

5.2.2 Overview - Air Distribution Housing Doors and Partitions, “Convenience”

Version
Note
♦ The air distribution housing is not disassembled. Refer to the Parts Catalog.
♦ There are different versions of the air distribution housing depending on which A/C system is installed in the
vehicle, “Convenience” or “Basis”. Refer to the Parts Catalog.
1 - “Convenience” Air Distribu‐

tion Housing
❑ Complete, do not disas‐
semble.
Note
From 08/2007 as a running change,

an A/C unit with an air distribution
housing with optimized air flow will
be introduced (versions “1” and “2”).
Refer to ⇒ , page 25 .

2 - Left Housing Half

3 - Right Housing Half
4 - Upper Housing for Vents
5 - Lever
6 - Lever
7 - Door for Left Indirect Venti‐
lation Vent
8 - Door in the “Defrost” Vent
9 - Door for Right Indirect Ven‐
tilation Vent
10 - Lever
11 - Lever
Left Instrument Panel Vent
Front Left Footwell Vent
14 - Lever
15 - Lever
16 - Vent Door Leading to the Rear Left Footwell Vent
17 - Lever
18 - Vent Door Leading to the Right Instrument Panel Vent
19 - Vent Door Leading to the Front Right Footwell Vent
20 - Lever
21 - Lever
22 - Vent Door Leading to the Rear Right Footwell Vent
23 - Shaft
24 - Shaft
25 - Connecting Rod
26 - Connecting Rod
27 - Connecting Rod
28 - Connecting rod
29 - Separator Wall
❑ If the air flow to the front and rear vents is separated from each other; the requirement for different front
and rear air temperatures (depends on the setting of each temperature door).
30 - Grommet
❑ Glued in the separating wall -item 29- ⇒ Item 29 (page 463) .
31 - Grommet
❑ Glued in the separating wall -item 29- ⇒ Item 29 (page 463) .
32 - Door in the Vent Leading to the Left Center Instrument Panel Vents
33 - Door in the Vent Leading to the Right Center Instrument Panel Vents
34 - Separator Wall
❑ If the air flow to the left and right vents is separated from each other; the requirement for different front
and rear air temperatures (depends on the setting of each temperature door).

35 - Vent Door Leading to the Rear Right Center Console Vent

36 - Vent Door Leading to the Rear Right Center Console Vent
5.3 Overview - Heater and A/C Unit Air Intake Housing
Note
♦ From 01/2008, A/C units which have an additional connection for the glove compartment cooling are being
installed as a running change. On vehicles without glove compartment cooling, this connection is sealed
with a plug. Refer to ⇒ “6.14 Glove Compartment Cooling Connection on Air Intake Housing”, page 616 .
Therefore, ensure the correct allocation of the right radiator housing and air intake housing. Refer to the
Parts Catalog.
♦ The following illustration shows the upper section of the air intake housing without a connection for the glove
compartment cooling.
♦ From MY 2012 (introduction depending on the vehicle version), a revised Fresh Air Blower Control Module
- J126- (and Fresh Air Blower - V2- , Climatronic Control Module - J255- A/C display and control head,
evaporator, expansion valves, actuators and A/C units are being used. Refer to the Parts Catalog. Use the
Vehicle Diagnostic Tester in the "Guided Fault Finding" function. Read all the information regarding these
components. Refer to ⇒ “4.1.1 Overview - Front Actuators, Basis Version”, page 388 .


1 - Foam Seal
❑ For sealing the fresh air
intake duct to the vehi‐
cle; bonded to the air in‐
take duct
2 - Air Intake Duct
❑ With back pressure -,
fresh air- and air recir‐
culation door
❑ Do not disassemble fur‐
ther
❑ Removing and installing
from the air intake hous‐
ing. Refer to
⇒ “6.9 Air Intake Duct,
ling”, page 604 .
3 - Curved Washer
❑ Actuated by two levers,
the back pressure- and
fresh air door
❑ Lightly coat the curved
washer guides as well
as the pins at the door
levers with lubricant (for
example, Lubricant - G
000 150- . Refer to the
Parts Catalog.
ling. Refer to
⇒ “4.3 Airflow Door Mo‐
tor V71 , Removing and
5 - Bolt
7 - Latch
❑ To lock the air intake housing to the A/C
8 - Upper Part of the Air Intake Housing
❑ Do not dismantle
Note

Original part, the upper and low‐
er sections are attached to each
other by screws or the upper sec‐
tion is welded to the lower sec‐
tion.

♦ Current, as a replacement part,

the air intake housing is deliv‐
ered as a single part. Assemble
both sections together and use
the screws -item 5-
⇒ Item 5 (page 465) to connect
the two sections together
-item 17- ⇒ Item 17 (page 470) .
❑ If one of the retaining tabs -item 16- ⇒ Item 16 (page 470) has broken off or if one of the welded points
no longer holds, both housing parts can be bolted together with screws -item 5- ⇒ Item 5 (page 465) .
❑ There are different versions (with and without a connection for glove compartment cooling), this illustra‐
tion shows the version without the connection. Refer to the Parts Catalog.
9 - Lower Part of the Air Intake Housing
❑ Do not dismantle
Note

Original part, the upper and low‐
er sections are attached to each
other by screws or the upper sec‐
tion is welded to the lower sec‐
tion.
♦ Current, as a replacement part,
the air intake housing is deliv‐
ered as a single part. Assemble
both sections together and use
the screws -item 5-
⇒ Item 5 (page 465) to connect
the two sections together
-item 17- ⇒ Item 17 (page 470) .
❑ If one of the retaining tabs -item 16- ⇒ Item 16 (page 470) has broken off or if one of the welded points
no longer holds, both housing parts can be bolted together with screws -item 5- ⇒ Item 5 (page 465) .
From MY 2012, a new version is being used. Read all the information regarding this component. Refer to
⇒ “4.1.1 Overview - Front Actuators, Basis Version”, page 388 .

Note
♦ From 08/2007 as a running

change, the Fresh Air Blower -
V2- is installed with an additional
foam jacket on the housing (as
noise insulation). Refer to

♦ As a running change from MY

2009, a Fresh Air Blower - V2-
with a revised housing with an
optimized motor and motor
mount, is being installed. The
new Fresh Air Blower - V2- does
not have the foam jacket on the
housing because the larger mo‐
tor mount. However, revised in‐
sulation is installed. Refer to
-item 14- ⇒ Item 14 (page 469)
page 506 .
page 506 .
ponent locations.
fer to
page 506 .

♦ From MY 2012 (depending on

- J126- , Fresh Air Blower - V2- ,
head and A/C units are gradually
being used. Be sure to use the
correct version and allocation.
Refer to the Parts Catalog. Use
tion.
nent. Refer to

Note

page 506 .
page 506 .


Blower - V2- for these vehicles
ing" function. Refer to ⇒ Wiring
diagrams, Troubleshooting &
fer to
page 506 .
nent. Refer to

13 - Cover for Dust and Pollen Filter
14 - Insulation
❑ Different versions, depending on the version of the Fresh Air Blower - V2- . Refer to -item 10-
⇒ Item 10 (page 466) and the Parts Catalog

15 - Screw Clips
16 - Catches on the Upper Part of the Air Intake Housing
17 - Attaching Point
5.4 Overview - Evaporator Housing

page 520 .
– Remove the evaporator housing from the A/C unit. Refer to
page 492 and to
⇒ “5.1.1 Overview - Attachments for Heater and A/C Unit and
Air Intake Housing, Basis Version”, page 451 (“Basis” A/C
Unit, Disassembling and Assembling) or to
⇒ “5.1.2 Overview - Attachments for Heater and A/C Unit and
Air Intake Housing, Convenience Version”, page 456 (“Con‐
venience” A/C Unit, Disassembling and Assembling).

Note
♦ From the start of production up to the changeover from MY 2012, evaporators approximately 40 mm wide
(block depth) were installed (A/C unit part number “8K_ 820 005”). From MY 2012 as a running change, an
evaporator with an approximately 50 mm width (block depth) is being installed depending on the vehicle
version (A/C unit part number “8T_ 820 005”). Pay attention to the correct allocation of the expansion valve
to the evaporator (there are different versions). Refer to the Parts Catalog.
♦ For refrigerant R1234yf, there must not be any separable connection points in the refrigerant circuit in the
vehicle interior (for example, separating points on the refrigerant lines to the evaporator). Therefore the A/
C unit (with the evaporator housing) must always be removed on these vehicles and the evaporator with the
refrigerant lines must be completely replaced. Refer to the Parts Catalog and
1 - Bolt
2 - Expansion Valve
❑ Already removed when
the A/C unit was re‐
moved. Refer to
Unit, Removing and In‐
stalling”, page 520 (A/C
unit, removing)
❑ Refrigerant lines with in‐
ner heat exchanger
from the expansion
valve, disconnecting
and reconnecting. Refer
to
Exchanger, Removing
and Installing”,
page 227 .
ling. Refer to
⇒ “2.15 Expansion
Valve, Removing and
sions. Refer to
⇒ “2.15 Expansion
Valve, Removing and
3 - O-Ring
❑ Replacing. Refer to
⇒ “3.13 Refrigerant Cir‐
cuit Seals”, page 109
❑ For allocation. Refer to
the Parts Catalog.
4 - O-Ring
❑ Replacing. Refer to ⇒ “3.13 Refrigerant Circuit Seals”, page 109
❑ For allocation. Refer to the Parts Catalog.
5 - Mounting Plate
6 - Rubber Grommet

❑ The installed supporting ring was already removed when the A/C unit was removed; pay attention to
correct installation position. Refer to ⇒ “5.11 Heater and A/C Unit, Removing and Installing”, page 520
(Removing the A/C unit)
7 - Evaporator Housing Upper Section
❑ There are different versions. Refer to -item 8- ⇒ Item 8 (page 472) and the Parts Catalog.
8 - Evaporator
❑ Removing with the A/C unit installed. Refer to ⇒ “5.5 Evaporator, Removing and Installing”, page 475 .
❑ There are different versions. Refer to ⇒ “2.15 Expansion Valve, Removing and Installing”, page 242 and
the Parts Catalog.
Note

“8K_ 820 005”). These evapora‐
tors can be replaced with the A/
C unit still installed. Refer to
Parts Catalog.
♦ From MY 2012 as a running-
change, evaporators approxi‐
mately 50 mm wide (block depth)
are being installed (A/C unit with
the part number “8T_ 820 005”)
depending on the vehicle ver‐
sion. These evaporators can be
replaced only together with the
evaporator housing (with the A/C
unit removed). Refer to Parts
Catalog.
♦ Pay attention to the correct allo‐
cation of the expansion valve to
the evaporator (there are differ‐
ent versions). Refer to the Parts
Catalog.
page 520 .
9 - Evaporator Cover
❑ Pay attention to the correct mounting on the evaporator. Refer to
⇒ “5.5 Evaporator, Removing and Installing”, page 475 (Evaporator with the A/C unit installed, removing
and installing).

10 - Evaporator Cover
and installing).
11 - Cover for Refrigerant Lines
❑ Pay attention to the correct mounting on the evaporator housing. Refer to
and installing).
12 - Screw
13 - Bracket
14 - Bracket for A/C Unit on the Center Tunnel
❑ The bracket equalizes the position tolerance of the A/C unit to the center tunnel.
15 - Evaporator Housing Lower Section
❑ There are different versions. Refer to -item 8- ⇒ Item 8 (page 472) and the Parts Catalog.
17 - Clamp
18 - Refrigerant Pipe to the Replacement Evaporator
❑ Included in the replacement evaporator kit. Refer to the Parts Catalog.
❑ Available only for evaporators approximately 40 mm wide (block depth). Refer to -item 8-
⇒ Item 8 (page 472) and Parts Catalog.
19 - Refrigerant Pipe to the Replacement Evaporator
❑ Available only for evaporators approximately 40 mm wide (block depth). Refer to -item 8-
⇒ Item 8 (page 472) and Parts Catalog.
20 - O-Ring for the Connection on the Replacement Evaporator
❑ Installing. Refer to ⇒ “3.13 Refrigerant Circuit Seals”, page 109 .
Note
Available only for evaporators ap‐

proximately 40 mm wide (block
depth). Refer to -item 8-
⇒ Item 8 (page 472) and Parts Cat‐
alog.
21 - O-Ring for the Connection on the Replacement Evaporator

❑ Installing. Refer to ⇒ “3.13 Refrigerant Circuit Seals”, page 109 .
Note

alog.
22 - Bracket for the Refrigerant Pipes in the Connection on the Replacement Evaporator
❑ Installing. Refer to ⇒ “5.5 Evaporator, Removing and Installing”, page 475 (Evaporator with the A/C
installed, removing and installing)

Note

alog.
23 - Bolt
❑ 5 Nm.
❑ Installing. Refer to ⇒ “5.5 Evaporator, Removing and Installing”, page 475 (Evaporator with the A/C
installed, removing and installing)
24 - Replacement Evaporator Cover
and installing).
❑ Depending on the version, prior to installation, the cover must be reworked in the area where refrigerant
pipes connect to the evaporator. Refer to ⇒ “5.5 Evaporator, Removing and Installing”, page 475 .
Note

alog.
25 - Replacement Evaporator Cover

and installing).
Note

alog.
26 - Replacement Evaporator
❑ This version is a replacement part. Refer to the Parts Catalog.
❑ The replacement evaporator includes the listed components (-item 18- ⇒ Item 18 (page 473) through
-item 27- ⇒ Item 27 (page 474) ). Refer to the Parts Catalog.
❑ Installing with the A/C unit installed. Refer to ⇒ “5.5 Evaporator, Removing and Installing”, page 475 .
Note

alog.
27 - Separator Wall

❑ After installing the replacement evaporator, this separating wall is installed in the lower section of evap‐
orator housing and sealed. Refer to ⇒ “5.5 Evaporator, Removing and Installing”, page 475 (Evaporator
with A/C unit installed, removing and installing).
Note

alog.
5.5 Evaporator, Removing and Installing

♦ A/C Pipe Pliers - T40147-
♦ Strong carpet knife with a point; the blade must be secure and
the handle must be strong
Only possible on an A/C unit with part number 8K_ 820 xxx (see
information below)

Note
♦ There is refrigerant oil in the removed evaporator that must be

re-delivered to the refrigerant circuit (with new evaporator).
frigerant Circuit Components, Replacing or ⇒ A/C Systems
♦ Revised A/C units and evaporators are gradually being instal‐
led from MY 2012 (use depends on the vehicle version) (A/C
unit part number “8T_ 820 005”). It is not possible to replace
the evaporator on this A/C unit when the A/C unit is installed.
Before working on the evaporator, check if it is available as an
installation kit either without the evaporator housing or only
together with the housing. Refer to the Parts Catalog. If the
evaporator is available only together with the housing, then it
is necessary to remove the A/C unit and replace the evapora‐
tor with the evaporator housing. Refer to
page 492 .
♦ For refrigerant R1234yf, there must not be any separable con‐
nection points in the refrigerant circuit in the vehicle interior
(for example, separating points on the refrigerant lines to the
evaporator). Therefore the A/C unit (with the evaporator hous‐
ing) must always be removed on these vehicles and the evap‐
orator with the refrigerant lines must be completely replaced.
page 520 .
♦ Evaporators with a block depth -A- of approximately 40 mm
(A/C unit with the part number “8K_ 820 005”) are being in‐
stalled from start of production through the changeover from
MY 2012. These evaporators can be replaced with the A/C unit
still installed. From MY 2012, evaporators with a block depth
-A- of approximately 50 mm are being installed (A/C unit with
the part number “8T_ 820 005”) as a running change depend‐
ing on the vehicle version. These evaporators can only be
replaced when removing the A/C unit together with the evap‐
orator housing. Refer to the Parts Catalog.
Parts Catalog.
♦ Pay attention to the correct allocation of the expansion valve
Parts Catalog.


Note
♦ The refrigerant pipe -D- on the Audi Q5 hybrid is wrapped with

insulation (butyl or tar tape) to reduce noise. The insulating
tape shields the A/C compressor noise, which seems to be
louder when the engine is idling.
♦ If the evaporator is going to be replaced on an Audi Q5 Hybrid,
then wrap the refrigerant pipe -C- on the replacement evapo‐
rator with insulating tape. Approximately 30 cm of 5 cm wide
insulating tape (commercially available butyl or tar tape) -B-
with a 3 mm strength will be needed.
♦ This insulating tape -B- is used when handling refrigerant as
commercially available butyl or tar tape. It is available in re‐
frigerant materials stores and comes in rolls approximately 10
m long.
Removing
– Move the driver and passenger seats as far back as possible.
Note


General Warnings .

WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.

ings .
ing .

DANGER!
Note

sequence:
♦ Body
Group 93)


– Visually inspect the high voltage components -D- (here the
cover -B-. Refer to
Warnings .
Voltage Cables .
Note


Note

stalling .

Note
Disconnect the Battery - A- ground connection so that it cannot

short circuit when the jumper cable post -C- is removed.
– Remove the jumper cable post cover -C- .

All Vehicles

– If equipped and necessary, remove the tower brace -B- (for

example, on the Audi A5 Coupe; not necessary, for example,
on the Audi Q5). Refer to ⇒ Suspension, Wheels, Steering;
Rep. Gr. 40 ; Suspension Strut and Upper Control Arm; Tower
Brace, Removing and Installing
– For vehicles with a 6-Cylinder diesel engine, remove the ple‐
num chamber front wall -A-. Refer to ⇒ Body Exterior; Rep.
Gr. 50 ; Bulkhead; Overview - Bulkhead .
Note


– Remove the expansion valve. Refer to
⇒ “2.15 Expansion Valve, Removing and Installing”,
page 242 .
Note
Seal open pipe connections.
– Remove the expansion valve retaining plate -A- from the re‐
frigerant lines -B and C-.
page 593 .

– Remove the bolt -A-.

– Loosen the retainer -C- and remove the cover for the refriger‐
ant lines leading to the evaporator -B- .
– Disconnect both refrigerant lines to the evaporator -A and B-

at the locations marked with -E- using the A/C Pipe Pliers -
T40147- .
Note
♦ This illustration show the refrigerant pipes -C and D- to the

evaporator not wrapped with butyl or tar tape.
♦ The refrigerant pipe -D- on the Audi Q5 hybrid is wrapped with
insulation (butyl or tar tape) to reduce noise. The butyl or tar
tape shields the A/C compressor noise, which seems to be
louder when the engine is idling.
– Loosen the disconnected refrigerant lines -C and D- from the

grommet -F- and remove both refrigerant lines.
– Bend the part of the refrigerant line -A- (which is already on
the evaporator) to the right (to the evaporator) so that it does
not interfere when removing the evaporator.
– Cut the housing wall -A- (on the right side of the A/C unit) using
a sharp knife (for example, a strong carpet knife with a point;
the blade must be secure and the handle must be strong.)
along the marked cutting line from the A/C unit.
– Remove the evaporator -B- in the direction of the -arrow- from
the A/C unit.
Installing
Read the information before installing the evaporator. Refer to ⇒
Refrigerant R134a Servicing; Rep. Gr. 87 ; Refrigerant Circuit
Components, Replacing or ⇒ A/C Systems with Refrigerant
R1234yf - General Information; Rep. Gr. 87 ; Refrigerant Circuit;
Components, Replacing .
following.

– Check the A/C unit via the evaporator installation shaft for dirt;
clean the A/C unit if necessary.
Note
When doing this, pay attention to both condensation water drains

-A- and their openings -B-.
– Check both connections -B and C- on the replacement evap‐

orator -A- for dirt and damage.
– Install both covers -D and F- on the correct side on the evap‐
orator.
Note
♦ Both covers are included in the replacement evaporator kit

Parts Catalog .
♦ Depending on the cover version -D- cut the part -E- from this
cover (on the side with the connections installed).
– Push the evaporator -A- into the A/C shaft; when doing this,
be careful not to loosen the covers -D and F- from the evapo‐
rator.
– Install the bracket -A- with the bolt -B- on the evaporator con‐
nector.
– Check the refrigerant lines -C and D- for damage and dirt.
Note
♦ Even slight damage (a scratch) or a little bit of dirt (a hair) can

cause leakage at a connection.
♦ The refrigerant lines -C and D-, the O-rings -E and F-, the
bracket -A- and the bolts -B and H- are all included in the re‐
placement evaporator kit. Refer to the Parts Catalog.
– Install the refrigerant lines -C and D- into the grommet -G- .
Note
♦ If replacing the evaporator on an Audi Q5 Hybrid, then wrap

the refrigerant pipe -C- on the replacement evaporator with
insulating tape as illustrated before installing. Approximately
30 cm of 5 cm wide insulating tape (butyl or tar tape) -B- with
a 3 mm strength will be needed.
♦ Wrap both ends of the refrigerant pipe -C- when it is removed,
as illustrated. Do not wrap approximately 15 mm in area -A-.
This is where a grommet will be installed facing the expansion
valve. Likewise, do not wrap the connection area to the evap‐
orator.

– Coat the O-rings -E and F- with refrigerant oil before installing.

– Mount the O-rings -E and F- on the refrigerant lines
-C and D-.
– Install the refrigerant lines -C and D- in the connection on the
evaporator.
– Install the bolt -H- .
– Install both bolts -B and H- equally far enough so that both
refrigerant lines -C and D- can be turned without pretension.
Note
♦ When installing the bolts -B and H- be careful not to twist the

bracket -A- together with the refrigerant lines.
♦ If the refrigerant pipe wrapping -B- touches the separating
walls of the evaporator housing -C- on an Audi Q5 hybrid, re‐
work the walls, if necessary.
– Install the expansion valve retaining plate -A- on the refrigerant

lines -B and C- .
– To align both refrigerant lines, first install the expansion valve
and the refrigerant line with the inner heat exchanger. Refer
to
page 242 and
Note
The expansion valve and the refrigerant line the inner heat ex‐
changer are installed first to align both refrigerant lines leading to
the evaporator, and after tightening both bolts on the evaporator
connect, they are removed again.

– Tighten the bolts -B and H- on the evaporator connector (tight‐

ening specification 5 Nm).
Note
♦ This illustration show the refrigerant pipes -C and D- to the

evaporator not wrapped with butyl or tar tape.
♦ On the Audi Q5 hybrid, wrap the refrigerant pipe to the evap‐
orator with a piece of butyl or tar tape in area -A- as illustrated
after tightening the screws to reduce noise. Then wrap the
entire area -D- on the evaporate with another piece of butyl or
tar tape.
– Remove the refrigerant line with the inner heat exchanger and
the expansion valve again.
– Install the expansion valve. Refer to
page 242 .
– Install the cover for the evaporator refrigerant lines -B- and the
bolt -A- .
– Make sure the cover -B- fits correctly and that it is free of ten‐
sion.
Note
Even the smallest leak at the groove/spring connection between

the cover -B- and the A/C unit -A- will cause whistling noises. Coat
the connecting surfaces lightly with silicone grease (part number
G 000 405 A2). Refer to the Parts Catalog.

– Clean and dry the groove in the A/C unit -E- before installing
the separating wall -C- .
– Fill the groove in the A/C unit -E- before installing the sepa‐
rating wall -C-, for example, with Silicone Adhesive - D 176
001 A3- . Refer to the Parts Catalog.
– Install the separating wall -C- .
Note
♦ The separating wall -C- is included in the replacement evap‐

orator kit. Refer to the Parts Catalog .
♦ There are different versions of the separating wall -C- (with
and without the sprayed-on sealing lip). Refer to the Parts
Catalog.
♦ If the connecting location between the A/C unit -E- and the
separating wall -C- is not sealing in area -D- condensation
water from the A/C unit could leak into the footwell when, for
example, driving around a curve.
– Remove any excess adhesive (the adhesive may only be in

the area -D-); and remove any excess adhesive out of the
groove -G-.
– Install the air intake housing. Refer to


General Warnings .
DANGER!
starts the vehicle.
Note
♦ Re-energize the high-voltage system:

sequence:
♦ Body
♦ 51 - Re-energize high-voltage (Repair Group 93)

– Reconnect the Battery - A- ground connection; when doing
this, pay attention to the notes regarding reconnecting the bat‐
tery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery;

All Vehicles
C Service Station .
Note

wrong. Refer to

fer to
Note

5.6 Evaporator Housing, Removing and In‐

stalling
Note
♦ Evaporators with a 40 mm block depth -A- (A/C unit with the

part number “8K_ 820 005”) are being installed from start of
production through the changeover from MY 2012. These
evaporators can be replaced with the A/C unit still installed.
Refer to
⇒ “5.5 Evaporator, Removing and Installing”, page 475 . From
MY 2012, evaporators with a block depth -A- of approximately
50 mm are being installed (A/C unit with the part number “8T_
820 005”) as a running change depending on the vehicle ver‐
sion. These evaporators can only be replaced when removing
the A/C unit together with the evaporator housing. Refer to the
Parts Catalog.
♦ Replace the evaporator and the evaporator housing if the
evaporator is not available as a single part, or if for other rea‐
sons it must be replaced together with the evaporator housing
(it is necessary to remove the A/C unit in order to replace the
evaporator). Refer to the Parts Catalog.
page 520 .
Parts Catalog.
Removing
page 520 .

Note
The following illustrations show a “Basis” A/C unit. The location

of certain components on the “Convenience” A/C unit may differ
(for example, the location and number of actuators).
– Remove the bolt -B-, unlock the tabs and remove the bracket
-A-.
– Remove the bolts -E-, unlock the tabs and remove the bracket
-A-.
– Remove the clamps -F- and the coolant pipes -G-.
Note
♦ Be careful not to drop the seals -B- into the heater core or the
A/C unit when removing the coolant pipes -A-.
♦ Do not re-use the seals -B- and clamps -D-. To replace them.
– Remove the bolts -A- (above the left radiator housing -C- on
the evaporator housing -B-).
Note
Left Radiator Housing, Removing and Installing -C-. Refer to

⇒ “5.13 Left Radiator Housing with Temperature Doors, Remov‐
ing and Installing ”, page 541

– Remove the right radiator housing -H-. Refer to

Temperature Doors)”, page 545 .
– If necessary, remove the heater core -I- and the honeycomb/
Auxiliary Heater Heating Element - Z35- . Refer to
Note
It is not really necessary to remove the heater core -I- and the
honeycomb/ Auxiliary Heater Heating Element - Z35- because
these components still fit loosely inside the left radiator housing.
It is easy to remove them.
– Remove the evaporator housing -A- from the left radiator

housing -B-/air distribution housing -C-.
Note
Currently the evaporator housing is not disassembled any further.

For the evaporator housing construction. Refer to
⇒ “5.4 Overview - Evaporator Housing”, page 470 .
Installing
– Check the evaporator housing -A-, left radiator housing -B-
and air distribution housing -C- for dirt and damage and clean
or replace if necessary.
– Assemble the evaporator housing -A- and the left radiator
housing -B-/air distribution housing -C-.
Note
Push the guides -D- (top and bottom) on the evaporator housing
-A- into the grooves -E- in the left radiator housing -B-.

– Install the bolts -A- (above the left radiator housing -C- on the
evaporator housing -B-).
– Install the heater core -I- and honeycomb/ Auxiliary Heater

Heating Element - Z35- . Pay attention to the installed position.
Refer to
– Install the right radiator housing -H-. Refer to

– Check both connections -C- on the heater core and the coolant
pipes -A- for dirt and damage and clean or replace them if
necessary.
– Coat both connections -C- on the heater core and coolant
pipes -A- lightly with silicone grease.
Note
The silicone grease part number is G 000 405 A2. Refer to the
Parts Catalog.
– Moisten the new seals -B- with coolant (or coat them lightly
with silicone grease) and then push them onto the coolant
pipes -A-.
– Position the coolant pipes -A- on the evaporator housing and
push them into the connections -C- in the heater core
-arrow-.
Caution
Risk of leaks at the heater core.

♦ Squeezed O-ring seals, sharp-edged or coolant pipes/
clamps that have not been inserted completely may lead
to leaks.
– Install the new coolant pipe clamps -F- on the connection -C-
on the heater core as illustrated (push them all the way on
-arrow-).
Note
♦ Do not re-use removed seals -B- and clamps -D-. To replace

them. Refer to the Parts Catalog.
♦ If a replacement heater core -C- is being installed instead of
the heater core shown above (standard production version),
then install the coolant pipes as described for this version of
the heater core. Refer to
– Install the remaining components for the air conditioner.

– Installing the heater and A/C unit. Refer to
page 520 .
5.7 Evaporator, Cleaning

⇒ “5.7.1 Evaporator, Cleaning with Ultrasound A/C Cleaner”,
page 496
⇒ “5.7.2 Evaporator, Cleaning with Suction Feed Spray Gun
VAG1538 and Spray Lance”, page 499
5.7.1 Evaporator, Cleaning with Ultrasound A/

C Cleaner
♦ Ultrasound A/C Cleaner - VAS6189B- . Refer to the Parts Cat‐
alog for currently available ultrasound machines.

♦ Ultrasound A/C Cleaner - Airco-Clean Fluid - VAS6189/1-

♦ Commercially Available Vacuum Cleaner
Note

are available on the market for cleaning the evaporator. Cur‐
rently for Audi, for example, the cleaning of the evaporator is
tested and approved using the Ultrasound A/C Cleaner and a
suction feed spray gun. Refer to
♦ Possible causes for noises from the A/C system. Refer to
♦ Odors originating in the A/C unit can mainly be detected in
fresh air mode and recirculating air mode. If a smell occurs
only in fresh air or recirculation mode, the cause is probably
not the A/C unit.
♦ In the case of a leaking heater core, the odor of the escaping
coolant mostly depends on the temperature setting. With
“Cold” temperature setting, air does not flow through the heat‐
er core and the odor is not as strong.
Preliminary Work
– Check whether odor is actually in A/C evaporator by switching
from fresh air to recirculation.
Note
The odor can only be removed by cleaning with the Ultrasound

A/C Cleaner - VAS6189B- if it originates in the evaporator.
– Check the plenum chamber and the water drain valves for dirt
and debris and clean if necessary. Refer to
⇒ “6.11 Plenum Chamber Water Drain, Checking”,
page 607 .
– Remove the dust and pollen filter and check for odors and dirt.
Refer to
556 .
Note
On this vehicle, the dust and pollen filter is installed between the
Fresh Air Blower - V2- and the evaporator, therefore it must be
removed during cleaning. Refer to
page 556
– Clean the installation slot of the A/C unit dust and pollen filter
(remove leaves, dust and other contaminants). Refer to
556 .
– Reseal the opening on A/C unit through which dust and pollen
filter was removed.
– Open the instrument panel vent and close the vehicle window
and sliding sunroof.

Note
♦ It is sufficient to activate the ready mode on vehicles with the

high-voltage system (watch the display in the Instrument Clus‐
ter Control Module - J285- ). Refer to the Owner's Manual.
♦ The engine must not be running when the ready mode is ac‐
tivated on vehicles with the Start/Stop System. Refer to the
Owner's Manual.
– Set the “recirculating air mode” on the Climatronic Control

Module - J255- A/C display and control head and switch the
A/C compressor off (the indicator lamp in the AC or A/C button
does not light up).
– Open instrument panel vents and set the lowest temperature
possible on the Climatronic Control Module - J255- A/C display
and control head (“Cold” temperature setting).
– Closes the windows and sliding sunroof.
– Set the lowest fresh air blower setting on the Climatronic Con‐
trol Module - J255- A/C display and control head and select
the “Instrument panel vents” for the airflow direction.
Cleaning
Note
Using the ultrasound A/C cleaner. Refer to the Ultrasound A/C

Cleaner - VAS6189B- Owner's Manual.
– Shake the bottle of Ultrasound A/C Cleaner - Airco-Clean Fluid

- VAS6189/1- and pour the contents into the Ultrasound A/C
Cleaner - VAS6189B- (when doing this, be sure to read the
operation manual which comes with the Ultrasound A/C
Cleaner - VAS6189B- .
– Place the Ultrasound A/C Cleaner - VAS6189B- in the front
passenger footwell.
– Start the Ultrasound A/C Cleaner - VAS6189B- (according to
the operating instructions) and route outlet hose belonging to
it so that the vapor escaping via A/C unit recirculated air open‐
ing (in the front passenger footwell behind the glove compart‐
ment) is drawn in by the Fresh Air Blower - V2- .
– Close the vehicle doors.
Note
The cleaning procedure lasts about 15 to 20 minutes. It is com‐

plete when vapor no longer comes out of the outlet hose of the
Ultrasound A/C Cleaner - VAS6189B- .
Final Procedures
– Switch off the Ultrasound A/C Cleaner - VAS6189B- .
– Open the vehicle doors and air out the passenger compart‐
ment for at least 10 minutes.
– Remove the Ultrasound A/C Cleaner - VAS6189B- from vehi‐
cle and clean it according to operating instructions.
– Switch off the ignition.

– Install the dust and pollen filter. Refer to

556 .
5.7.2 Evaporator, Cleaning with Suction Feed

Spray Gun - VAG1538- and Spray
Lance
♦ Suction Feed Spray Gun - VAG1538- . Refer to the Parts Cat‐
alog for currently available suction feed spray guns.
♦ Suction Feed Spray Gun - Probe for Evaporator (Straight) -
VAG1538/5- -A- (short version approximately 500 mm, bent to
specification for this vehicle, or Suction Feed Spray Gun -
Probe - VAS1538/9- ). Refer to the Parts Catalog for probes
that can be delivered currently.
♦ Cleaning Solution for A/C System Evaporator “D 600 100

A2” (for cleaning fluids that can currently be delivered. Refer
♦ Commercially Available Vacuum Cleaner
Note

are available on the market for cleaning the evaporator. Cur‐
rently for Audi, for example, the cleaning of the evaporator is
tested and approved using the Ultrasound A/C Cleaner -
VAS6189B- and a suction feed spray gun. Refer to
♦ Possible causes for noises from the A/C system. Refer to
♦ Odors originating in the A/C unit can mainly be detected in
fresh air mode and recirculating air mode. If a smell occurs
only in fresh air or recirculation mode, the cause is probably
not the A/C unit.
♦ In the case of a leaking heater core, the odor of the escaping
coolant mostly depends on the temperature setting. With
“Cold” temperature setting, air does not flow through the heat‐
er core and the odor is not as strong.
WARNING
A/C unit may be contaminated by other substances

♦ Only use a suction feed spray gun and a spray lance that
were not already used with other fluids.

Note
♦ The vacuum cleaner is only necessary if there is dirt in the

plenum chamber or in the A/C intake shroud, or if dirt has got‐
ten into the evaporator housing through the dust and pollen
filter.
♦ It is recommended to have several short and long spray lan‐
ces, 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.

Recommended bend radius of the Suction Feed Spray Gun -

Probe for Evaporator (Straight) - VAG1538/5- -A- for this vehicle.
Note
♦ The guide washer -B- is attached opposite of the spray lance

holes -C-. This also allows the spray direction to be recognized
when the spray lance is inserted.
♦ The Suction Feed Spray Gun - Probe for Evaporator (Straight)
- VAG1538/5- -A- with this bend radius is also suitable for the
following vehicles: Audi A3 from MY 2013, Audi A6 from MY
2011, Audi A7 from MY 2011 and Audi A8 from MY 2010.
Preliminary Work
– Switch the ignition on.
– Switch the A/C system on.
– Check whether the odor is actually originating from the A/C
unit evaporator by switching from fresh air to recirculating air
mode.
Note
♦ The cause or the location of the odor must be determined be‐

fore 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 (and with it the A/C system and Fresh
Air Blower - V2- ).
– Remove the cover under the glove compartment. Refer to ⇒
Body Interior; Rep. Gr. 68 ; Storage Compartments/Covers;
Glove Compartment, Removing and Installing .
– Remove and check the dust and pollen filter. Replace it if nec‐
essary after cleaning the evaporator. Refer to
556 .
Note
Replacing a dirty dust and pollen filter is recommended after each

cleaning.
– Check the area between the dust and pollen filter installation
slot and the Fresh Air Blower - V2- in the evaporator housing
for contamination and clean if necessary. Refer to
556 .
– Check the plenum chamber and the plenum chamber water
drain and clean them if necessary. Refer to
page 607 .

Note
The water drains in the plenum chamber must be checked ac‐

cording to the repair manual before starting to clean. Clean them
if necessary.
– Place a drip tray under the vehicle to collect the cleaning fluid
that is draining out via the condensation water drain. Refer to
page 577 for the layout of the condensation water drain out‐
let openings.
– Cover the carpet in the front passenger footwell with a liquid-
tight foil and absorbent paper.
Evaporator, Cleaning
WARNING
The cleaning solution is combustible. Vapors may form an ex‐

plosive mixture with the air.
♦ Keep any ignition sources away and do not smoke.
♦ Only work with the cleaning solution in well-ventilated
areas.
Cleaning solution may pose a health risk.
Protect eyes by wearing protective eyewear.
♦ Use safety equipment, such as protective eyewear and
gloves.
♦ Keep an eye bath on hand.
♦ If the cleaning solution has come in contact with the eyes,
flush them thoroughly with cool or lukewarm water for 15
minutes.
♦ Then apply eye drops and consult a doctor immediately
even if no pain is felt.
♦ Inform the doctor which cleaning solution has gotten into
the eyes.
Protect hands by wearing rubber gloves.
♦ Use safety equipment, such as protective eyewear and
gloves.
♦ If liquid cleaning solution has come in contact with the
hands or skin, clean them with soap and water and rinse
thoroughly.
Do not breathe in the cleaning fluid vapors and do not ingest
any cleaning fluid.
♦ Only work with the cleaning solution in well-ventilated
areas.
♦ If any liquid cleaning solution was ingested, do not induce
vomiting. Consult a doctor immediately.
♦ Inform the doctor which cleaning solution was ingested.

Caution
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.
• The ignition (along with the A/C system) is switched off.

• The preliminary work was performed and the specified com‐
ponents are removed. Refer to ⇒ page 501 .
– Fill the suction feed spray gun with the attached spray lance
with one liter of cleaning solution for the A/C system evapora‐
tor.
– Set a pressure of approximately 7.5 bar (109 psi) on the com‐
pressed air supply for the suction feed spray gun (minimum
pressure: 5 bar (73 psi)/maximum pressure: 10 bar (145 psi).
Note
This compressed air supply pressure results in a working pres‐

sure of 3.5 to 4.5 bar (51 to 65 psi) at the spray lance.
– Connect the Suction Feed Spray Gun - VAG1538- to the com‐

pressed air supply.

– With the spray directed toward the evaporator, guide the spray
lance -A- into the evaporator housing via the opening for the
removed dust and pollen filter -B-.
Note
The guide washer -C- for the spray lance -A- secures the spray
direction.
Caution
No cleaning fluid must flow into the vehicle interior from the A/
C unit evaporator housing when cleaning.
♦ Cover the area under the spray lance in the evaporator
housing with absorbent paper.
♦ After spraying approximately 0.1 to 0.2 liters of cleaning
fluid, check that the fluid is actually draining into the drip
tray under the vehicle via the condensation water drains.
The condensation water drain must be cleaned before
continuing the cleaning procedure if the fluid is only drip‐
ping out. Refer to
⇒ “5.20 Condensation Water Drain, Removing and Instal‐
ling”, page 577 .
– 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.
Note
♦ The contaminate-heavy cleaning fluid flows out via the con‐

densation water drain.
♦ The drainage of the cleaning fluid via the condensation water
drain must be monitored during the cleaning procedure.
– 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.
Note
Used cleaning solution can be disposed of, for example, via the
wastewater disposal (observe the local governmental regula‐
tions).
Allow the cleaning solution to work for at least 30 minutes.
Note
The removed components can be reinstalled at this time.
– 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.
– Set the airflow direction to all vents on the A/C system control
head.
– Set the maximum speed for the Fresh Air Blower - V2- on the
A/C system control head.
– Then start the engine and switch on the A/C system (the indi‐
cator lamp in the A/C button (or the A/C button) illuminates.
– 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 be‐
tween cold and warm several times on the A/C system control
head.

5.8 Auxiliary Heater Heating Element -

Z35- , Checking
Note
♦ Currently, vehicles with a diesel engine and certain gasoline

engines (for example, vehicles that can use bioethanol “Flex
Fuel Vehicle” from MY 2010 and on high voltage vehicles)
have an electric auxiliary heater. Refer to the Audi Sales Pro‐
gram. The air is supplied with heat energy after leaving the A/
C heater core if there is a request from the Climatronic Control
♦ The air is supplied with heat energy via the Auxiliary Heater
Heating Element - Z35- after it has left the A/C heater core. An
optional parking heater may be activated later as an “auxiliary
heater” (introduction open). Refer to
♦ Vehicles without an Auxiliary Heater Heating Element - Z35-
have a honeycomb installed inside the A/C unit instead of the
Auxiliary Heater Heating Element - Z35- . Refer to
♦ For vehicles with a diesel engine, the electrical auxiliary heater
(the Auxiliary Heater Heating Element - Z35- ) is activated via
the respective engine control module (for this, the control
modules exchange information via the Data Bus system) using
ponent locations.
♦ For vehicles with a gasoline engine, the electric auxiliary heat‐
er (the Auxiliary Heater Heating Element - Z35- ) is activated
by the Climatronic Control Module - J255- display and control
head via the local Data Bus (activated via the same outlet and
also via the Fresh Air Blower Control Module - J126- ) on the
Auxiliary Air Heater Control Module - J604- . The Auxiliary Air
Heater Control Module - J604- then activates the Low Heat
Output Relay - J359- and the High Heat Output Relay - J360-
and these send the current to the Auxiliary Heater Heating
Element - Z35- using the Vehicle Diagnostic Tester in the
♦ In the measured values block for the Climatronic Control Mod‐
ule - J255- A/C display and control head, it is shown that the
request to the respective engine control module/ Auxiliary Air
Heater Control Module - J604- to switch on the electrical aux‐
iliary heater is being sent using the Vehicle Diagnostic Tester
in the "Guided Fault Finding" function. If the request is
changed or why the activation did not occur despite the re‐
quest will appear in the measured values block for the engine
control module on a diesel vehicle using the Vehicle Diagnos‐
tic Tester in the "Guided Fault Finding" function.
♦ The Auxiliary Air Heater Control Module - J604- installed on
vehicles with a certain gasoline engine is currently not diag‐
nostic-capable using the Vehicle Diagnostic Tester in the "Gui‐
page 506 .

♦ The test for the activation of the Auxiliary Heater Heating El‐
ement - Z35- depends on the engine version. For a vehicle
with a diesel engine, this can be found in the Guided Fault
Finding for the engine installed in this vehicle. For a vehicle
with a gasoline engine, this can be found in Guided Fault Find‐
ing for the A/C system using the Vehicle Diagnostic Tester in
♦ In MY 2009, as a running change, a new version of the Auxil‐
iary Heater Heating Element - Z35- is being installed (the
heating elements are a bit more narrow); be sure to use the
correct version and note the allocation. Refer to the Parts Cat‐
alog.
cific engines as optional equipment. For vehicles with a Start/
Stop System, the Auxiliary Heater Heating Element - Z35- ac‐
tivation is switched off for the time in which the stop function
is active (to protect the Battery - A- ). After the engine is started
again via the Start function, the Auxiliary Heater Heating Ele‐
ment - Z35- is activated again using the Vehicle Diagnostic
♦ Check the resistance value of the Auxiliary Heater Heating El‐
ement - Z35- using the Vehicle Diagnostic Tester in the "Gui‐

Auxiliary Heater Heating Element - Z35- Design and Function

♦ The Auxiliary Heater Heating Element - Z35- is comprised of
several layers of resistance elements -E and F-. These can
achieve a heating output of approximately 1000 W via all three
-A through C-. These resistance elements have a positive
temperature coefficient (the resistance increases with the tem‐
perature and current pick and the heating output decrease).
♦ The resistance heating elements (-E and F-) are activated via
the cables -A through C-; the current flows through the ground
connection -D- .
♦ The Auxiliary Heater Heating Element - Z35- is designed so
that a current greater the 35 A can flow via the contacts
-A through C- when switched on. Immediately after switching
on, the resistance on the resistance heating elements
-E and F- increases and the current goes down.
♦ To reach the maximum heating output of approximately 1000
W (3 x 333 W), the resistance heating elements temperature
must be low and the Generator - C- must deliver enough cur‐
rent.
♦ The wire -A- provides the voltage to the resistance heating
elements -F- via the Low Heat Output Relay - J359- . Refer to
♦ The wires -B and C- provide the voltage to the resistance
heating elements -E- via the High Heat Output Relay - J360- .
locations.
♦ The resistance of the heating elements depends on the tem‐
perature; the resistance is approximately 0.2 to 5 Ω; measured
between the connections -A through C- (in the connector) and
the ground connection -D-
Note
♦ To measure the resistances and to check the activation of the

Auxiliary Heater Heating Element - Z35- , disconnect the con‐
nector from the A/C unit. Refer to
♦ Since resistances smaller than 10 Ω can no longer be meas‐
ured with sufficient accuracy using workshop tools, a short
circuit in the Auxiliary Heater Heating Element - Z35- cannot
be determined.
♦ Activate the Low Heat Output Relay - J359- and the High Heat
Output Relay - J360- to check the function, for example, “out‐
put diagnostic test mode” for the respective engine control
module. When doing so, measure the voltage between the
contacts in the mating connector to the connector on the Aux‐
iliary Heater Heating Element - Z35- and the ground using the
tion.
♦ The engine control module/ Auxiliary Air Heater Control Mod‐

ule - J604- activates the Auxiliary Heater Heating Element -
Z35- in 3 stages. Contacts -A through C- are supplied with
voltage as follows. Refer to the wiring diagram for the respec‐
tive wiring. Refer to ⇒ Wiring diagrams, Troubleshooting &
– For stage “1”, the voltage from the Low Heat Output Relay -
J359- is switched to the contact -A-

– For stage “2”, stage “1” is switched off and the voltage is
switched to contacts -B and C- via the High Heat Output Relay
- J360- .
– For stage “3”, stage “2” and stage “1” are switched on using
function.
Note
The respective control module constantly monitors the Generator

- C- load. The next stage is selected if the load remains under a
certain limit. If the load exceeds a specified limit, then the stage
is switched down.
Switch-On Criteria for Electric Auxiliary Heater Activation
Note
These switch-on conditions in the Climatronic Control Module -

J255- A/C display and control head must be met so that the
request can be sent to the respective engine control module.
– The Climatronic Control Module - J255- A/C display and con‐

trol head sends a request to switch on the auxiliary heater to
the engine control module as long as the following require‐
ments are fulfilled:
♦ Engine is running for a minimum of 8 seconds and engine
speed is greater than 500 RPM.
♦ Engine temperature is less than 75 °C (167 °F).
♦ The calculated outside air temperature is lower than 8 °C (46°
F).
♦ The electrical system voltage is greater than 12.2 volts and no
request that forbids the switch-on is sent by Vehicle Electrical
♦ There is no malfunction stored in the Climatronic Control Mod‐
ule - J255- A/C display and control head.
♦ No DTC is stored in engine control module and the Generator
- C- load is less than 30 to 77% (depending on engine speed).
♦ Based on the setting and the measured temperatures, the Cli‐
has calculated that additional heat output is necessary to
reach the desired passenger compartment temperature.
trol head has calculated that more than 90% of the air will be
guided through the A/C heater core.

Note
The engine control module/ Auxiliary Air Heater Control Module -

J604- activates the Auxiliary Heater Heating Element - Z35- (3-
stage) via both auxiliary heating relays ( Low Heat Output Relay
- J359- and High Heat Output Relay - J360- ), so that the load on
the Generator - C- does not exceed 95% using the Vehicle Diag‐
nostic Tester in the "Guided Fault Finding" function (for the engine
control module on vehicles with a diesel engine or the A/C system
control module on vehicles with a gasoline engine) and to the
wiring diagram. Refer to ⇒ Wiring diagrams, Troubleshooting &
Component locations. Thus the next stage only is switched on if
the Generator - C- load is less than 30 to 77%, depending on
engine RPM.
Switch-Off Criteria for Electric Auxiliary Heater Activation
Note
Activation is switched off as soon as a switch-on condition is no

longer met in the Climatronic Control Module - J255- A/C display
and control head, or in the respective engine control module or
one of the switch-off criteria has been detected.

trol head switches off the request to switch on the electrical
auxiliary heater.
♦ When one of the switch-on requirements is no longer met.
♦ The calculated outside air temperature is higher than 11 °C
(52 °F).
♦ The Generator - C- load is greater than 95%.
trol head has calculated that less than 60% of the air will be
guided through the A/C heater core (position of temperature
doors)

5.9 Auxiliary Heater Heating Element -

Z35- , Removing and Installing
Note
♦ Currently, vehicles with a diesel engine and certain gasoline

engines (for example, vehicles that can use bioethanol “Flex
Fuel Vehicle” from MY 2010 and on high voltage vehicles)
have an electric auxiliary heater. Refer to the Audi Sales Pro‐
gram. The air is supplied with heat energy after leaving the A/
C heater core if there is a request from the Climatronic Control
♦ For vehicles with a diesel engine, the electrical auxiliary heater
(the Auxiliary Heater Heating Element - Z35- ) is activated via
the respective engine control module (for this, the control
modules exchange information via the Data Bus system) using
ponent locations.
Auxiliary Air Heater Control Module - J604- . The Auxiliary Air
Heater Control Module - J604- then activates the Low Heat
Output Relay - J359- and the High Heat Output Relay - J360-
and these send the current to the Auxiliary Heater Heating
Element - Z35- using the Vehicle Diagnostic Tester in the
♦ Check the Auxiliary Heater Heating Element - Z35- function.
Refer to
page 506 .
♦ Vehicles without an Auxiliary Heater Heating Element - Z35-
have a honeycomb inside the A/C unit as a place holder. Refer
to ⇒ “6.2 Air Intake and Outlet Openings”, page 586 (air in‐
take, air vent and air guide in the A/C unit) and the Parts
Catalog.
♦ In MY 2009, as a running change, a new version of the Auxil‐
iary Heater Heating Element - Z35- is being installed (the
heating elements are a bit more narrow); be sure to use the
correct version and note the allocation. Refer to the Parts Cat‐
alog.
Removing
– Set the airflow direction to “DEF” (toward the windshield) on
head.


– Disconnect the connector -B- and loosen the connector -C-
from the right radiator housing.
Caution
When folding back the carpet, be careful not to damage the

center console.
– Carefully fold the carpet back near the center console and
loosen the ground connection to the Auxiliary Heater Heating
Element - Z35- -A- from the ground point on the right side of
the center tunnel. Refer to ⇒ Wiring diagrams, Troubleshoot‐
ing & Component locations.
– Disconnect the connector -B- and loosen the connector -C-
from the right radiator housing.
– Loosen the wiring to the Auxiliary Heater Heating Element -
Z35- -D- from the mounts on the right radiator housing.
– Remove the right radiator housing. Refer to
– Pull the Auxiliary Heater Heating Element - Z35- -A- from the
A/C unit.
Installing

– The installed Auxiliary Heater Heating Element - Z35- (the

honeycomb) is, depending the A/C system version, supplied
with foam seals -A and B-.
1 - Honeycomb for a vehicle equipped with a “Basis” A/C system.
2 - Honeycomb for a vehicle equipped with a “Convenience” A/C
system.
3 - Auxiliary Heater Heating Element - Z35- for a vehicle equipped
with a “Basis” A/C system.
4 - Auxiliary Heater Heating Element - Z35- for a vehicle equipped
with a “Convenience” A/C system.
Note
♦ On vehicles with the “Convenience” A/C system, there are dif‐

ferent temperature settings for the left and right sides as well
as for the rear. The seal -B- separates the air guides for the
left and right sides in the A/C unit. Refer to
⇒ “6.2 Air Intake and Outlet Openings”, page 586 .
♦ The seal -B- must be applied in the center of the honeycomb
of the Auxiliary Heater Heating Element - Z35- .
♦ Seal may curl up on insertion if not correctly bonded on.
♦ If the seal is damaged or installed incorrectly, cold air can flow
past the Auxiliary Air Heater Heating Element - Z35- (past the
honeycomb); on vehicles equipped with the “Convenience” A/
C system, it is possible that there is no clear separation be‐
tween the left and right side.

– With the Auxiliary Heater Heating Element - Z35- (honey‐

comb) removed, check the A/C unit, the heater core and the
evaporator -B- for dirt; if necessary clean.
– Slide the Auxiliary Heater Heating Element - Z35- (honey‐
comb) -A- into the A/C unit.
Note
On the “Convenience” A/C system, be careful when installing the

groove / spring connection -C and D-

Note

this sequence does not conform with the specification, the ac‐
tuators will adapt incorrectly and the door control will be wrong.
Refer to
30 .

– After installing, check the Auxiliary Heater Heating Element -
Z35- activation and function, if necessary. Refer to
page 506 .
Tightening Specifications
Designation Tightening Specification
Ground connection threaded 9 Nm
connection to center tunnel
5.10 A/C System Temperature Door Heat

Output Activation, Checking
♦ Vehicle Diagnostic Tester .
the right and left)


General Warnings .
WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.

nition turned on

DANGER!


ning engine.
Note
to be active.
Manual.
Module - J285- ).

DANGER!

Note
♦ If the ignition is turned on and the ready mode is active, the

engine runs or starts only, when heated coolant is necessary
to reach the temperature setting in the passenger compart‐
ment or, for example, the Traction Battery - A2- (hybrid battery)
♦ The coolant flow through is maintained by the heater core for
the A/C system via the Coolant Recirculation Pump - V50-
when the ignition is turned on and the drive ready mode is
active (the engine is not running). Refer to ⇒ Rep. Gr. 19 ;
Coolant System/Coolant . Depending on the vehicle version,
the Coolant Recirculation Pump - V50- is activated directly by
head or at the request of the Climatronic Control Module -
J255- from the respective engine control module. Refer to
– Activate the ready mode (observe the display in the Instrument

Cluster Control Module - J285- ). Refer to Owner's Manual.
All Vehicles
If coolant circuit is not completely bled after filling, air may accu‐
mulate in heater core of A/C unit, thus reducing heating output of
A/C system, additional noises may occur or customer may com‐
plain of different air temperatures flowing out of vents at driver
side and front passenger's side at the same setting.
Corrective measure:
– Perform a longer road test at a higher engine RPM with the
setting “A/C system maximum heating output” (at least for 10
minutes, engine RPM higher than 2,500). Select a low gear
during the test to prevent excessive vehicle speed.
– If the customer complains of poor heating output at certain
engine speeds, check the incorporation of the A/C heater core
in the coolant circuit. If both coolant hoses (supply and return)
of the engine are interchanged, the coolant flows through the
heater core in the wrong direction. Refer to ⇒ Rep. Gr. 19 ;
Cooling System/Coolant; Connection Diagram - Coolant Ho‐
ses .

If a different air temperature is coming out of the vents during A/

C system control mode, it may be caused by the following.
♦ One or more of the temperature flaps in the radiator housing
do not close completely or do not reach their end position.
♦ There is air in the heat exchanger (fluctuating flow through
heat exchanger and heat is not distributed uniformly) .
♦ A foam seal has loosened during installation of heater core
and air may flow past at heater core. Refer to
♦ If, when installing the Auxiliary Heater Heating Element - Z35- /
honeycomb, a foam seal has become loose, air can flow out
where the seal has separated. Refer to
♦ The A/C system refrigerant circuit is not filled with the correct
quantity of refrigerant (perform a cooling output test). Refer to
⇒ “3.8 Cooling Output, Checking”, page 73 .
Note

perature exceeds a certain value using the Vehicle Diagnostic
♦ For vehicles with the Start/Stop System, an additional Coolant
Recirculation Pump - V50- ( Water Pump - V36- ) is installed
for the Start/Stop System, depending on the vehicle equip‐
ment level and vehicle version. Refer to, ⇒ Rep. Gr. 19 ;
Coolant Pump/Thermostat and use the Vehicle Diagnostic
Recirculation Pump - V50- ( Water Pump - V36- is activated
to support the engine coolant pump using the Vehicle Diag‐
tion (only the allocated pump can be activated) using the

The Actuation of the Temperature Doors Differs between the “Ba‐

sis” A/C System and the “Convenience” A/C System. Refer to
⇒ , page 591 .
– On the “Convenience” A/C system, the right front temperature
door is actuated by the Right Temperature Door Motor - V159-
and left front temperature door by the Left Temperature Door
Motor - V158- . Both temperature doors for the rear right foot‐
well vents and the rear left footwell vent, as well as the vent in
the rear center console are connected by a connecting rod;
they are actuated by the Rear Temperature Door Motor -
V137-
– On the “Basis” A/C system, the upper and lower temperature
doors (for the front right vents and the right footwell vents) as
well as the upper and lower temperature doors (for the front
left vents and the left footwell vents) are connected to each
other by the shafts. The right and left temperature door shafts
are connected to each other by a connecting rod; they are both
actuated by the Temperature Regulator Door Motor - V68- .
Information for Vehicles with a Parking Heater
If there are complaints that there is poor or insufficient heating
output on a vehicle with a “parking heater”, then check the acti‐
vation and function of the Heater Coolant Shut-Off Valve - N279-
using the Vehicle Diagnostic Tester in the "Guided Fault Finding"
function (parking heater).
♦ On the Audi Q5, the Heater Coolant Shut-Off Valve - N279-
can be actuated only up to an engine RPM of approximately
1,200. If the Heater Coolant Shut-Off Valve - N279- is actuated
at a higher engine RPM, it may not open when the activation
is switched off due to the increased flow of coolant (and not
warmed up coolant is flowing into the A/C heater core).
If, for vehicles with an optional “parking heater”, there are com‐
plaints that there is poor or insufficient heating output at lower
engine RPMs, check the activation and function of the Recircu‐
lation Pump - V55- for the parking heater (the request is made by
head, the activation is carried out by the Auxiliary Heater Control
Module - J364- ).
♦ The Climatronic Control Module - J255- sends the request to
activate the Recirculation Pump - V55- so that it can support
the engine coolant pump at specific engine RPMs, depending
on the version of the vehicle, of the engine, of the parking
heater and when the vehicle was manufactured. This function
must be properly adapted in the Auxiliary Heater Control Mod‐
ule - J364- so that the request to activate the Recirculation
Pump - V55- by the Auxiliary Heater Control Module - J364-
can be performed.
All Vehicles
Refer to
ing Requirements”, page 52
Refer to
⇒ “3.7.2 Heat Output and Temperature Door Activation, Check‐
ing”, page 59
5.11 Heater and A/C Unit, Removing and In‐

stalling
♦ Cooling System Tester - VAG1274B- (and corresponding
adapters)

♦ Hose Clamps - Up To 25mm - 3094- and Hose Clamps - Up

To 40mm - 3093-
♦ Commercial compressed-air gun with rubber end piece
Note
♦ When removing, record the bolt lengths and allocation rein‐

stallation.
♦ All cable ties and other wiring harness fasteners released or
cut open on removing air conditioner unit are to be re-attached
in same position on installation.
Removing
– Move the driver and passenger seats as far back as possible.
head.
Note


General Warnings .

WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.

ings .
ing .

DANGER!
Note

sequence:
♦ Body
Group 93)

– Visually inspect the high voltage components -D- (here the
cover -B-. Refer to
Warnings .
Voltage Cables .
Note


Note

stalling .

Note
The Battery - A- ground connection is disconnected so that it will

not short circuit when the jumper cable post -C- is removed and
when disconnecting the positive cable to both relays for the Aux‐
iliary Heater Heating Element - Z35- -J- .
– Remove the jumper cable post cover -C-.

All Vehicles
– For vehicles with an Auxiliary Heater Heating Element - Z35- ,
loosen the positive cable to both relays for the Auxiliary Heater
Heating Element - Z35- -J- from the jumper cable post -C-.
Refer to ⇒ Electrical Equipment; Rep. Gr. 97 ; Relay Panels,
Fuse Panels and E-Boxes; Overview - Relay Panels, Fuse
Panels and E-Boxes .

– If equipped and necessary, remove the tower brace -B- (for

example, on the Audi A5 Coupe; not necessary, for example,
on the Audi Q5). Refer to ⇒ Suspension, Wheels, Steering;
Rep. Gr. 40 ; Suspension Strut and Upper Control Arm; Tower
Brace, Removing and Installing
Note

– Remove the expansion valve. Refer to

page 242 .
Note
♦ The air conditioner can be removed and installed with the ex‐
pansion valve still installed. Removing and installing with the
expansion valve removed is described here due to the in‐
creased space.
♦ Seal open pipe connections.
♦ To seal off all open connections on expansion valve, sealing
caps from a replacement expansion valve can be used (pre‐
venting dirt and moisture from entering the system).
– Remove the expansion valve mounting plate -A- from the re‐
frigerant lines -B and C- (so that it does not get lost while
removing).
– Coat the inner side of the grommet -D- with grease and remove
the supporting ring -E- .
– Loosen the grommet -D- from the plenum chamber rear wall
toward the passenger compartment (it is removed and instal‐
led with the A/C unit).
– Open the cap on the coolant expansion tank and release the
pressure in the coolant system. Refer to ⇒ Rep. Gr. 19 ;
Coolant System/Coolant; Coolant, Draining and Filling .

– Mark the arrangement of coolant hoses -A- (supply to cylinder

head) and -B- (return to coolant pump).
Note
♦ The heater core is designed for a specific coolant flow direc‐

tion. Therefore, coolant hoses must be connected on the
correct sides.
♦ Bleed the coolant circuit. Refer to ⇒ Rep. Gr. 19 ; Coolant
– Clamp the coolant hoses -A and B- with hose clamps.

– Cover the area beneath connections for coolant hoses
-A and B-, for example, with absorbent paper.
– Remove the coolant hoses -A and B- from the connections to
the A/C heater core. Refer to ⇒ Rep. Gr. 19 ; Coolant System/
Coolant .
– Insert one section each of hose -A and B- on to both connec‐

tions to heater core.
– Place a container -B- under the other end of the hose -C- .
– Using a compressed air gun -D-, carefully blow coolant out of
heater core (into container -B-) via hose -A-.
– Loosen the grommet -H- from the plenum chamber rear wall
and remove it from the heat exchanger coolant pipes.
– Remove the center console and the instrument panel. Refer
to ⇒ Body Interior; Rep. Gr. 68 ; Center Console; Center
Console, Removing and Installing and ⇒ Body Interior; Rep.
Gr. 70 ; Instrument Panel; Instrument Panel, Removing and
Installing .
Note
To prevent the instrument panel shell from damage, instrument

panel should be placed on a clean work bench which is covered
with clean cardboard.
– Remove the air intake manifold. Refer to

– Remove the air guides to the left and right instrument panel
vents.

Note
The air guide channel leading the left instrument panel vent -A-
is secured by an expanding clip or a screw -B- onto the instrument
panel crossmember -C-; the expanding clip or the screw can only
be removed when the outer instrument panel shell is removed.
– Remove the air guides to the instrument panel center vents

-C- and to the defrost vent -D- .
– Remove the bolts -A and B-.
– Remove the connector from the Brake Lamp Switch - F- . Refer
to ⇒ Brake System; Rep. Gr. 45 ; Sensors; Brake Lamp
Switch, Removing and Installing .
– Loosen the instrument panel crossmember (the central tube)
-E- from the vehicle and the A/C unit. Refer to ⇒ Body Interior;
Rep. Gr. 70 ; Instrument Panel Central Tube; Instrument Pan‐
el Central Tube, Removing and Installing .
Note
Except for the left fuse box, do not loosen any other left relay- or
control module brackets from the instrument panel cross member.
– Remove the air guide to the rear center console vent -C- (only
on vehicles equipped with the “Convenience” A/C system).
– Loosen the air guide to the rear footwell vents -A and B- from
the intermediate piece -D- and remove the intermediate piece
-D- .
– On vehicles equipped with an Auxiliary Heater Heating Ele‐

ment - Z35- , loosen the ground connection -A- and disconnect
the connector -B-. Refer to
– Remove both condensation water drain hoses from the A/C
unit. Refer to
page 577 .

– Loosen the “driver side” fuse panel on the left side of instru‐
ment panel crossmember (the central tube) -A- from the in‐
strument panel crossmember. Refer to ⇒ Electrical Equip‐
ment; Rep. Gr. 97 ; Relay Panels, Fuse Panels and E-Boxes;
Overview - Relay Panels, Fuse Panels and E-Boxes .
Note
Since the instrument panel cross member is loosen only from the
vehicle (not completely removed), the remaining relay/fuse carri‐
ers and connector stations must not be removed from the instru‐
ment panel cross member
– Loosen all electric connections between the instrument panel

cross member and the vehicle on the passenger side -B- .
– Cover the carpet in the area of the center tunnel with a mat
-C- (and both seats if not already done).
Note
The instrument panel cross member must not be completely re‐

moved in order to remove the A/C unit; it is enough to disconnect
the A/C unit from the vehicle and then to swivel it to the rear and
place it on the center tunnel.
– Carefully remove the instrument panel cross member from the

vehicle and carefully swivel it (and when doing this not to dam‐
age any components) to the passenger side -B- far enough to
the rear -arrow- so that the A/C unit can be removed to the
right -arrow- .
– Remove the vehicle wiring harness in the area of the instru‐
ment panel cross member from the A/C unit.
– Carefully remove the A/C unit from the vehicle (with doing this,
do not damage any connections and components still not re‐
moved).

ment - Z35- , mark the location of the mounting points -B- (with
cable ties on the A/C unit) on the positive cable to both relays
for the Auxiliary Heater Heating Element - Z35- -A- (for exam‐
ple, with a suitable pin on the cable).
– Disconnect the cable -A- from the A/C unit.
– Remove the remaining vehicle wiring harness mounts (for ex‐
ample with cable ties) on the A/C unit.

– Remove the A/C unit -A- in the direction of the front passenger
side.
Note
The “A/C system” wiring harness is removed together with the A/

C unit.
Installing
Note
Before installing, check all gaskets and grommets on the A/C unit
for damage and replace if necessary.
– Install the A/C unit -A- and the components also removed with
the A/C unit (wiring harness “A/C unit”, grommet on the evap‐
orator refrigerant lines, etc.) in the vehicle
– Coat the grommet -D- with grease and install it in the plenum
chamber rear wall.
– Install the support ring -E- in the grommet -D- .
– Install the instrument panel cross member (central tube). Re‐
fer to ⇒ Body Interior; Rep. Gr. 70 ; Instrument Panel Central
Tube; Instrument Panel Central Tube, Removing and Instal‐
ling .
– Install the expansion valve mounting plate -A- to the refrigerant
lines -B and C-.
– Install the grommet -H- in the plenum chamber rear wall.

– Check the position of the coolant and refrigerant line in both
grommets, and if necessary, align the A/C unit so that the lines
are not tensioned in the grommets.

– Install the screws -A-.

– Slide the strap -F- all the way to the bracket -H-, then turn it
downward (when doing this, the bracket -G- locks the A/C unit
to the strap)
– Install the bolts -B- .
– Connect both condensation water drain hoses to the A/C unit.
Refer to
page 577 .
Note
♦ When installing the intermediate piece, -D-, the air guides to

the rear footwells -A and B- and the air guide to the vent in the
rear center console -C- make sure that they fit correctly and
are securely connected. If the connection points are not con‐
nected tightly, warm or cool air could leak out and influence
how the A/C system works (this air will be drawn in by the
Interior Temperature Sensor Fan - V42- and the measured
value for the Instrument Panel Temperature Sensor - G56- will
deviate from the actual temperature in the passenger com‐
partment).
♦ The intermediate piece -D- latches on the air outlet openings
on the air conditioner. There are slits inside the intermediate
piece -D-. If the door position is incorrect, especially on vehi‐
cles with the “Convenience” A/C system, whistling noise can
come from these slits. The upper slits are covered with tape
during production (adhesive strips from 02/2009 as a running
change). Refer to
⇒ “6.15 Rear Vent Air Guide Slots, Sealing”, page 617 .
– Install the air intake housing. Refer to

– Install the expansion valve. Refer to
page 242 .
ing and Installing”, page 227

– Make sure the grommet -H- fits correctly in the back of the
plenum chamber.
– Pay attention to the marking and properly connect the coolant
hoses to the heater core.
A - Supply hose from cylinder head
B - Return to the coolant pump
– Connect the coolant hose -A- to the heater core coolant pipe
(pay attention to the marking) and secure it with the clamp
-D- .
– Attach the coolant hose to the heater core -B- onto the coolant
pipe -F- just far enough as to not cover the bleed hole -G-.
– Remove the hose clamp from the coolant hose -A- .
– Fill the coolant expansion tank with coolant. Refer to ⇒ Rep.
ing .
– Carefully force the coolant out of the coolant overflow reservoir
into the heater core using, for example, the hand pump from
the Cooling System Tester - VAG1274B- .
– As soon as the coolant comes out the ventilation hole -G-, in‐
stall the coolant hose -B- on to the coolant pipe -F- at the
marking.
– Secure the coolant hose -B- with the clamp -E- on the marked
location.
– Remove the hose clamp from the coolant hose -B-.
– Add more coolant to the coolant expansion tank, if necessary.
Refer to ⇒ Rep. Gr. 19 ; Coolant System/Coolant; Coolant,
Draining and Filling .
Note
This procedure completely bleeds the cooling system. If, for some
other reason, there is still some air in the cooling system, bleed
the coolant system after installing all of the removed components,
if necessary. Refer to ⇒ Rep. Gr. 19 ; Coolant System/Coolant;
Coolant, Draining and Filling .
Check the Connections at the Heater Core for Leaks as Follows:

– Carefully increase the pressure in the coolant circuit by using,
for example, the hand pump of the Cooling System Tester -
VAG1274B- .

– Check coolant circuit for leaks, pay particular attention to the

connection between coolant hoses and heater core Engine
Mechanical.
Note
♦ This illustration shows the coolant pipes on a replacement

heater core. The coolant pipes are attached to the heater core
by clamps. Refer to
♦ When bleeding the coolant circuit, take special care to ensure
complete bleeding of the heater core. If there are still air bub‐
bles in the heater core, it may cause the customer to complain
of insufficient heating output in winter or different air temper‐
ature from vents at same setting in regulated mode. Refer to
⇒ “5.10 A/C System Temperature Door Heat Output Activa‐
tion, Checking”, page 514 .
♦ Depending on vehicle equipment and on engine, heat insula‐
tion has been applied to coolant hoses, these must not be
damaged and must be re-applied after installing.
– Secure the wiring harness once again on the provided places

and install the different air guides in reverse order.
– Reinstall the instrument panel, the center console, the glove
compartment, etc. Refer to ⇒ Body Interior; Rep. Gr. 70 ;
Instrument Panel; Instrument Panel, Removing and Installing ,
⇒ Body Interior; Rep. Gr. 68 ; Center Console; Center Con‐
sole, Removing and Installing , ⇒ Body Interior; Rep. Gr. 68 ;
Storage Compartments and Covers; Glove Compartment, Re‐
moving and Installing .
Note
When installing the instrument panel, make sure that the “defrost”
intermediate piece its properly on A/C unit and the defroster vent
does not pinch the intermediate piece. Refer to
⇒ “6.1 Overview - Air Routing and Air Distribution in Passenger


General Warnings .
DANGER!
starts the vehicle.
Note

sequence:
♦ Body


All Vehicles
C Service Station .
Note

wrong. Refer to

fer to
Note

5.12 Heater and A/C Unit Air Intake Housing,

Note

ing, this connection is sealed with a plug. Refer to
Housing”, page 616 . Therefore, ensure the correct alloca‐
tion of the right radiator housing and air intake housing. Refer
♦ From MY 2012, a new version is being used. Read all the in‐
formation regarding this component. Refer to
page 388 .
Removing
head.
to
– Remove the screw clips -A- and remove the insulation mat
-B- .


– Loosen the air guide to the right instrument panel vent from
the instrument panel crossmember (there are different ver‐
sions). Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instrument
Panel Central Tube .
Note
The air guide from the air guide channel -B- is attached to the right
instrument panel vent with two bolts. To loosen, remove the bolt
which is installed at the bottom and is accessible.
– Detach the bracket -B- and place it to the side or remove it.
– Disconnect the connector -A- from the Fresh Air Blower Con‐
– If equipped, remove the Headlamp Range Control Module -

J431- -1- (or the Cornering Lamp and Headlamp Range Con‐
trol Module - J745- ) and the related frame. Refer to ⇒
Electrical Equipment; Rep. Gr. 94 ; Automatic Headlamp
Range Control; Headlamp Range Control Module, Removing
and Installing .
– Loosen the wiring -A- from the mounting points on the air in‐
take housing.
– Disengage locking mechanism -C- (between the A/C and the
air intake housing -B-) for example, using a screwdriver -D- (lift
slightly and pull in the direction of the -arrow-)
– Pull the right side of the air intake manifold -B- downward in
direction of -arrow-.
– Mark the connector to the Airflow Door Motor - V71-
-E and F- to the Recirculation Door Motor - V113- (due to the
danger of confusing them with other identical connectors) and
disconnect them from the actuators.

– Loosen the upper A/C unit tab -E- from the air intake housing
mount -D- .
– Loosen both lower mounting points between the A/C unit -B-
and the air intake housing -A-.
– Remove the air intake housing.
Installing
following.
– Check the evaporator -A- and the air guide in the A/C unit
leading to the evaporator -B- for dirt and clean, if necessary.
– Check the dust and pollen filter and the air guide in the air
intake housing leading to the A/C unit -C- for dirt and clean if
necessary.
– Check the groove around the A/C unit -D- and the bevel
around the air intake housing -E- for damage.
Note
If the groove or the bevel are damaged, fill the damaged spot with,
for example, silicone sealant D176 001 A3. Refer to the Parts
Catalog. When using the A/C system, air could leak from here and
this could result in noises.
– Check the seal on the fresh air intake shaft -A- for damage
before installing the air intake housing -C-. Replace the seal if
it is damaged.
– Check the position of the lock, only if the latch -B- is in the
position shown, can the air intake housing -C- and the A/C unit
-D- be joined together.

– According to the markings, connect the connectors to the Air‐

flow Door Motor - V71- -E- and to the Recirculation Door Motor
- V113- -F- with the actuators.
– Insert both lower air intake housing tabs -A- into the A/C unit
mounting points -B- .
– Lift the air intake housing to the right far enough so that the
upper A/C unit tab -C- fits into the air intake housing bracket
-D- and then press both parts together.
Caution
♦ Do not use force when attaching the air intake housing to

the A/C unit.
♦ If you use force to attach the air intake housing to the A/C
unit, the tabs on the air intake housing -A- will bend.
♦ If the tabs on the air intake housing -A- bend, the A/C sys‐
tem will make a whistling noise when it is running due to
the slight air leakage.
Note
♦ If the latch -E- should slip forward while installing, both parts
cannot be joined together
♦ When joining the two parts together, make sure no other com‐
ponents get jammed in and that the bevel on air intake housing
fits into the groove on the A/C unit all around.
– Slide the latch -C- opposite the direction of the -arrow- (this
locks the A/C unit with the air intake housing -B-).
– Loosen the cables -A- into the mounting points on the air intake
housing.
Note
When routing the wires, make sure that they are routed on the
actuators so that they cannot get caught in any moving parts on
the actuators.
– Reinstall the removed parts in the opposite order.


Note

wrong. Refer to
♦ Make sure then both actuators, the Airflow Door Motor - V71-
and the Recirculation Door Motor - V113- are attached cor‐
rectly on the wiring. Check the activation using the “A/C
system output diagnostic test mode”. When the glove com‐
partment is removed, the air recirculation door - F- is visible
ing" function.
– Check the DTC memory of Climatronic Control Module - J255-

display and control head and, if necessary, erase any errors
displayed using the Vehicle Diagnostic Tester in the "Guided
♦ Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instrument Panel Cen‐
tral Tube; Overview - Instrument Panel Central Tube .
Designation Tightening Specification
Bracket threaded connection 3.6 Nm
for instrument panel central
tube and air intake manifold
Air duct threaded connection 3 Nm
for right instrument panel vent
and instrument panel central
tube
5.13 Left Radiator Housing with Temperature

Doors, Removing and Installing
Note
♦ The activation of the temperature doors and with it the radiator

housing with the left temperature doors is different between
vehicles equipped with “Convenience” and “Basis” A/C sys‐
tems. Refer to
⇒ “5.2 Overview - Air Distribution Housing Doors and Parti‐
tions”, page 461 and the Parts Catalog.
♦ To maintain the A/C unit stability, only one radiator housing
(the left or right side) may be removed with the A/C unit in‐
stalled.

Caution
Do not remove the left and right radiator housing at the same
time.
♦ Both radiator housings are support components of the A/
C unit and must not be removed at the same time or the
A/C unit will become unstable.
♦ If necessary, remove the left and right radiator housing
one after the other.
Removing
page 593 .
– On a vehicle equipped with the “Convenience” A/C system,
remove the retaining plate together with the Left Footwell Door
Motor - V108- and the Left Center Vent Motor - V110- as well
as the Left Temperature Door Motor - V158- . Refer to
stalling ”, page 438 and
⇒ “4.11 Left Temperature Door Motor V158 , Removing and
– On a vehicle equipped with the “Basis” A/C system, remove
the retaining plate together with the Footwell Door Motor -
V261- . Refer to
to

– Carefully disconnect the connector rod -B- (so the lever does
not get damaged) from the lever on the right temperature door
-A- .
– Loosen the bolt -C-.
– Loosen or remove the bolt -F- (installed from 07/2007, there

are different versions).
Note
♦ At the start of production, A/C units were installed, where the

left and right side of the radiator housing -D and E- were bolted
together on the underside with the bolt -C- . From 07/2007 as
a running change, A/C units are being installed, where both
radiator housings -D and E- are bolted together with the bolt
-F- .
♦ From 07/2007 through 09/2007, the bolt -F- with the hex nut
-G- was installed on the left radiator housing -D-. The left ra‐
diator housing -D- only has a hole and not an attaching point.
To remove and install the bolt -F- and the hex nut -G- on this
actuator version, the Temperature Regulator Door Motor -
V68- or the Rear Temperature Door Motor - V137- must be
removed. Refer to
page 404 .
♦ You can place a catch on the holes on the right side of the
radiator housing -E- which will prevent the bolt -C- (and the
bolt -F-) from falling in the hole after being loosened.
– Carefully disconnect the connector rod -A- (so the lever does
not get damaged) from the lever on the defrost door -B- .
– Remove the bolt -C-.
– Remove the left radiator housing -D- (together with the De‐
froster Door Motor - V107- and Temperature Regulator Door
Motor - V68- or the Rear Temperature Door Motor - V137- )
from the A/C unit; when doing this, pay attention to the lever
on the defroster door -B- (and the lever on the door for the left
center instrument panel vent -E- on vehicles equipped with the
“Convenience”) A/C system).
Installing
following.

– Check the groove -A- on the left radiator housing -F- and the
spring on the A/C unit -B- for damage.
Note
If the groove -A- on the left radiator housing -F- or the spring on
the A/C unit -B- are damaged, seal these with, for example, Sili‐
cone Adhesive D176 001 A3. Refer to the Parts Catalog.
– Check the heater core -C- and evaporator -D- for dirt; clean if
necessary.
– Check the foam seals on the heater core -C- and on the Aux‐
iliary Heater Heating Element - Z35- (or on the honeycomb on
vehicles without an Auxiliary Heater Heating Element - Z35- )
for damage.
– Insert the grooves -A- on the left radiator housing -F- into the
springs on the A/C unit -B- and push the left radiator housing
-F- into the A/C unit.
Note
Pay attention to the connecting rod to the right temperature door

-E- and the lever on the defroster door -G- (and the lever on the
door for the left center instrument panel vent on vehicles equipped
with the “Convenience” A/C system).

Note

wrong. Refer to

♦ Refer to
⇒ “5.1 Overview - Attachments for Heater and A/C Unit and
Air Intake Housing”, page 451

5.14 Right Radiator Housing, Removing and

Installing (with Temperature Doors)
⇒ “5.14.1 Right Radiator Housing, Removing and Installing, on
Basic A/C System or with Actuator Retaining Plate Removed”,
page 545
⇒ “5.14.2 Right Radiator Housing with Actuator Retaining Plate,
Removing and Installing, Only for Comfort A/C System”,
page 550
5.14.1 Right Radiator Housing, Removing and

Installing, on “Basic” A/C System or with
Actuator Retaining Plate Removed
Note

for the glove compartment cooling are being installed. Refer
to
Housing”, page 616 . Ensure the correct allocation of the
right radiator housing and air intake housing (different ver‐
sions). Refer to the Parts Catalog.
♦ The activation of the temperature doors and with it the right
radiator housing is different between vehicles equipped with
“Convenience” and “Basis” A/C systems. Refer to
stalled.
♦ Vehicles with the “Convenience” A/C system can have the
right radiator housing and the retaining plate installed/re‐
moved for the actuators removed/installed. Vehicles with the
“Basis” A/C system do not have this mounting plate.
Caution
time.
♦ Right radiator housing together with the right retaining plate

and actuators, removing and installing (only on vehicles with
“Convenience” A/C system). Refer to
⇒ “5.14.2 Right Radiator Housing with Actuator Retaining
Plate, Removing and Installing, Only for Comfort A/C System”,
page 550 .
♦ Vehicles with “Basis” A/C system (no actuator retaining plate).

♦ Vehicles with “Convenience” A/C system where the right re‐

taining plate and actuators and the right radiator housing must
be removed one after the other.
Removing
head.
Vehicles with “Convenience” A/C system.
– Remove the right retaining plate with the Right Footwell Door
Motor - V109- and Right Center Vent Motor - V111- . Refer to
Vehicles with “Basis” A/C system.
– Remove the Center Vent Adjustment Motor - V102- . Refer to
⇒ “4.4 Center Vent Adjustment Motor V102 , Removing and
All vehicles
-A- .
Note

– Loosen the bolt -C- until the bolt head rests on the support.

– Loosen the bolt -F- until the bolt head rests on the support
(installed starting from 07/2007; there are different versions).
Note

-F- .
removed. Refer to
page 404 .
♦ Place a catch on the holes on the right side of the radiator
housing -E- which will prevent the bolt -C- (and the bolt -F-)
from falling in the hole after being loosened.
– For a vehicle with a “Comfort” A/C system, mark the connector

-A- (to prevent any mix-ups) and remove it from the Right
Temperature Control Door Motor - V159- .
Note
The Right Temperature Door Motor - V159- is only installed on


– Remove the bolt -C-.
Note
The bolt -C-, on vehicles equipped with the “Convenience” A/C

system, was already removed when the Right Footwell Door Mo‐
tor - V109- and the Right Center Vent Motor - V111- were re‐
moved.
– Remove the bolts -D-.

ment - Z35- , loosen the wiring -G- from the right radiator
housing -E-. Refer to
– Pull the right radiator housing -E- (with the Right Temperature
Control Door Motor - V159- ) out of the A/C unit. While doing
so, pay attention to the lever on the door for the instrument
panel vent -F-.
Installing
following.

– Check the heater core -A- and evaporator -B- for dirt; clean if
necessary.
– Check the foam seals on the heater core -A- and on the Aux‐
iliary Heater Heating Element - Z35- -C- (or on the honeycomb
on vehicles without an Auxiliary Heater Heating Element -
Z35- ) for damage.
– Check the springs on the A/C unit - B- and the grooves -A- on
the right radiator housing -C- for damage.
Note
If the groove -A- on the right radiator housing -C- or the spring on
– Insert the grooves -A- on the right radiator housing into the
springs on the A/C unit -B- and push the right radiator housing
-C- into the A/C unit.

Note
♦ On vehicles equipped an Auxiliary Heater Heating Element -

Z35- , pay attention to the wiring -D- when installing the
housing -C-.
♦ When inserting, pay attention to the lever on the door for the
instrument panel vent -F-.
– Install the bolts -B and C-.

Note

wrong. Refer to

♦ Refer to

5.14.2 Right Radiator Housing with Actuator

Retaining Plate, Removing and Instal‐
ling, Only for “Comfort” A/C System
Note

for the glove compartment cooling are being installed. Refer
to
Housing”, page 616 . Ensure the correct allocation of the
right radiator housing and air intake housing (different ver‐
sions). Refer to the Parts Catalog.
♦ The activation of the temperature doors and with it the right
radiator housing is different between vehicles equipped with
“Convenience” and “Basis” A/C systems. Refer to
stalled.
♦ Vehicles with the “Convenience” A/C system can have the
right radiator housing and the retaining plate installed/re‐
moved for the actuators removed/installed. Vehicles with the
“Basis” A/C system do not have this mounting plate.
Caution
time.
♦ Right radiator housing, removing and installing (vehicles with

“Basis” A/C system and vehicles with “Convenience” A/C sys‐
tem, where the right retaining plate with the actuators and the
right radiator housing must be removed one after the other).
Refer to
⇒ “5.14.1 Right Radiator Housing, Removing and Installing, on
Basic A/C System or with Actuator Retaining Plate Removed”,
page 545 .
♦ The retaining plate for the right actuators is installed only on
vehicles with the “Convenience” A/C system.
Removing
head.


– Remove the two bolts -B- and remove the bracket -A-.
-A-.
Note

– Loosen the bolt -C- until the bolt head rests on the support.
– Loosen the bolt -F- until the bolt head rests on the support
(installed starting from 07/2007; there are different versions).
Note

-F-.
removed. Refer to
page 404 .
♦ Place a catch on the holes on the right side of the radiator
housing -E- which will prevent the bolt -C- (and the bolt -F-)
from falling in the hole after being loosened.

– Remove the connector -A- from the Evaporator Vent Temper‐

ature Sensor - G263- . Refer to
– Mark the connectors -B- (for the Right Footwell Door Motor -
V109- ), -C- (for the Right Center Vent Motor - V111- ) and
-D- (for the Right Temperature Door Motor - V159- ) to avoid
confusion.
– Disconnect the connectors -B, C, and D- from the actuator.
– Loosen the wiring harness -E- from the mounting points on the
retaining plate.
– Carefully loosen the different connecting rods (from -A to D-)

from each door.
Note
♦ The connecting rods (from -A through D-) are clipped on to the

damaged.
– Remove bolts -E-.

ment - Z35- , loosen the wiring to the Auxiliary Heater Heating
Element - Z35- from the right radiator housing. Refer to
– Pull the right radiator housing -A- (together with the retaining
plate, actuators and levers, curved washers and connecting
rods) in the direction of the -arrow- from the A/C unit.
Installing
following.

– Check the heater core -A- and evaporator -B- for dirt; clean if
necessary.
– Check the foam seals on the heater core -A- and on the Aux‐
iliary Heater Heating Element - Z35- -C- (or on the honeycomb
on vehicles without an Auxiliary Heater Heating Element -
Z35- ) for damage.
– Check the springs on the A/C unit - B- and the grooves -A- on
the right radiator housing -C- for damage.
Note
If the groove -A- on the right radiator housing -C- or the spring on
– Insert the grooves -A- on the right radiator housing into the
springs on the A/C unit -B- and push the right radiator housing
-C- just a little into the A/C unit.

Note
♦ On vehicles equipped an Auxiliary Heater Heating Element -

Z35- , pay attention to the wiring to the Auxiliary Heater Heat‐
ing Element - Z35- when installing the housing -C-.
♦ Pay attention to the door lever for the instrument panel vent
-C- “right center” and the different connecting rods for the
doors on the air distribution housing.
– Slide the lever on the door for the instrument panel vent -C-
all the way up in the direction of -arrow-.
Note
Since the airflow direction was set to “DEF” (to the windshield) on
the Climatronic Control Module - J255- display and control head
before removing the radiator housing, the curved washer -D- is
now positioned so that the pin -B- fits into the groove in the curved
washer -E- when the radiator housing is installed.
– Line up the door connecting rods so they do not get caught

when the radiator housing is completely installed.
– Carefully push the radiator housing -A- all the way into the A/
C unit.
– Check the position of the pin -B- inside the groove in the curved
washer -E- using an illuminated mirror or endoscope.
– Install the bolts -E-.

– Carefully connect the various connector rods -A through D- to
the lever of each door.
Note
♦ The connecting rods (from -A through D-) are clipped into the
damaged.

– Install the bolts -C and F-.

– Carefully attach the connecting rod -B- (so the lever does not
get damaged) on the lever on the right temperature flap -A-.
Note

– Route the wiring -E- into the mounting points on the retaining
plate as illustrated so that any moving components cannot
come in contact.
– Connect the connector -B, C, and D- according to the markings
on the motors.
Note

wrong. Refer to

♦ Refer to

5.15 Dust and Pollen Filter, Removing and

Installing
Note
♦ For the dust and pollen filter change interval. Refer to the
Maintenance Tables.
♦ There are different versions of the dust and pollen filter (with‐
out and with filter insert with activated charcoal) On vehicles
equipped with the “Convenience” A/C system, there is cur‐
rently a dust and pollen filter with an activated charcoal filter
element installed; on vehicles equipped with the “Basis” A/C
system, there is a dust and pollen filter without the activated
charcoal filter element installed. Refer to the Parts Catalog.
♦ Clean the surrounding area of the dust and pollen filter in the
A/C unit shaft before installing a new filter.
♦ On vehicles with driving school equipment, pedals for the driv‐
ing school equipment must be removed if necessary (depend‐
ing on version, service disconnect points are present on
driving school pedals). Refer to Driving School Equipment In‐
stallation Instructions.
♦ In MY 2012, vehicles with a “Convenience” A/C system will
have a modified dust and pollen filter with an activated char‐
coal filter element installed as a running change. This filter with
an improved interception rate for fine particulates has approx‐
imately the same air resistance values as the filter installed
prior to the change, and for this reason will be in installed in
vehicles built up to the change. Refer to the Parts Catalog.
♦ If the customer requests it, it is permitted the exchange a dust
and pollen filter without an activated charcoal filter element
that came with the vehicle from the manufacturer for a dust
and pollen filter with an activated charcoal filter element so
long as the vehicle has the “Basis” A/C system. Refer to the
Parts Catalog.
♦ Depending on the version, for some countries with high dust
levels (for example China), a filter is installed instead of fresh
air intake grille. Check and replace these if necessary. Refer
to
page 600 .
Removing
-B- .
– Cover floor carpet in area beneath dust and pollen filter with
paper.

– Loosen the catches -B-, slide the cover -A- in the direction of
the -arrow- and remove the cover.
Note
If the cover -A- can no longer be held by the catches -B-, secure
it with screws -D- on the mounting points -C- .
– Remove the dust and pollen filter -A- from the A/C unit shaft
-B-.
Installing
following.
– Clean the A/C unit via the shaft -B- (for example, using a vac‐
uum cleaner) after removing the dust and pollen filter -A-.
– Install the dust and pollen filter -A- on the correct side (the
angle -C- on the side facing the fresh air blower -D-)
Note
♦ The dust and pollen filter -A- for this vehicle does not have a
specific flow direction.
♦ There are different versions of the dust and pollen filter, with‐
out and with a filter insert with activated charcoal; make sure
the correct version is installed). Refer to the Parts Catalog.
5.16 Fresh Air Blower - V2- , Removing and

Installing

Note
♦ The Fresh Air Blower - V2- as a replacement part is available

in different versions. To ensure the correct allocation. Refer to
the Parts Catalog.
♦ From 08/2007 as a running change, the Fresh Air Blower - V2-
-A- is installed with an additional foam jacket -B- (as noise
insulation). Refer to the Parts Catalog.
♦ As a running change from MY 2009, a Fresh Air Blower - V2-
-A- with a revised housing with an optimized motor with a
suitable motor mount, is being installed. With the use of the
revised Fresh Air Blower - V2- , the additional foam jacket on
the housing -B- is discontinued because the larger motor
mount has a new insulation mat (see -B- in the next illustra‐
tion). Refer to Parts Catalog.
♦ From MY 2012 (depending on the vehicle version), a revised
Fresh Air Blower Control Module - J126- , Fresh Air Blower -
V2- , Climatronic Control Module - J255- A/C display and
control head and A/C units are gradually being used. Be sure
to use the correct version and allocation. Refer to the Parts
Parts Catalog.
Refer to
page 506 .
page 506 .
Auxiliary Air Heater Control Module - J604- . Also check the
Auxiliary Air Heater Control Module - J604- if there is a concern
about the Fresh Air Blower Control Module - J126- or the Fresh
Air Blower - V2- for these vehicles using the Vehicle Diagnostic
♦ From MY 2012 (use depends on the vehicle version), a revised
Fresh Air Blower Control Module - J126- (and Fresh Air Blower
- V2- , Climatronic Control Module - J255- A/C display and
control head and A/C units with part number “8T_ 820 005”)
are gradually being used. The air intake housing, along with
the Fresh Air Blower Control Module - J126- and the A/C unit
was also revised. Be sure to use the correct version and allo‐
cation. Refer to the Parts Catalog and use the Vehicle Diag‐

♦ If the allocation or adaptation of the Climatronic Control Mod‐

ule - J255- to the Fresh Air Blower Control Module - J126- (with
the part number 8K0 820 521 or 8T0 820 521) is not according
to the specification, then the Fresh Air Blower - V2- is not
regulated by the Fresh Air Blower Control Module - J126- .
There may not always be an entry in the DTC memory even
though the activation of the Fresh Air Blower - V2- is not OK.
Make sure the Climatronic Control Module - J255- is adapted
correctly. Refer to the Parts Catalog and to using the Vehicle
Refer to
page 506 .
Removing
-B- .
– Disconnect the connector -B- from the Fresh Air Blower Con‐
– Remove the Fresh Air Blower Control Module - J126- (version

-A-). Refer to
⇒ “5.17 Fresh Air Blower Control Module J126 , Removing
Note
A revised Fresh Air Blower Control Module - J126- -B- and Fresh
Air Blower - V2- are being installed as a running change (de‐
pending on the vehicle version) from MY 2012. It is not always
necessary to remove the Fresh Air Blower Control Module - J126-
in order to remove the Fresh Air Blower - V2- on the revised
version -B-.

– Loosen the locking mechanism -A- and turn the Fresh Air
Blower - V2- -B- housing in the direction of the -arrow-.
Caution
Do not grasp fan wheel of Fresh Air Blower - V2- , force against
the fan wheel or shifting the balancing weights fastened to fan
wheel may cause imbalance and then problems during oper‐
ation.
Installing
following.
– If the locking mechanism -A- breaks or can no longer hold, the
Fresh Air Blower - V2- -B- can also be secured to the air intake
housing with a bolt -C-.
– When installing, make sure the Fresh Air Blower - V2- -B- fits
correctly in air intake housing.
– To check the function, perform the output diagnostic test mode
5.17 Fresh Air Blower Control Module -

J126- , Removing and Installing

Note
♦ There are different versions of the replacement Fresh Air

Blower Control Module - J126- (for example, versions
-A and B-). Pay attention to the correct allocation. Refer to the
Parts Catalog.
♦ From the start of production through MY 2012, version -A- was
installed. From MY 2012, version -A- was gradually switched
to version -B- (the time when the changeover took place de‐
pends on the vehicle version). Version -B- also has a seal
-C-. Refer to the Parts Catalog.
♦ From MY 2012 (use depends on the vehicle version), a revised
Fresh Air Blower Control Module - J126- -B- (and Fresh Air
Blower - V2- , Climatronic Control Module - J255- A/C display
and control head and A/C units with part number “8T_ 820
005”) are gradually being used. The air intake housing, along
with the Fresh Air Blower Control Module - J126- and the A/C
unit was also revised. Be sure to use the correct version and
allocation. Refer to the Parts Catalog and use the Vehicle Di‐
correctly. Refer to the Parts Catalog and to using the Vehicle
Parts Catalog.
♦ When the ignition is turned on and the Fresh Air Blower - V2-
activated, The Fresh Air Blower Control Module - J126- con‐
nects (for example with version -A-) “Positive” from terminal
“4” of connector -C- to the terminal “1” of connector -B-. The
Fresh Air Blower - V2- speed is regulated by Fresh Air Blower
Control Module - J126- via the ground connection between
terminal “2” of connector -B- and terminal “3” of connector
-C- using the Vehicle Diagnostic Tester in the "Guided Fault
Finding" function. Refer to ⇒ Wiring diagrams, Troubleshoot‐
ing & Component locations.
Refer to
page 506 .
page 506 .


Auxiliary Air Heater Control Module - J604- . Also check the
Auxiliary Air Heater Control Module - J604- if there is a concern
about the Fresh Air Blower Control Module - J126- or the Fresh
Air Blower - V2- for these vehicles using the Vehicle Diagnostic
Refer to
page 506 .
Removing
– Disconnect the connector -A and B-.

WARNING
The heat sink on Fresh Air Blower Control Module - J126- may
be hot.
– Remove the Fresh Air Blower Control Module - J126- -D- from
the air intake housing.
Installing
following.
– To check the function, perform the output diagnostic test mode
5.18 Heater Core, Preparing for Removal

head.


General Warnings .
WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.

ings .
Warnings .
High Voltage System, Turning Off Voltage

DANGER!
Note
♦ Disable the high voltage system:

♦ Body
♦ 51 - De-energize the high voltage (Repair Group
93)


cover -B-. Refer to
Warnings .
– Remove the cowl panel trim -C-. Refer to ⇒ Body Exterior;
Rep. Gr. 50 ; Bulkhead; Plenum Chamber Cover, Removing
and Installing .
– Remove the high voltage cables to the Electrical A/C Com‐
pressor - V470- and the Traction Battery - A2- from the Electric
Drive Power and Control Electronics - JX1- . Refer to ⇒ Elec‐
trical System Hybrid; Rep. Gr. 93 ; High Voltage Cables;
Overview - High Voltage Cables .
Note


♦ Visually inspect the high voltage components -D- and high
General Warnings .
– Remove the plenum chamber cover (not always necessary;
there are different versions). Refer to ⇒ Body Exterior; Rep.
Gr. 50 ; Bulkhead; Plenum Chamber Cover, Removing and
Installing .
Note
Disconnect the Battery - A- ground connection so that it cannot

short circuit when the jumper cable post -C- is removed.
– Remove the jumper cable post cover -C- .

– Remove the jumper cable post -C- from the tower brace and
move it to the side. Refer to ⇒ Electrical Equipment; Rep. Gr.
97 ; Relay Panels, Fuse Panels and E-Boxes; Overview - Re‐
lay Panels, Fuse Panels and E-Boxes .
All Vehicles
– Remove the right radiator housing. Refer to
♦ Heater core, removing. Refer to
5.19 Heater Core, Removing and Installing

♦ Cooling System Tester - VAG1274B- (and corresponding
adapters)
♦ Hose Clamps - Up To 25mm - 3094- or Hose Clamps - Up To
40mm - 3093-
♦ Commercial compressed-air gun with rubber end piece

Note
Due to space limitation when the instrument panel is installed, it

is not possible to install the factory-installed heat exchanger and
clamps -B and C- again. If a factory installed heat exchanger
(Original part) must be installed again, remove the instrument
panel and the air guide leading to the “Defrost” vent. Coat the O-
ring lightly with coolant (as described for installing a replacement
heat exchanger) on the coolant pipes -D and E- and then push
the coolant pipes -D and E- (with the O-ring) from the top into the
connections in the heat exchanger -A-. Hold the coolant pipes
-D and E- in the heat exchanger and install the clips -B and C-.
Further assembly is performed as described for installing a re‐
placement part - heat exchanger.
Removing
– Perform the preparation work for removing the heater core.
Refer to
⇒ “5.18 Heater Core, Preparing for Removal”, page 562 .
– Open the cap on the coolant expansion tank and release the
pressure in the coolant system. Refer to ⇒ Rep. Gr. 19 ;
Coolant System/Coolant; Coolant, Draining and Filling .
– Mark the arrangement of coolant hoses -A- (supply to cylinder

head) and -B- (return to coolant pump).
Note
♦ The heater core is designed for a specific coolant flow direc‐

tion. Therefore, coolant hoses must be connected on the
correct sides.
♦ Bleed the coolant circuit. Refer to ⇒ Rep. Gr. 19 ; Coolant
– Clamp the coolant hoses -A and B- with hose clamps.

– Cover the area beneath connections for coolant hoses
-A and B-, for example with absorbent paper.
– Remove the coolant hoses - A and B- from the connections to
the A/C heater core. Refer to ⇒ Rep. Gr. 19 ; Coolant System/
Coolant .
– Insert one section each of hose -A and B- on to both connec‐

tions to heater core.
– Place a container -B- under the other end of the hose -C- .
– Using a compressed air gun -D-, carefully blow coolant out of
heater core (into container -B-) via hose -A-.

– Remove the clamps -B and C- from the heater core connec‐

tions -A- .
– Loosen both coolant pipes -D and E- from the heater core
connections -A-.
– Remove the heater core -A- in the direction of the -arrow- .
Note
The upper illustration shows a heater core with connectors as it

is installed in production. If the heater core was already replaced
once, then both coolant pipes are held in the replacement heater
core with a bracket -A- . Remove the bolt -B- on this heater core.
Install a longer screw -C- (with a M5 thread) all the way to the end
as shown in the illustration and with this screw, loosen the bracket
-A- from the connection.
Installing

– Depending on the A/C system and vehicle version, cover the

heater core with the foam seals provided -A through D-.
1 - Heater core for a vehicle equipped with a “Basis” A/C system.
2 - Heater core for a vehicle equipped with a “Convenience” A/C
system.
3 - Ignore item -3-.
– Check the seals on the heater core; only install a heater core
with seals that are not damaged and are secured glued on.
Note
♦ If the vehicle has the “Convenience” A/C system, then there

are different temperature settings for the right and left sides as
well as for the rear. The seals -C- and -D- separate the air
guides in the A/C unit from each other. Refer to
⇒ “6.2 Air Intake and Outlet Openings”, page 586 .
♦ The heater core has a color mark that shows where to affix the
seal -C-. The seal -D- must be applied to the center of the
heater core as illustrated.
♦ The seal -C- may have different lengths (a short version as
illustrated or a long version which reaches all the way around
the heater core). If the heater core is delivered with the longer
seal -C-, then attach it all the way around the heater core.
♦ Seal may curl up on insertion if not correctly bonded on.
♦ If the seal is damaged or installed incorrectly, cold air can flow
over the heater core; on vehicles equipped with the “Conven‐
ience” A/C system, it is possible that there is no clear separa‐
tion between the various areas.
– Check the A/C unit and the evaporator -F- with the heater core
removed -A- (via heater core opening) for dirt.
– Remove any dirt or coolant which has leaked out of the A/C
unit (for example, after removing a leaking heater core).

– Check both connections -A and B- on the heater core -C- for

damage and dirt.
– Grease both connections -A and B- on the heater core -C- with
silicone grease.
Note
♦ The silicone grease part number is G 000 405 A2. Refer to the
Parts Catalog.
♦ This illustration shows the connection area of a heater core
installed as a replacement part.
♦ If the heater core installed by the manufacturer is to be reused
(for example, after replacing the evaporator with the evapora‐
tor housing with the A/C unit removed), both O-rings -B- and
both clips for the coolant pipes -F- are to be replaced. Install
the coolant pipes -A- with the O-rings -B- and the clips for the
coolant pipes -F- in the heater core. Refer to
page 492 (Evaporator housing, removing and installing).
– Lightly moisten the seals -D- (contained in the heater core de‐
livery) with coolant (or lightly with silicone grease).
Note
This and the following illustrations show the connection area and
the installation of coolant pipes with a heater core installed as a
replacement part.
– Install the new seals -D- on both heater core coolant pipes
-E and F-.

– Push the heater core -A- into the A/C unit.

– Support the heater core -A-, for example, with a plastic wedge
-B- on the center tunnel -C- so that it cannot slip down when
attaching the coolant pipes.
– Install a longer screw -G- (with a M5 thread) all the way to the
stop in the bracket -C- as shown in the illustration.
– Install and push both coolant pipes -E and F- with each seal
-D- into the heater core connection flange all the way -H-.
Caution
Risk of leaks at the heater core.

♦ Squeezed O-ring seals, sharp-edged or coolant pipes/
clamps that have not been inserted completely may lead
to leaks.
Note
Do not bend the coolant pipes -D and E- when pushing them into
the connections on the heater core.
– Make sure the seals -C- between the coolant pipes

-D and E- and the connections in the flange connection -B- of
the heater core -A- fit securely.
Caution
Seals that are incorrectly installed or jammed -C- will leak.

♦ The seals -C- must be installed completely into both the
coolant pipe connections -D and E- and the flange con‐
nections -B-.

– Secure both coolant pipes -E and F- with the bracket -C- on

the heater core flange -H- .
Note
The screw -G- is used to help with the installation and must be
removed after the bracket is installed.
– Insert the screw -A- and the washer -B- and tighten the screw
-A- .
Screw tightening specification -A- 2.5 Nm.
– Remove the screw -G- .

– Make sure the grommet -H- fits correctly in the back of the
plenum chamber.
– Properly connect the coolant hoses to the heater core, pay
attention to the marking.
A - Supply hose from cylinder head
B - Return to the coolant pump
– Connect the coolant hose -A- to the heater core coolant pipe
(pay attention to the marking) and secure it with the clamp
-D- .
– Attach the coolant hose to the heater core -B- onto the coolant
pipe -F- just far enough as to not cover the bleed hole -G-.
– Remove the hose clamp from the coolant hose -A-.
– Fill the coolant expansion tank with coolant. Refer to ⇒ Rep.
ing .
– Carefully force the coolant out of the coolant overflow reservoir
into the heater core using, for example, the hand pump from
the Cooling System Tester - VAG1274B- .
– As soon as the coolant comes out the ventilation hole -G-, in‐
stall the coolant hose -B- on to the coolant pipe -F- at the
marking.
– Secure the coolant hose -B- with the clamp -E- on the marked
location.
– Remove the hose clamp from the coolant hose -D- .
– Add more coolant to the coolant reservoir, if necessary. Refer
to ⇒ Rep. Gr. 19 ; Coolant System/Coolant; Coolant, Draining
and Filling .
Note
This procedure completely bleeds the cooling system. If, for some
other reason, there is still some air in the cooling system, install
all removed components and bleed the system once again. Refer
to ⇒ Rep. Gr. 19 ; Coolant System/Coolant; Coolant, Draining
and Filling .
Check the Connections at the Heater Core for Leaks as Follows:

– Carefully increase the pressure in the coolant circuit by using,
for example, the hand pump of the Cooling System Tester -
VAG1274B- .

– Check the coolant circuit for leaks, paying special attention to

the connection between the coolant pipes and the heater core.
Refer to ⇒ Rep. Gr. 19 ; Coolant System/Coolant; Cooling
System, Checking for Leaks .
Note
♦ When bleeding the coolant circuit, take special care to ensure

complete bleeding of the heater core. If there are still air bub‐
bles in the heater core, it may cause the customer to complain
of insufficient heating output in winter or different air temper‐
ature from vents at same setting in regulated mode. Refer to
⇒ “5.10 A/C System Temperature Door Heat Output Activa‐
tion, Checking”, page 514 .
♦ Depending on vehicle equipment and on engine, heat insula‐
tion has been applied to coolant hoses, these must not be
damaged and must be re-applied after installing.
– Install all the components in reverse sequence. Refer to

⇒ “5.18 Heater Core, Preparing for Removal”, page 562 (Prep‐
aration work for removing the heater core).
– Attach the high voltage cables to the Electrical A/C Compres‐
sor - V470- and the Traction Battery - A2- to the Electric Drive
Power and Control Electronics - JX1- . Refer to ⇒ Electrical
System Hybrid; Rep. Gr. 93 ; High Voltage Cables; Overview
- High Voltage Cables .
– Install the cowl panel trim -C-. Refer to ⇒ Body Exterior; Rep.
Gr. 50 ; Bulkhead; Plenum Chamber Cover, Removing and
Installing .

– Make sure the Electric Drive Power and Control Electronics -

JX1- -D- and related wires -D- are installed correctly. Refer to
DANGER!
starts the vehicle.
Note

sequence:
♦ Body

All Vehicles

Note

wrong. Refer to

5.20 Condensation Water Drain, Removing

and Installing
Removing
– Remove the glove compartment (for the right condensation
water drain). Refer to ⇒ Body Interior; Rep. Gr. 68 ; Storage
Compartments and Covers; Glove Compartment, Removing
and Installing .
– Remove storage compartment on driver side (for the left con‐
densation water drain). Refer to ⇒ Body Interior; Rep. Gr. 68 ;
– Carefully fold the carpet near the condensation water drain
hose (left or right) far enough back, so that the condensation
water drain is visible. Refer to ⇒ Body Interior; Rep. Gr. 70 ;
Passenger Compartment Trim; Carpet, Removing and Instal‐
ling .

– Check the condensation water drain hoses -B- that they are
properly routed and for dirt. Correct, for example, if the hose
is constricted.
– Cover the area under both openings -D- (for condensation
water drain -C-) with absorbent paper (so that any water
present does not get under the carpet).
– Remove both condensation water drain hoses -B- .
– Check both A/C condensation water drains -A- for soiling (for
example, using a piece of wire).
– Check the gap between the insulation mat installed in the cen‐
ter tunnel -E- and the end of the condensation water hose
-C- above the openings -F- in the floor panel -D- ; the gap must
be large enough so that the condensation water can flow out
of the hose -B- .
Installing
following.
– Install both condensation water drain hoses -B- so that they
are not twisted or kinked (different versions for the left and right
side). Refer to the Parts Catalog.
– Make sure the carpet does not push up against the conden‐
sation water drain hose -B- when installing.
– If a condensation water drain hose -B- fits too loose on the A/
C condensation water drain -A-, secure it with a clamp, for ex‐
ample, so that it cannot slide off.
5.21 Condensation Water Drain, Checking

Note
♦ This vehicle is equipped with two condensation water drains

(left and right on the A/C unit or center tunnel).
♦ The end -C- of the condensation water drain hose -B- does not
have a valve or a door. The condensation water flows out over
the rubber seals.
♦ There are different versions of the condensation water drain
hoses -B-. On version “1” (see illustration above), the conden‐
sation water drain -B- is inserted directly in the opening -D-.
On version “2”, the condensation water drain -B- is inserted
into the bracket -A-. The bracket -A- is held in the opening
-D- in the floor panel -C- by tabs on the bracket -A-. After in‐
stalling the bracket -A-, the condensation water drain -B- must
be pushed with pretension into the floor panel -C- to prevent
any condensation water coming out of the drain -B- into the
passenger compartment. Seal the area between both parts
with silicone adhesive D176 001 A3. Refer to the Parts Cata‐
log.
For Complaints of Moisture in Passenger Compartment, Check

the Following as Well as Condensation Water Drain:
– Plenum chamber water drains. Refer to
page 607 .
– Check the cowl panel trim and the fresh air intake housing for
proper installation and damage. Refer to
page 600 .
– the dust and pollen filter for soiling and correct installation.
Refer to
556 .
– Forced air extraction vents in luggage compartment. Refer to
⇒ “6.7 Passenger Compartment Forced Air Extraction, Check‐
ing”, page 596 .
– Back pressure door/fresh air door activation and function and
air recirculation door for example, via the “output diagnostic
test mode” of the Guided Fault Finding using the Vehicle Di‐
agnostic Tester in the "Guided Fault Finding" function. Refer
to
⇒ “4.3 Airflow Door Motor V71 , Removing and Installing”,
page 408 and
⇒ “4.10 Recirculation Door Motor V113 , Removing and In‐
♦ If there are complaints regarding humidity in the passenger
compartment which only appears when the A/C compressor
is switched on and under certain climatic conditions, check the
temperature of the air coming out of the vents from the evap‐
orator as follows:
– Select “read measured values block” for Guided Fault Finding
(using the measured value from the Evaporator Vent Temper‐
ature Sensor - G263- ) using the Vehicle Diagnostic Tester in

– Check the output temperature of air at evaporator under con‐

ditions reported by the customer or at the following setting on
the Climatronic Control Module - J255- A/C display control
head, “Auto” operating mode, A/C compressor switched on
(indicator lamp in the AC or A/C button lights up), temperature
setting “Cold”, middle fresh air blower speed at a voltage of
approximately 7V on the Fresh Air Blower - V2- , fresh air mode
(indicator lamp “Recirculation” button does not light up) and
open instrument panel vents, the air vent temperature at the
evaporator.
– The sensor measured value is too low (at an ambient temper‐
ature above 0 °C (32 °F), longer time colder than 0 °C (32 °F))
or too high Even though the A/C system is working correctly,
above, for example, 10 °C (50 °F). Correct the cause of the
difference and note the information for the cooling output test.
Refer to ⇒ “3.8 Cooling Output, Checking”, page 73 .

6 Air Guide
Compartment”, page 581
⇒ “6.2 Air Intake and Outlet Openings”, page 586
⇒ “6.3 Driver Side Footwell Vent, Removing and Installing”, page
593
⇒ “6.4 Front Passenger Side Footwell Vent, Removing and In‐
⇒ “6.5 Plugs, Installing in Center Vent Air Duct”, page 595
⇒ “6.6 Passenger Compartment Forced Air Extraction, Removing
⇒ “6.7 Passenger Compartment Forced Air Extraction, Check‐
ing”, page 596
⇒ “6.8 Fresh Air Intake, Removing and Installing”, page 600
⇒ “6.9 Air Intake Duct, Removing and Installing”, page 604
⇒ “6.10 Plenum Chamber Water Drain, Removing and Installing”,
page 605
⇒ “6.11 Plenum Chamber Water Drain, Checking”, page 607
⇒ “6.12 Plenum Chamber Water Drain, Cleaning”, page 611
⇒ “6.13 Instrument Panel Vents and Rear Vents, Removing and
Housing”, page 616
⇒ “6.15 Rear Vent Air Guide Slots, Sealing”, page 617
6.1 Overview - Air Routing and Air Distribution in Passenger Compartment
Note
♦ Refer to ⇒ “6.2 Air Intake and Outlet Openings”, page 586

♦ For component locations of individual components. Refer to
⇒ “1.2 Overview - Components Inside Front Passenger Compartment”, page 135 and
⇒ “4 Actuators”, page 388 .
♦ The passenger compartment ventilation occurs via two vent frames (in luggage compartment at the right
and left near the bumper). Refer to
⇒ “6.7 Passenger Compartment Forced Air Extraction, Checking”, page 596 (passenger compartment
forced air extraction).
♦ The air routing and the air distribution in the passenger compartment is different on vehicle equipped with
the “Convenience” A/C system and the “Basis” A/C system.
♦ The following illustrations show the location of the components on an Audi A5 Coupe; an Audi A5 Sportback,
Audi A4, Audi Q5, etc. The location of the components varies slightly. The description of the components is
not different; removing and installing is performed in the same way as on the Audi A5 Coupe.
6. Air Guide 581

1 - Defroster Vent/Windshield
❑ Air guide to windshield
ling. Refer to ⇒ Body
Instrument Panel; Front
Center Defroster Vent,
ling .
❑ If the intermediate piece
air flow/defrost (-item 8-
⇒ Item 8 (page 583)
and -item 7-
⇒ Item 7 (page 583) )
was crushed or crum‐
pled when the dash pan‐
el was being installed,
then the air flow to the
windshield will be un‐
even or insufficient. Re‐
fer to ⇒ Body Interior;
Rep. Gr. 70 ; Instrument
Panel; Instrument Pan‐
el, Removing and Instal‐
ling .
2 - Vents for Indirect Ventila‐
tion
❑ Installed only in vehicles
with “Convenience” ver‐
sion A/C system
❑ Air flows out of these
vents on vehicles equip‐
ped with the “Conven‐
ience” A/C system. The
opening in the A/C unit
is sealed (different A/C
versions) on vehicles
equipped with the “Ba‐
sis” A/C system.
3 - Instrument Panel
❑ With air guides to defroster vents and various instrument panel vents
❑ There are different versions, depending on the A/C system version (“Convenience” and “Basis”). Refer
❑ Removing and installing. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instrument Panel; Instrument Panel,
4 - Defroster Vent/Right Side Window
Panel .
5 - Right Instrument Panel Vent
6 - Air Guide/Instrument Panel
❑ With air guides to defroster vents and various instrument panel vents
❑ The air guide is a component of the instrument panel -item 3- ⇒ Item 3 (page 582) and cannot be replaced
separately. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instrument Panel; Overview - Instrument Panel .
❑ Instrument panel removing and installing. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instrument Panel;
Instrument Panel, Removing and Installing .

7 - Air Guide Intermediate Piece/Defrost (“Basis”)

❑ To remove and install, remove the instrument panel. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instrument
Panel; Instrument Panel, Removing and Installing .
❑ If the intermediate piece for air routing/defrost was crushed or crumpled when the instrument panel was
installed, the air routed to the windshield will be uneven or insufficient. Refer to ⇒ Body Interior; Rep.
Gr. 70 ; Instrument Panel; Instrument Panel, Removing and Installing .
8 - Air Guide Intermediate Piece/Defrost (“Convenience”)
❑ If the intermediate piece for air routing/defrost was crushed or crumpled when the instrument panel was
installed, the air routed to the windshield will be uneven or insufficient. Refer to ⇒ Body Interior; Rep.
Gr. 70 ; Instrument Panel; Instrument Panel, Removing and Installing .
9 - Air Duct to the Right Instrument Panel Vent
⇒ “5.12 Heater and A/C Unit Air Intake Housing, Removing and Installing”, page 537 (A/C air intake
housing, removing and installing)
10 - Air Duct to the Right Instrument Panel Vent
❑ Removing and installing. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instrument Panel; Instrument Panel
Vent, Removing and Installing .
11 - Fresh Air Intake
❑ The air is extracted out of the plenum chamber. Refer to
12 - A/C Unit with Air Intake Housing
to ⇒ “5.1 Overview - Attachments for Heater and A/C Unit and Air Intake Housing”, page 451 and the
Parts Catalog
❑ A/C unit, removing and installing. Refer to
❑ Air intake housing, removing and installing. Refer to
⇒ “5.12 Heater and A/C Unit Air Intake Housing, Removing and Installing”, page 537
❑ Air intake apparatus, air outlet and air guide in A/C unit. Refer to
⇒ “6.2 Air Intake and Outlet Openings”, page 586
13 - Air Intake from the Vehicle Interior (Recirculating Air Mode)
❑ The air is taken from the passenger footwell under the glove compartment.
14 - Right Front Footwell Vent
⇒ “6.4 Front Passenger Side Footwell Vent, Removing and Installing”, page 594 .
15 - Air Guide to the Rear Vents
❑ On vehicles equipped with the “Basis” A/C system, there is no air guide and no vents in the rear center
console.
6. Air Guide 583

Note
This air guide is attached to the air

outlet openings of the A/C unit.
There are slits inside the air guide.
If the door position is incorrect, es‐
pecially on vehicles with the “Con‐
venience” A/C system, whistling
noise can come from these slits.
The upper slits are covered with
tape during production (adhesive
strips from 02/2009 as a running
change). Refer to
⇒ “6.15 Rear Vent Air Guide Slots,
Sealing”, page 617 .
16 - Air Duct to Right Rear Footwell Vent

❑ Removing and installing; carpet, removing. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Passenger Com‐
partment Trim; Carpet, Removing and Installing .
17 - Right Rear Footwell Vent
❑ The air flows out from under the front passenger seat.
Note
The right rear footwell vent can be

removed without having to remove
the carpet; just separate the con‐
necting rib on the carpet. Secure the
connecting rib again with a suitable
adhesive after installing the footwell
vent.
18 - Air Guide to Vent in Rear Center Console

❑ Removing and installing; rear center console, removing. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Center
Console; Center Console, Removing and Installing .
19 - Air Guide to Vent in Rear Center Console
❑ Removing and installing; rear center console, removing. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Center
Console; Center Console, Removing and Installing .
20 - Vent in Rear Center Console
❑ To remove and install. Refer to
Interior; Rep. Gr. 68 ; Center Console; Overview - Center Console .
❑ Only installed on the “Convenience” A/C system (on the “Basis” A/C system, the opening in the center
console is sealed).
❑ With Rear Temperature Selection Potentiometer - G538-
❑ The Rear Temperature Selection Potentiometer - G538- is vent component and cannot be replaced
separately. Refer to the Parts Catalog
21 - Left Rear Footwell Vent
❑ The air flows out under the driver seat.

Note
The left rear footwell vent can be re‐

moved without having to remove the
carpet; just separate the connecting
rib on the carpet. Secure the con‐
necting rib again with a suitable ad‐
hesive after installing the footwell
vent.
22 - Air Duct to Left Rear Footwell Vent

23 - Left Front Footwell Vent
⇒ “6.3 Driver Side Footwell Vent, Removing and Installing”, page 593 .
24 - Air Duct to the “Center” Instrument Panel Vent
❑ On vehicles equipped with the “Basis” A/C system, the Center Vent Temperature Sensor - G191- is
installed in this air guide. Refer to
❑ On vehicles equipped with the “Convenience” A/C system, the Center Vent Temperature Sensor - G191-
opening in the air guide is sealed with a grommet (the Center Vent Temperature Sensor - G191- is not
installed here). Refer to Parts Catalog
Note
This air guide has an opening. At

certain setting, whistling noises may
be present at this opening. There‐
fore, this opening is sealed with a
plug at the factory (running change
from 02/2009). Refer to
⇒ “6.5 Plugs, Installing in Center
Vent Air Duct”, page 595 .
25 - Air Duct to the Left Instrument Panel Vent

26 - Air Duct to the Left Instrument Panel Vent
❑ Removing and installing. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instrument Panel; Instrument Panel
Vent, Removing and Installing .
27 - Center Instrument Panel Vent
28 - Left Instrument Panel Vent
29 - Defroster Vent/Left Side Window
Panel .
6. Air Guide 585

6.2 Air Intake and Outlet Openings
Note
♦ Air routing and air distribution in passenger compartment. Re‐

fer to
♦ Component locations for the individual components; refer to
⇒ “1.2 Overview - Components Inside Front Passenger Com‐
partment”, page 135 (A/C system components in the passen‐
ger compartment), and refer to ⇒ “4 Actuators”, page 388
(components for the A/C unit and air intake housing).
♦ The air routing and the air distribution in the passenger com‐
partment is different on vehicle equipped with the “Conven‐
ience” A/C system and the “Basis” A/C system.
Air Intake and Air Outlet Openings and A/C Unit. Refer to
⇒ , page 586 .
Air Routing in Air Intake Housing and A/C Unit. Refer to
⇒ , page 589 .
Temperature Doors in the Left and Right Radiator Housing. Refer
to ⇒ , page 591 .
Air Intake and Air Outlet Openings and A/C Unit
Note
♦ This illustration show the “Convenience” A/C system; some vent openings are not part of the “Basis” A/C
system.
♦ The activation of the different doors in the vents and the temperature doors differs between the “Basis” and
“Convenience” A/C systems

1 - A/C Unit
sions depending on the
A/C system installed
(“Convenience” and
“Basis”). Refer to
⇒ “5.1 Overview - At‐
tachments for Heater
and A/C Unit and Air In‐
take Housing”,
page 451 (A/C unit, dis‐
assembling and assem‐
bling) and to the Parts
Catalog
❑ A/C unit, removing and
Unit, Removing and In‐
ling. Refer to
ling”, page 537 .
sembling. Refer to
take Housing”,
page 464 .
3 - Air Outlet to the Left Indirect
Ventilation Vent
❑ Present only on vehicles
equipped with the “Con‐
venience” A/C system
(not on the “Basis” A/C
system).
❑ Depending on the setting, different temperatures for the left and right side are possible. Refer to
4 - Air Outlet to the Right Indirect Ventilation Vent
❑ Present only on vehicles equipped with the “Convenience” A/C system (not on the “Basis” A/C system).
5 - Air Outlet to the Instrument Panel Defroster Vent
❑ The air is extracted out of the plenum chamber. Refer to
8 - Air Intake from the Vehicle Interior (Recirculating Air Mode)
❑ The air is taken from the passenger footwell under the glove compartment.
9 - Air Outlet to the Right Instrument Panel Vent
❑ On the “Basis” A/C system, the doors in the vents to the left and right instrument panel vents are con‐
nected by a connecting rod. Refer to
6. Air Guide 587

10 - Air Outlet to Right Front Footwell Vent

❑ On the “Basis” A/C system, the doors in the vents to the front left and right footwell are connected by a
connecting rod. Refer to ⇒ “5.2 Overview - Air Distribution Housing Doors and Partitions”, page 461 .
11 - Air Outlet to the Right Center Instrument Panel Vent
❑ Depending on the setting on the “Convenience” A/C system, different air temperatures are possible on
the left and right side. Refer to
❑ On the “Basis” A/C system, the left and right side is included in one vent and only one door in installed.
Refer to ⇒ “5.2 Overview - Air Distribution Housing Doors and Partitions”, page 461 .
12 - Air Outlet to the Left Center Instrument Panel Vent
❑ Depending on the setting on the “Convenience” A/C system, different air temperatures are possible on
the left and right side. Refer to
❑ On the “Basis” A/C system, the left and right side is included in one vent and only one door in installed.
Refer to ⇒ “5.2 Overview - Air Distribution Housing Doors and Partitions”, page 461 .
13 - Air Outlet to Right Rear Footwell Vent
❑ On the “Basis” A/C system, the doors in the left and right rear footwells are connected to each other by
a shaft. Refer to ⇒ “5.2 Overview - Air Distribution Housing Doors and Partitions”, page 461 .
❑ Depending on the setting, on the “Convenience” A/C system, different air temperatures are possible for
the front and rear. Refer to ⇒ “5.2 Overview - Air Distribution Housing Doors and Partitions”, page 461 .
14 - Outlet to Vent in Rear Right Center Console
❑ Depending on the setting, different air temperatures for the front and rear are possible. Refer to
15 - Outlet To Vent in Rear Left Center Console
❑ Depending on the setting, different air temperatures for the front and rear are possible. Refer to
16 - Air Outlet to The Rear Left Footwell Vent
❑ On the “Basis” A/C system, the doors in the left and right rear footwells are connected to each other by
a shaft. Refer to ⇒ “5.2 Overview - Air Distribution Housing Doors and Partitions”, page 461 .
❑ Depending on the setting, on the “Convenience” A/C system, different air temperatures are possible for
the front and rear. Refer to ⇒ “5.2 Overview - Air Distribution Housing Doors and Partitions”, page 461 .
17 - Air Outlet to the Front Left Footwell Vent
❑ On the “Basis” A/C system, the doors in the vents to the front left and right footwell are connected by a
connecting rod. Refer to ⇒ “5.2 Overview - Air Distribution Housing Doors and Partitions”, page 461 .
18 - Air Outlet to the Left Instrument Panel Vent
❑ On the “Basis” A/C system, the doors in the vents to the left and right instrument panel vents are con‐
nected by a connecting rod. Refer to

Air Routing in Air Intake Housing and A/C Unit
Note
♦ This illustration shows the “Convenience” A/C system; some components are not part of the “Basis” A/C
system.
♦ The activation of the different doors in the vents and the temperature doors differs between the “Basis” and
“Convenience” A/C systems
♦ In order to show the air flow in the air intake house and in the A/C unit, both these components are shown
cut open through the “A - A” and “B - B” lines.
♦ This illustration shows the A/C without a connection for glove compartment cooling. On vehicles with glove
compartment cooling, the cooled air comes directly past the evaporator into the glove compartment
-item 8- ⇒ Item 8 (page 590) .
1 - A/C Unit
sions, depending on the
A/C system version
(“Convenience” and
“Basis”). Refer to
⇒ “5.1 Overview - At‐
tachments for Heater
and A/C Unit and Air In‐
take Housing”,
page 451 and the Parts
Catalog
❑ The air is extracted out
of the plenum chamber.
Refer to
⇒ “6.8 Fresh Air Intake,
ling”, page 600 .
4 - Air Intake from the Vehicle
Interior (Recirculating Air
Mode)
❑ The air is drawn out of
the front passenger
footwell when the air re‐
circulation flap under
the glove compartment
is open.
❑ In this illustration, the air
recirculation door is
shown in the “closed”
position.
sions of the dust and pollen filter (without and with filter insert with activated charcoal). Refer to
⇒ “3.11 Dust and Pollen Filter with Activated Charcoal Insert, Element Information”, page 107 and the
Parts Catalog
6. Air Guide 589

7 - Air Intake Housing Lower Section (with Installation Components)

❑ This illustration shows the air intake housing sectioned by the “A - A ” line.
8 - Evaporator
9 - Lower Part of the A/C Unit (with Installation Components)
❑ This illustration shows the A/C unit sectioned by the “A - A ” line
10 - Temperature Door for the Front Right Vent
❑ In this illustration, the temperature door is shown in the “heat” position.
❑ On the “Convenience” A/C system, the front right and left temperature doors are each actuated by an
actuator. Both temperature doors for the rear vents are connected to each other by a connecting rod;
they are actuated by another actuator. Refer to
❑ On the “Basis” A/C system, one shaft connects the front temperature flaps and the temperature flap for
the rear footwell vent to each other. The right and left temperature flap shafts are connected to each
other by a connecting rod; they are actuated by one actuator. Refer to
❑ Temperature doors in the left and right radiator housing. Refer to ⇒ , page 591 .
11 - Right Rear Vent Temperature Door
❑ In this illustration, the temperature door is shown in the “cooling” position.
❑ Instructions for actuating the temperature doors -item 10- ⇒ Item 10 (page 590)
12 - Heat Exchanger
❑ Heat exchanger with the A/C unit installed, removing and installing. Refer to
❑ Covered with different foam seals, depending on the A/C system version (“Convenience” and “Basis”).
Refer to ⇒ “5.19 Heater Core, Removing and Installing”, page 567 .
The Auxiliary Heater Heating Element - Z35- is installed on vehicles with a diesel engine and on vehicles with
certain gasoline engines. Refer to ⇒ “5.8 Auxiliary Heater Heating Element Z35 , Checking”, page 506 .
Vehicles with a gasoline engine and without an Auxiliary Heater Heating Element - Z35- have a honeycomb
installed in the installation space as a place holder (this assures that current conditions in the A/C unit with and
without Auxiliary Heater Heating Element - Z35- are the same).
Note
♦ As a running change from MY
2010, gasoline engines that can
run on bioethanol (Flex Fuel ve‐
hicles) were introduced, which
currently have an Auxiliary Heat‐
er Heating Element - Z35- . Refer
to
page 506 .


page 506 .
14 - Separator Wall
❑ Present only on vehicles equipped with the “Convenience” A/C system (not on the “Basis” A/C system;
here only one temperature setting for all vents is possible).
❑ On the “Convenience” version, the air guide to the left and right vents separate and responsible for the
differing air temperatures coming out of the vents. The temperature of the air coming out depends on
the position of the respective temperature doors -item 10- ⇒ Item 10 (page 590) .
15 - Separator Wall
❑ Present only on vehicles equipped with the “Convenience” A/C system (not on the “Basis” A/C system;
here only one temperature setting for all vents is possible).
❑ On the “Convenience” A/C system, the air flow to the front and rear vents are separated from each other;
the requirement for different front and rear air temperatures (depends on the setting of each temperature
door -item 10- ⇒ Item 10 (page 590) ).
16 - Temperature Door for the Rear Left Vent
❑ Instructions for actuating the temperature doors -item 10- ⇒ Item 10 (page 590) .
17 - Temperature Door for the Front Left Vent
❑ Instructions for actuating the temperature doors -item 10- ⇒ Item 10 (page 590) .
Temperature Doors in the Left and Right Radiator Housing
Note
♦ On the “Convenience” A/C system, the front right temperature doors -item 1- ⇒ Item 1 (page 592) and the
front left -item 2- ⇒ Item 2 (page 592) are each actuated by an actuator ( Right Temperature Door Motor
- V159- and Left Temperature Door Motor - V158- ) . Both temperature doors for the right rear vents
-item 3- ⇒ Item 3 (page 592) and the left rear -item 4- ⇒ Item 4 (page 592) are connected to each other
by a connecting rod; they are actuated via the Rear Temperature Door Motor - V137- . Refer to
♦ On the “Basis” A/C system, the temperature door for the right instrument panel vents -item 1-
⇒ Item 1 (page 592) and the front and rear right footwell vents -item 3- ⇒ Item 3 (page 592) as well as
the temperature door for the left instrument panel vents -item 2- ⇒ Item 2 (page 592) and the front and
rear left footwell vents -item 4- ⇒ Item 4 (page 592) are connected to each other by the shafts (-item 13-
⇒ Item 13 (page 593) and -item 12- ⇒ Item 12 (page 593) ) . The right -item 3- ⇒ Item 3 (page 592)
and left -item 4- ⇒ Item 4 (page 592) temperature door shafts are connected to each other by a connecting
rod; they are both actuated by the Temperature Regulator Door Motor - V68- . Refer to
6. Air Guide 591

1 - Upper Right Temperature

Door
❑ On the “Convenience”
A/C system, for the right
and center instrument
panel vents as well as
the front right footwell
vent
❑ On the “Basis” A/C sys‐
tem, for the right and
center instrument panel
vents
❑ In this illustration, the
temperature door is
shown in the “heat” po‐
sition.
Note
The “Basis” A/C system does not

have separating walls, therefore, air
does not get diffused after it has left
the Auxiliary Heater Heating Ele‐
ment - Z35- /honeycomb.
2 - Upper Left Temperature

Door
❑ On the “Convenience”
A/C system, for the left
and left center instru‐
ment panel vents as well
as for the front left foot‐
well vent
❑ On the “Basis” A/C sys‐
tem, for the left and cen‐
ter instrument panel
vents -item 1-
⇒ Item 1 (page 592) .
3 - Lower Right Temperature Door
❑ On the “Convenience” A/C system, for the rear right footwell vents
❑ On the “Basis” A/C system, for the front right and rear right footwell vents -item 1- ⇒ Item 1 (page 592) .
4 - Lower Left Temperature Door
❑ On the “Convenience” A/C system, for the rear left footwell vents
❑ On the “Basis” A/C system, for the left front and the left rear footwell vents -item 1-
⇒ Item 1 (page 592) .
5 - Right Radiator Housing
❑ Different versions, depending on the A/C system version (“Convenience” and “Basis”).
6 - Left Radiator Housing
❑ Different versions, depending on the A/C system version (“Convenience” and “Basis”).
7 - Heat Exchanger
Refer to ⇒ “5.19 Heater Core, Removing and Installing”, page 567 .
8 - Foam Seal
❑ Only on vehicles equipped with the “Convenience” A/C system; present to separate the air flow between
the right and left side

9 - Foam Seal
❑ Only on vehicle equipped with the “Convenience” A/C system; equipped to separate the air flow between
the front and rear
Note

11 - Foam Seal
❑ Only on vehicles equipped with the “Convenience” A/C system; present to separate the air flow between
the right and left side
12 - Upper Temperature Door Shaft
❑ on the “Basis” A/C system, connected with the shaft -item 13- ⇒ Item 13 (page 593) (the doors move
together).
13 - Lower Temperature Door Shaft
❑ on the “Basis” A/C system, connected with the shaft -item 12- ⇒ Item 12 (page 593) (the doors move
together).
14 - Upper Temperature Door Shaft
❑ On the “Convenience” A/C system, located in the shaft -item 15- ⇒ Item 15 (page 593) (the doors move
independent of each other).
15 - Lower Temperature Door Shaft
❑ On the “Convenience” A/C system, located in the shaft -item 14- ⇒ Item 14 (page 593) (the doors move
independent of each other).
6.3 Driver Side Footwell Vent, Removing

and Installing
Removing
6. Air Guide 593

– Remove the connector -C- from the Footwell Vent Tempera‐

ture Sensor - G192- / Left Footwell Vent Temperature Sensor
- G261- .
– Left footwell vent -B-, removing
Installing
following.
6.4 Front Passenger Side Footwell Vent,

Note
From 01/2008, A/C units which have an additional connection for

the glove compartment cooling are being installed. Refer to
Housing”, page 616 . Make sure that the correct right radiator
housing and air intake housing are installed. Refer to the Parts
Catalog.
Removing
– Disconnect the connector -A- from the temperature sensor
(only installed on the “Convenience” A/C system).
– Remove the right footwell vent -C-.
Installing
following.
J255- display and control head and erase any malfunctions
displayed if necessary (only on the “Convenience” A/C sys‐
tem) using the Vehicle Diagnostic Tester in the "Guided Fault
Finding" function.

6.5 Plugs, Installing in Center Vent Air Duct
Note
This air guide has an opening. At certain setting, whistling noises

may be present at this opening. Therefore, this opening is sealed
with a plug at the factory (running change from 02/2009).
– Cover the upper center console to prevent damage.

– Remove the Front Information Display Control Head - J685- .
Refer to ⇒ Communication; Rep. Gr. 91 ; Infotainment Sys‐
tem; Infotainment System Display, Removing and Installing .
– Reach into the opening in the instrument panel and install the
plug -B- into the opening in the air guide -A-.
– Make sure the plug -B- fits tightly inside the opening -A-.
Note
♦ The illustration shows the opening -A- on an Audi A4. On the

Audi Q5 is covered by a brace and is difficult to reach.
♦ The plug -B- is a replacement part (replacement part number:
8K9 805 673 C). Refer to the Parts Catalog.
6.6 Passenger Compartment Forced Air Ex‐

traction, Removing and Installing
Note
♦ One vent frame -A- is installed in the body vent opening -C-
on the left and the right for the forced air extraction.
♦ The forced air extraction vent frames -A- are removed and in‐
stalling from the outside (with the bumper cover removed).
♦ There are different versions of the vent frame for the forced air
extraction -A- on vehicles with and without noise insulation
-D-. Installing the noise insulation -D- depends on the version
of the vehicle. Refer to the Parts Catalog.
– Remove the rear bumper cover. Refer to ⇒ Body Exterior;

Rep. Gr. 63 ; Rear Bumper; Bumper Cover, Removing and
Installing .
6. Air Guide 595

Note
♦ The ventilation frames -A- can only be installed in one position

to ensure the sealing lips -B- close correctly.
♦ In this illustration, ventilation frame -A- is depicted with rear
bumper cover removed.
♦ When installing, vent frame -A- should be pressed into open‐
ing on the rear lid end piece until all retaining tabs engage
securely.
6.7 Passenger Compartment Forced Air Ex‐

traction, Checking

6. Air Guide 597

Note
♦ The following is a test for the forced air extraction on an Audi

A5 Coupe. On other vehicles such as the Audi A5 Sportback,
Audi A4, Audi Q5, etc. the location of the components may
differ, but removing and installing the components is identical.
♦ On the Audi A4 sedan, the passenger compartment is venti‐
lated by an opening between the rear window -B- and the rear
shelf -A- (in the body) into the luggage compartment. The air
is guided through the ventilation openings -C- in the space
between the body and the luggage compartment trim -D-.
♦ On the Audi A4 Avant and the Audi Q5 the air is routed via the
left and right sides in the vent grille -A- installed in the side trim
panel near the back of the luggage compartment side trim
panel. From there the air flows to the ventilation frame -B-.
♦ On the roof is closed on the Audi A5 Cabrio, for example, over
the openings near the rear shelf -A- (behind the head restraints
-B-), the air is guided through the safety belt guides -C- and
through the roof trim -D-.
♦ The passenger compartment on the Audi A5 Cabrio is venti‐
lated the same way as on the other vehicles when the roof is
closed. There are ventilation slots -C- in the luggage compart‐
ment trim panel -B-, which guide the air to the ventilation frame
for forced air extraction -A-.
♦ One vent frame -A- is installed in the body vent opening -C-
on the left and the right for the forced air extraction.
♦ The forced air extraction vent frames -A- are removed and in‐
stalling from the outside (with the bumper cover removed).
♦ There are different versions of the vent frame for the forced air
extraction -A- on vehicles with and without noise insulation
-D-. Installing the noise insulation -D- depends on the version
of the vehicle. Refer to the Parts Catalog.
♦ For vehicles with a high voltage system (hybrid vehicles), the
Auxiliary Battery - A1- might need to be removed so that the
left noise insulation cover -D- can be reached. Refer to ⇒
Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Remov‐
ing and Installing .
Checking the Ventilation Openings in the Luggage Compartment

Trim Panel
– Check the air routing through the vent frames for the left and
right luggage compartment trim panels -C- and behind the
luggage compartment trim panel (left and right) to both vent
frames -A- to make sure they are not blocked.
Note
♦ To ensure proper passenger compartment ventilation, the left

and right ventilation frames -C- in the luggage compartment
trim panel must not be blocked.
♦ Obstructed ventilation frames in the luggage compartment trim
panels -C- or obstructed vents in the ventilation frames -A- can
cause the windows to fog up.
♦ The illustration shows the luggage compartment on an Audi
A5 Coupe. On the Audi A5 Sportback, the Audi A4, the Audi
Q5, the location of the components may differ.

Check Forced Air Extraction Vent Frames from Inside:

– Remove the luggage compartment trim panel covers (left and
right). Refer to ⇒ Body Interior; Rep. Gr. 70 ; Luggage Com‐
partment Trim Panels; Overview - Luggage Compartment
Side Trim Panel .
– Make sure the left and right ventilation frames -A- are not ob‐
structed.
Note
♦ Sealing lips -B- in vent frames -A- must move freely and close
by themselves, stuck sealing lips -B- can cause windows to
fog.
♦ On vehicles equipped with noise insulation -D-, make sure the
air vent under the noise insulation -arrow- leading to the ven‐
tilation frame -A- is not obstructed by objects.
♦ Closed or plugged air ducts to the vent frames -A- can cause
windows to fog.
♦ To ensure sealing lips -B- close correctly, vent frame -A- must
be installed on the correct side.
Check Forced Air Extraction Vent Frames from the Outside:

– Remove the rear bumper cover. Refer to ⇒ Body Exterior;
Rep. Gr. 63 ; Rear Bumper; Bumper Cover, Removing and
Installing .
– Make sure the left and right ventilation frames -A- are not ob‐
structed and that the sealing lips -B- function properly.
Note
♦ Stuck sealing lips -B- can cause windows to fog.

♦ The ventilation frames -A- can only be installed in one position
to ensure the sealing lips -B- close correctly.
♦ In this illustration, ventilation frame -A- is depicted with rear
bumper cover removed.
6. Air Guide 599

6.8 Fresh Air Intake, Removing and Instal‐

ling
Note
♦ Depending on the version, for some countries with high dust

levels (for example China), a dust filter -C-is installed in the
filter mount -B- instead of the intake grille -A-. The dust filter
-C- prevents pollen and sand from getting sucked into the
Fresh Air Blower - V2- . Refer to the Parts Catalog.
♦ Make sure when removing the dust filter -C- that dirt does not
fall into the A/C intake shroud.
♦ The dust filter -C- is held in the filter mount -B- with the tab
-D-.
♦ Note the replacement interval for the dust filter -C-. Refer to
Maintenance Table
♦ Clean the air intake shroud and the area around the dust filter
-C- in the plenum chamber before installing a new filter.
♦ Pay attention to the air flow direction -arrows- when installing
the dust filter -C-.
Preliminary Work
General Warnings .
WARNING

voltage system.

WARNING

connector.
DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
6. Air Guide 601

cover -B-. Refer to
Warnings .
General Warnings .
Note
To clean the water drains, it may be necessary to remove the cowl

panel trim -C-. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Bulkhead;
Plenum Chamber Cover, Removing and Installing .

Note
♦ The following illustrations show the location of the components

on an Audi A5 Coupe; an Audi A5 Sportback, Audi A4, Audi
Q5, etc. the location of the components varies slightly. The
description of the components is not different; removing, in‐
stalling and checking is performed in the same way as on the
Audi A5 Coupe.
♦ The fresh air intake shaft -A- may have an additional cover
with a rain water drain channel -B- depending on the vehicle
version and the plenum chamber cover installed. Refer to the
Parts Catalog.

– Remove both windshield wiper arms (only on vehicles where

the cowl and the fresh air intake cover on the cowl -A- are one
piece). Refer to ⇒ Electrical Equipment; Rep. Gr. 92 ; Wind‐
shield Wiper System; Windshield Wiper Arms, Removing and
Installing .
– Pull off the rubber seal -B- on the left side as far as necessary.
Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Bulkhead; Plenum
– Remove the cover for the fresh air intake on the cowl panel
trim -A- or the cowl panel trim (different versions). Refer to ⇒
Body Exterior; Rep. Gr. 50 ; Bulkhead; Plenum Chamber
Cover, Removing and Installing .
Note
If necessary, carefully loosen the cowl panel trim from the retainer
on the windshield cross member -C-. Refer to ⇒ Body Exterior;
Rep. Gr. 50 ; Bulkhead; Plenum Chamber Cover, Removing and
Installing .
All Vehicles
Checking
– Check the cowl panel trim -A- for proper installation and dam‐
age. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Bulkhead;
– Check the seals between the fresh air intake cover -A-, the
cowl and the windshield cross member -C- for damage and
proper fit. These seals prevent water from entering between
the window cross member and the cowl panel trim and running
into the A/C intake shroud. Refer to ⇒ Body Exterior; Rep. Gr.
50 ; Bulkhead; Plenum Chamber Cover, Removing and In‐
stalling .
Note
Depending on the version, for some countries with high dust lev‐
els (for example China), a dust filter installed instead of intake air
grille -A-, which prevents dust and sand from entering the fresh
air blower. Refer to the Parts Catalog.
– Perform the preparatory work. Refer to ⇒ page 600 .
– Disconnect the connector -B- from the Air Quality Sensor -

G238- / Humidity Sensor in Fresh Air intake Duct - G657-
(there are different locations).
Note
There are different versions of the air intake shroud for the fresh
air intake -C- (with and without a mount for the Air Quality Sensor
- G238- -A-, front mount or on the side). To ensure the correct
version. Refer to the Parts Catalog.
6. Air Guide 603

– If equipped, remove the screws -C- (tightening specification:

3 Nm) and remove the cover with the rain water drain channel
-B-.
– Remove the screws -B-.

– Remove the fresh air intake -C- .
• Pay attention to the tightening sequence for the nuts -B- when
installing them.
– Tighten the nuts -B- lightly by hand in the following sequence.
♦ Tighten the inner lying nut -B- (at right in the illustration).
♦ Tighten the outer lying nut -B- (top left in the illustration).
♦ Tighten the outer lying nut -B- (bottom left in the illustration).
– Tighten the nuts -B- according to the above tightening se‐
quence (tightening specification: 3.5 Nm).
Note
♦ Check for damage prior to installing the fresh air intake -C- on
the fresh air intake and the bonded seal; if there is damage,
replace the seal or fresh air intake -C-. Refer to the Parts Cat‐
alog .
♦ When installing, make sure the fresh air intake -C- and seal
are seated correctly; if the fresh air intake -C- is not installed
correctly, water can seep into the A/C unit intake shroud
through the sealing surface -D-.
♦ Prior to installing the cowl cover -A- (there are different ver‐
sions), check the cowl and the seals for the cover -A- and the
window cross member -C- for damage; if the cover, the cowl
or the seal are damaged, water can seep into the fresh air
intake and also into the A/C intake shroud.
6.9 Air Intake Duct, Removing and Installing

Removing

– Loosen the catches -A- and remove the air intake duct -B- from
the air intake housing -C-
Installing
following.
– Insert the air intake duct -B- into the brackets -C- on the air
intake housing -C- and join both parts together.
Note
If one of the retaining tabs -A- has broken off or if one of the wel‐
ded points no longer holds, both housing parts can be bolted
together with screws -D- .

6.10 Plenum Chamber Water Drain, Remov‐

ing and Installing
Removing
General Warnings .
WARNING

voltage system.
6. Air Guide 605

WARNING

connector.
DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.

cover -B-. Refer to
Warnings .
General Warnings .
All Vehicles
Note

Audi A5 Coupe.
♦ The water drain grommets -A- are snapped into the plenum
chamber openings from above.
– Remove the grommets -B- by pressing them from the top, out
the water drain openings -A- .
Installing
– Install the grommets -A- by pressing them from the top, into
the water drain openings.
– Check the function of the -A- grommets after installing them
(the valves -B- must not stick and must close)
– Install all removed components again in reverse order.
6.11 Plenum Chamber Water Drain, Check‐

ing
General Warnings .
6. Air Guide 607


WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
6. Air Guide 609

cover -B-. Refer to
Warnings .
General Warnings .
All Vehicles

Note

Audi A5 Coupe.
♦ The draining of water from plenum chamber may be impaired
by deposits (leaves, diverse tree needles etc.) accumulating
in plenum chamber water drains -A-. The water level in the
plenum chamber then rises if the vehicle is taken to an auto‐
matic car wash or in the event of heavy rain, water enters via
intake housing into the A/C unit and is blown by the Fresh Air
Blower - V2- onto the evaporator together with the air con‐
veyed.
♦ If both water drain grommets -A- (right and left in plenum
chamber) are blocked by leaves and pine needles, it may
cause the drains to freeze up in winter and water can no longer
drain out. After a short drive, heat emitted from engine and
exhaust system melts the ice in the drains again and water
may drain off again before vehicle arrives at the workshop.
♦ In addition to the two water drain grommets -A- there is an
opening on the right side of the body -C- in which water can
drain out behind the wheel housing in case both water drain
grommets -A- should become obstructed. Likewise, make
sure these openings are not obstructed by dirt.
– Check the function of the -A- grommets (the valves -B- must
not stick or be obstructed with dirt)
Note
To check the water drains that are difficult to reach, use a com‐
mercially available and illuminated endoscope, for example. It is
best to use one that has a flexible waterproof head.
6.12 Plenum Chamber Water Drain, Clean‐

ing
General Warnings .
6. Air Guide 611

WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
6. Air Guide 613

cover -B-. Refer to
Warnings .
General Warnings .
Note
To clean the water drains, it may be necessary to remove the cowl

panel trim -C-. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Bulkhead;

All Vehicles

Note

Audi A5 Coupe.
♦ In addition to the two water drain grommets -A- there is an
opening on the right side of the body -C- in which water can
drain out behind the wheel housing in case both water drain
grommets -A- should become obstructed. Likewise, make
sure these openings are not obstructed by dirt.
– Clean the left and right water drains -A- .

– Clean the plenum channel from debris (leaves, pine tree nee‐
dles) and other objects.
Note
Use a commercially available flexible gripping tool to clean, for

example coarse dirt from difficult to reach water drains. Then
wash out the any remaining contaminates.
6. Air Guide 615

6.13 Instrument Panel Vents and Rear Vents,

Note

Q5, etc. the location of the components varies slightly. Re‐
moving and installing the components is the same as descri‐
bed for the Audi A5 Coupé.
♦ Instrument panel vents -B and C-, removing and installing.
Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instrument Panel;
Instrument Panel Vent, Removing and Installing .
♦ Remove the vent in the rear center console in the same way
as removing the vents in the instrument panel. Refer to ⇒ Body
Interior; Rep. Gr. 68 ; Center Console; Overview - Center
Console .
Caution
♦ So that instrument panel vent is not damaged when re‐

moving, the T-Handle Hook - 3438- -A- must not be en‐
gaged on to fins of the vents -B and C-.

– Open the affected vent.
– Insert the T-Handle Hook - 3438- -A- into the vent as illustra‐
ted.
– Swivel the T-Handle Hook - 3438- -A- approximately 90° to‐
ward the vent housing; insert the hook into the removal holes
inside the vent housing.
– Carefully remove instrument panel vent -B or C- from the in‐
strument panel.
6.14 Glove Compartment Cooling Connec‐

tion on Air Intake Housing

Note

ing, this connection is sealed with a plug .
♦ On an air intake housing -D- with a connection for glove com‐
partment cooling -C- the tab -E- is approximately 3 mm longer
than on the version with the glove compartment cooling con‐
nection -C-, be sure to pay attention to the correct allocation.
♦ If an air intake housing -D- with a connection for glove com‐
partment cooling -C- is installed into a vehicle, which before
did not have an intake air housing -D- with a connection for
glove compartment cooling -C-, then the pin -A- on the right
radiator housing -B- must be shortened by approximately 3
mm (different versions).
♦ On vehicles with an air intake housing -D- with a glove com‐
partment cooling connection -C- but without the option “glove
compartment cooling”, the connection -C- is sealed with a plug
-F-.
♦ If the vehicle has the option “glove compartment cooling” then
remove the plug -F- from the glove compartment cooling -C-.
♦ On vehicles with “glove compartment cooling”, the cooled air
is routed from the A/C unit through the connection -C- and the
air guide on the air intake housing -A- into the glove compart‐
ment. The foam seal seals the air guide and the glove com‐
partment -B-.
♦ For vehicles with glove compartment cooling, pay attention to
the correct glove compartment version. Refer to the Parts Cat‐
alog and ⇒ Body Interior; Rep. Gr. 68 ; Storage Compart‐
ments and Covers; Overview - Glove Compartment .
6.15 Rear Vent Air Guide Slots, Sealing
Note
This air guide is attached to the air outlet openings of the A/C unit.
There are slits inside the air guide. If the door position is incorrect,
especially on vehicles with the “Convenience” A/C system, whis‐
tling noise can come from these slits. The upper slits are covered
with tape during production (running change from February
2009).
– Cover the upper center console to prevent damage.

– Remove the Radio - R- and Multimedia System Control Head
- E380- . Refer to ⇒ Communication; Rep. Gr. 91 ; Radio;
Radio, Removing and Installing and ⇒ Communication; Rep.
Gr. 91 ; Infotainment System; Multimedia System Control
Head - E380- , Removing and Installing .
– Remove the Climatronic Control Module - J255- A/C display
and control head. Refer to
page 636 .
– If equipped, remove the Front Information Display Control
Head Control Module - J523- .
6. Air Guide 617

– Reach into the opening in the center console and cover both
slits at the top -A- of the air guide -C- with adhesive tape -B-
(approximately 2 cm x 4 cm, made of air-tight material).
Note
♦ The slots -A- are covered by the brace -D-.

♦ Cut out, for example, two adhesive strips -B- from the insula‐
tion (replacement part number 8E0 260 329). Refer to the
Parts Catalog.

7 Coolant Circuit
⇒ “7.1 Coolant Shut-Off Valve N82 / Climatronic Coolant Shut-
Off Valve N422 Location, Activation and Function”, page 619
⇒ “7.2 Coolant Recirculation Pump V50 ( Water Pump V36 ) Lo‐
cation, Activation and Function”, page 623
7.1 Coolant Shut-Off Valve - N82- / Clima‐

tronic Coolant Shut-Off Valve - N422-
Location, Activation and Function
Climatronic Coolant Shut-Off Valve - N422- / Coolant Shut-Off
Valve - N82-
Note
♦ On certain vehicles (depending on the engine), vacuum-con‐

trolled coolant Shut-Off valves -A- were installed on vehicles
without a “parking heater” from start of production. Electrically
controlled Shut-Off valves -B- were introduced later as a run‐
ning change. These valves may be referred to as a Climatronic
Coolant Shut-Off Valve - N422- or a Coolant Shut-Off Valve -
N82- depending on the engine version and on the time of
production. Refer to ⇒ Wiring diagrams, Troubleshooting &
Component locations and use the Vehicle Diagnostic Tester
♦ Pay attention to the flow direction of the coolant -arrow- when
installing.
♦ This valve is referred to as a Climatronic Coolant Shut-Off
Valve - N422- or a Coolant Shut-Off Valve - N82- depending
on the engine version and on the time of production. Refer to
⇒ Wiring diagrams, Troubleshooting & Component locations
and use the Vehicle Diagnostic Tester in the "Guided Fault
Finding" function.
♦ The activation of the Climatronic Coolant Shut-Off Valve -
N422- / Coolant Shut-Off Valve - N82- varies, depending on
the vehicle version and on the period of production (either by
head or by the respective engine control module). Refer to
♦ On vehicles with an engine with a regulated coolant circuit (for
example, with a regulated coolant pump and a Cylinder Head
Coolant Valve - N489- ), no Climatronic Coolant Shut-Off
Valve - N422- / Coolant Shut-Off Valve - N82- is currently in‐
stalled. On an engine with a regulated coolant pump, the
engine control module activates the coolant pump, and in do‐
ing so regulates the coolant circuit. Refer to ⇒ Rep. Gr. 19 ;
Coolant Pump/Thermostat .
Information regarding a Coolant Shut-Off Valve Activated by Vac‐

uum
7. Coolant Circuit 619

The component location and the version of the Climatronic Cool‐

ant Shut-Off Valve - N422- -B- and of the coolant Shut-Off valve
-A- depends on the engine, on the vehicle version and the vehicle
build date.
♦ This illustration shows the location and version of the Clima‐

tronic Coolant Shut-Off Valve - N422- -B- on a 6-Cylinder FSI
engine as installed at the start of production. Version “1” of the
Climatronic Coolant Shut-Off Valve - N422- -B- is installed
near the cylinder head.
♦ The Climatronic Coolant Shut-Off Valve - N422- -B- is installed
in the plenum chamber on certain vehicles (such as the Audi
Q5 with a 6-Cylinder diesel engine). This illustration shows
version “2” of the Climatronic Coolant Shut-Off Valve - N422- .
♦ The Climatronic Coolant Shut-Off Valve - N422- was installed
only on vehicles with a 6-Cylinder FSI engine at start of pro‐
duction, for example. It was introduced on other engines as a
running change in MY 2008. The exact introduction depends
on the vehicle equipment and build date. Refer to ⇒ Rep. Gr.
19 ; Coolant Pump/Thermostat .
When installing the Climatronic Coolant Shut-Off Valve - N422-
-B-, ensure the proper connection of the vacuum hoses.

♦ On version “1” the vacuum hose to the Shut-Off valve -A- is

connected to connection “3” -C-. The vacuum supply from the
engine comes from the connection “2” -D-.
♦ On version “2” the vacuum hose -C- to the Shut-Off valve -A-
is connected to connection “3”. The vacuum supply from the
engine comes from the connection “2” -D-.
♦ The illustration shows the allocation on a MY 2009 4-Cylinder
diesel engine.
♦ The ventilation of the Shut-Off valve vacuum diaphragm -A-
after the end of activation, for example, on version “2” of the
Climatronic Coolant Shut-Off Valve - N422- -B- occurs via the
connection “1” under the cap -E-.
♦ The vacuum hose -C- (leading to the Shut-Off valve -A-) is
identified with a white mark, depending on the version.
Caution
♦ Pay attention to the correct allocation of the vacuum hoses

on the Climatronic Coolant Shut-Off Valve - N422- -B-
♦ If the vacuum hoses are interchanged, there may be no
heating in the passenger compartment.
♦ The Climatronic Coolant Shut-Off Valve - N422- -B- is briefly

activated, for example, by the Climatronic Control Module -
J255- A/C display and control head to check function (without
the function being required) in certain intervals (for example,
after 20 engine starts). If the vacuum hoses are incorrectly
connected to the Climatronic Coolant Shut-Off Valve - N422-
-B-, then the coolant Shut-Off valve -A- is activated briefly. If
the hoses are interchanged, the vacuum will remain in the
vacuum hose vacuum diaphragm -A- for an undetermined
amount of time after the activation is completed. The Shut-Off
valve -A- will not open. Coolant will flow into the heat exchang‐
er and the A/C system will not heat when the Shut-Off valve
-A- is closed.
♦ If the vacuum hoses are connected incorrectly, the engine will
continue to take in some fresh air via the connection “1” on the
Climatronic Coolant Shut-Off Valve - N422- . This can lead to
additional problems in the engine idle RPM which will be en‐
tered in the engine control module data memory.
Information for All

♦ An electric Shut-Off valve -B- or a vacuum-controlled coolant

Shut-Off valve -A- is installed either in the plenum chamber or
in the engine compartment depending on the engine and the
vehicle version.
♦ The Climatronic Coolant Shut-Off Valve - N422- / Coolant
Shut-Off Valve - N82- is then only activated, for example, via
the A/C system controls (either directly or via the engine con‐
trol module) when the A/C system is set to “OFF”. The engine
RPM must be lower than 5,000 and the coolant temperature
must be below 90 °C (194 °F). Shutting off the coolant circuit
to the A/C heater core accelerates the engine warming up
when the coolant is cold.
♦ If the vehicle, for example, has a parking heater as an option,
then the vehicle does not have a Climatronic Coolant Shut-Off
Valve - N422- / Coolant Shut-Off Valve - N82- -B- or a Shut-
Off valve -A-. For vehicles with a parking heater, the installed
Heater Coolant Shut-Off Valve - N279- performs this function.
♦ The Climatronic Coolant Shut-Off Valve - N422- activation can
be switched off via the “adaptation” function for the A/C system
ing" function.
♦ Vehicles with a 6-Cylinder FSI engine (currently not on the 6-
Cylinder TFSI engine) and on other engines with certain op‐
tional equipment (for example, vehicles with the Start/Stop
System) but without a “parking heater” also have a Coolant
Recirculation Pump - V50- ( Water Pump - V36- ) installed.
Refer to ⇒ Rep. Gr. 19 ; Coolant Pump/Thermostat . For an
illustration of the pump and additional information. Refer to
ded Fault Finding using the Vehicle Diagnostic Tester in the
♦ Depending on the production time period, the Coolant Recir‐
culation Pump - V50- ( Water Pump - V36- ) is activated via
the Recirculation Pump Relay - J160- (via the same output as
the Climatronic Coolant Shut-Off Valve - N422- ) or, as a run‐
ning change in MY 2009, directly by the Climatronic Control
Module - J255- A/C display and control head. Activation takes
place after the Climatronic Control Module - J255- makes the
request via the engine control module on certain vehicles (Au‐
di Q5 Hybrid). Pay attention to the correct version of the
head and the correct coding and adaptation using the Vehicle
Diagnostic Tester in the "Guided Fault Finding" function. Refer
tions.
♦ If the vehicle has a Recirculation Pump Relay - J160- (for ex‐
ample, MY 2008 vehicles), then the Coolant Recirculation
Pump - V50- ( Water Pump - V36- ) is then always activated
when the ignition is turned on, if the Climatronic Coolant Shut-
Off Valve - N422- / Coolant Shut-Off Valve - N82- is not
activated (for example, with the temperature preset “warm” on
head). Refer to
Gasoline Engine”, page 625 and ⇒ Wiring diagrams, Trou‐
bleshooting & Component locations.

♦ For vehicles without a Recirculation Pump Relay - J160- (grad‐

ual introduction from MY 2009), the Coolant Recirculation
Pump - V50- ( Water Pump - V36- ) is directly activated by the
Climatronic Control Module, depending on the coolant tem‐
perature and the setting on the Climatronic Control Module -
J255- A/C display and control head when the ignition is
switched on. For certain vehicles (for example, on the Audi Q5
hybrid) activation takes place after the Climatronic Control
Module - J255- makes the request via the engine control mod‐
ule. Refer to
Gasoline Engine”, page 625 and ⇒ Wiring diagrams, Trou‐
bleshooting & Component locations.
and the Climatronic Coolant Shut-Off Valve - N422- activation
depends on the vehicle equipment level and the vehicle date
of manufacture using the Vehicle Diagnostic Tester in the
♦ If the vehicle has a Coolant Recirculation Pump - V50- ( Water
Pump - V36- ) and a Climatronic Coolant Shut-Off Valve -
N422- / Coolant Shut-Off Valve - N82- that are activated
directly by the Climatronic Control Module - J255- A/C display
and control head, then the Climatronic Control Module - J255-
A/C display and control head will store any faults on these
components. Therefore pay attention to the version, the cod‐
ing and the adaptation of the Climatronic Control Module -
J255- using the Vehicle Diagnostic Tester in the "Guided Fault
Finding" function.
7.2 Coolant Recirculation Pump - V50-

( Water Pump - V36- ) Location, Activa‐
tion and Function
Location, Activation and Function, Vehicles with 4- or 6-Cylinder
Engine”, page 623
Location, Activation and Function, Vehicles with 6-Cylinder Gas‐
oline Engine”, page 625
7.2.1 Coolant Recirculation Pump - V50-

( Water Pump - V36- ), Location, Activa‐
tion and Function, Vehicles with 4- or 6-
Cylinder Engine
Location for vehicles with a 4-Cylinder engine and for certain ve‐
hicles with a 6-Cylinder engine

Note
♦ The Coolant Recirculation Pump - V50- can be installed in dif‐

ferent locations. For most vehicles with a 4-Cylinder engine
and for certain vehicles with a 6-Cylinder engine, it is located
between the plenum chamber bulkhead and the engine. The
installed location on vehicles with a 6-Cylinder engine. Refer
to
ferent locations. For vehicles with a high voltage system (hy‐
brid vehicles) it is located between the plenum chamber
bulkhead and the engine.
♦ The activation of the Coolant Recirculation Pump - V50- var‐
ies. For vehicles with a high voltage system (hybrid vehicles),
the activation occurs after the Climatronic Control Module -
J255- makes the request via the engine control module. Refer
tions.

♦ For vehicles with a 4-Cylinder engine and the “Start/Stop Sys‐

tem”, but without a “parking heater”, a Coolant Recirculation
Pump - V50- ( Water Pump - V36- ) is installed. Refer to ⇒
Rep. Gr. 19 ; Coolant Pump/Thermostat . The Coolant Recir‐
culation Pump - V50- ( Water Pump - V36- ) activation depends
on the vehicle equipment level and the vehicle date of manu‐
facture using the Vehicle Diagnostic Tester in the "Guided
Fault Finding" function. Refer to ⇒ Wiring diagrams, Trouble‐
shooting & Component locations.
♦ For vehicles with a 4-Cylinder engine and the “Start/Stop Sys‐
tem”, but without a “parking heater”, the Coolant Recirculation
Pump - V50- ( Water Pump - V36- ) -A-, for example, is instal‐
led in the area between the engine and the plenum chamber
front wall. Refer to ⇒ Rep. Gr. 19 ; Coolant Pump/Thermostat .
♦ This illustration shows the location on an Audi A4 with a 4-
Cylinder TFSI engine from the MY 2010. The Coolant Recir‐
culation Pump - V50- ( Water Pump - V36- ) -A- can also be
installed in a different location (for example, in the plenum
chamber) depending on the engine, vehicle model and date of
manufacture. Refer to ⇒ Rep. Gr. 19 ; Coolant Pump/Ther‐
mostat .
♦ When the Coolant Recirculation Pump - V50- ( Water Pump -
V36- ) is working, the coolant is drawn through the coolant
hose -B- (from the engine through the A/C heater core and
coolant Shut-Off valve -D-) and then back to the engine
through the coolant hose -C- (note the flow direction
-arrows-).
is directly activated by the Climatronic Control Module, de‐
pending on the coolant temperature and the setting on the
head when the ignition is switched on using the Vehicle Diag‐
nostic Tester in the "Guided Fault Finding" function. Refer to
Recirculation Pump - V50- is then activated to support the en‐
gine coolant pump using the Vehicle Diagnostic Tester in the
trol head or the respective engine control model directly acti‐
vates the Coolant Recirculation Pump - V50- ( Water Pump -
V36- ) and the Climatronic Coolant Shut-Off Valve - N422- /
Coolant Shut-Off Valve - N82- on vehicles with the “Start/Stop
System”. If any faults on these components are stored in the
head, check the version, coding and adaptation of the Clima‐
tronic Control Module - J255- using the Vehicle Diagnostic
♦ For vehicles with the optional equipment “parking heater”,
there is no Climatronic Refrigerant Shut-Off Valve - N422- /
Coolant Shut-Off Valve - N82- and Coolant Recirculation
Pump - V50- ( Water Pump - V36- ) installed. In these vehicles,
the parking heater components assume this function (the
Heater Coolant Shut-Off Valve - N279- and the Recirculation
Pump - V55- ).
7.2.2 Coolant Recirculation Pump - V50-

( Water Pump - V36- ), Location, Activa‐
tion and Function, Vehicles with 6-

Cylinder Gasoline Engine
Location on certain vehicles with a 6-Cylinder engine
Note

ferent locations. The installed location on vehicles with 6-
Cylinder engines can be on the longitudinal member (or
between the plenum chamber bulkhead and the engine. Refer
to
Location, Activation and Function, Vehicles with 4- or 6-Cyl‐
inder Engine”, page 623 .
and production period. From MY 2012 beginning with start of
production, pumps that were controlled by a 500 Hertz signal
(500 pulses per second) are being replaced by pumps that are
controlled by a variable (100 to 500 Hertz) signal depending
on the engine. Pumps that are activated by a variable signal
are also equipped with a diagnostic function and are activated
mostly via the respective engine control module. Therefore,
ensure the correct allocation (only the allocated pump can be
activated) using the Vehicle Diagnostic Tester in the "Guided
Fault Finding" function. Refer to ⇒ Wiring diagrams, Trouble‐
shooting & Component locations and to the Parts Catalog.

♦ 6-Cylinder vehicles with an FSI engine (currently not on 6-

Cylinder TFSI engine) and on other engines with certain op‐
tional equipment (for example, vehicles with “Start/Stop
System”) but without a “parking heater”) have a Coolant Re‐
circulation Pump - V50- ( Water Pump - V36- ) installed. Refer
to ⇒ Rep. Gr. 19 ; Coolant Pump/Thermostat . The Coolant
Recirculation Pump - V50- ( Water Pump - V36- ) activation
depends on the vehicle equipment level and the vehicle date
of manufacture using the Vehicle Diagnostic Tester in the
♦ On vehicles with a 6-Cylinder FSI engine but without a “parking
heater”, the Coolant Recirculation Pump - V50- ( Water Pump
- V36- ) -A- is installed, for example, in the area between the
engine and the right longitudinal member under the right head‐
lamp. The illustration shows the location on an Audi A5 Coupe
with a 6-Cylinder FSI engine, on an Audi A5 Sportback, an
Audi A4, an Audi Q5, etc. The location of the components may
be different on vehicles with a different engine. Refer to ⇒ Rep.
Gr. 19 ; Coolant Pump/Thermostat .
♦ When the Coolant Recirculation Pump - V50- ( Water Pump -
V36- ) is running, the coolant is drawn in via the coolant hose
-B- (from the engine) and is delivered via the coolant hose
-C- to the heater core in the A/C unit (note the flow direction
-arrows-).
♦ Depending on the production time period, the Coolant Recir‐
culation Pump - V50- ( Water Pump - V36- ) is activated via
the Recirculation Pump Relay - J160- (via the same output as
the Climatronic Coolant Shut-Off Valve - N422- ) or, as a run‐
ning change in MY 2009, directly by the Climatronic Control
Module - J255- A/C display and control head. Refer to ⇒ Wiring
diagrams, Troubleshooting & Component locations and use
function.
♦ If the vehicle has a Recirculation Pump Relay - J160- (for ex‐
ample, MY 2008 vehicles), then the Coolant Recirculation
Pump - V50- ( Water Pump - V36- ) is then always activated
when the ignition is turned on, if the Climatronic Coolant Shut-
Off Valve - N422- is not activated (for example, with the
temperature preset “warm” on the Climatronic Control Module
- J255- A/C display and control head). Refer to ⇒ Wiring dia‐
grams, Troubleshooting & Component locations and
♦ On vehicles without a Recirculation Pump Relay - J160- (run‐
ning change from MY 2009), the Coolant Recirculation Pump
- V50- ( Water Pump - V36- ) is directly activated by the Cli‐
matronic Control Module, depending on the coolant tempera‐
ture and the setting on the Climatronic Control Module - J255-
A/C display and control head when the ignition is switched on
the “Stop function” is active (running change as optional equip‐
ment from MY 2010), but also when the engine is running
(when, for example, the “warm” temperature preset is selected
control head (“HI” in the display on the A/C display and control
head and the display in the MMI). The Coolant Recirculation
Pump - V50- is then activated to support the engine coolant
pump using the Vehicle Diagnostic Tester in the "Guided Fault
Finding" function.

♦ If the vehicle has a Coolant Recirculation Pump - V50- ( Water

Pump - V36- ) and a Climatronic Coolant Shut-Off Valve -
N422- / Coolant Shut-Off Valve - N82- that are activated
directly by the Climatronic Control Module - J255- A/C display
and control head, then the Climatronic Control Module - J255-
A/C display and control head will store any faults on these
components. Therefore pay attention to the version, the cod‐
ing and the adaptation of the Climatronic Control Module -
J255- using the Vehicle Diagnostic Tester in the "Guided Fault
Finding" function.
♦ For vehicles with the optional equipment “parking heater”,
there is no Climatronic Refrigerant Shut-Off Valve - N422- /
Coolant Shut-Off Valve - N82- and Coolant Recirculation
Pump - V50- ( Water Pump - V36- ) installed. In these vehicles,
the parking heater components assume this function (the
Heater Coolant Shut-Off Valve - N279- and the Recirculation
Pump - V55- ).

8 Display and Control Head

⇒ “8.1 Display and Control Head Location”, page 629
⇒ “8.2 Display and Control Head, Removing and Installing”, page
636
⇒ “8.3 Interior Temperature Sensor Fan, Removing and Installing
”, page 639
8.1 Display and Control Head Location

The Climatronic Control Module - J255-
♦ From 08/2007, the “Convenience” A/C system with an air dis‐
tribution housing with optimized air distribution will be intro‐
duced (distinguishing characteristic between versions “1” and
“2”. Refer to ⇒ , page 25 and the Parts Catalog).
activation differs depending on the date of manufacture.
Note
The Coolant Recirculation Pump - V50- ( Water Pump - V36- )

version and activation differ depending on the vehicle version and
production period. From MY 2012 as a running change, the
pumps installed from the start of production, which were activated
via a 500 Hertz signal (500 pulses per second), are being re‐
placed by pumps that are activated by a variable (100 to 500
Hertz) signal depending on the engine. Pumps, controlled by a
variable signal, also have a diagnostic function and are controlled
by the engine control module. Check for the correct allocation us‐
function. Refer to ⇒ Wiring diagrams, Troubleshooting & Compo‐
– On vehicles with the A/C unit version “2”, only the Climatronic
Control Module - J255- A/C display and control heads with the
“Convenience” version with part number “8T1 820 043” be‐
ginning with the index “Q” are or will be installed.
– If on vehicles with the A/C unit version “1”, a Climatronic Con‐
trol Module - J255- A/C display and control head with the
“Convenience” version, with part number “8T1 820 043” be‐
ginning with the letter “Q” is installed, the adaptation is
changed accordingly using the Vehicle Diagnostic Tester in
8. Display and Control Head 629

Note
Parts Catalog.

trol heads for the “Convenience” version with the part number
“8T1 820 043” up to letter “L” may not be installed on the A/C
unit version “2”.
Note
On the “Basis” A/C system, the A/C unit and the air distribution
housing were not changed.
♦ On the Audi A5 Coupé and Audi A4 from MY 2009, the Cli‐

matronic Control Module - J255- display and control heads
with the part number 8T1 820 043 starting with the index “T”
are installed (on the Audi Q5 this was already installed since
the start of production). Refer to the Parts Catalog.
– On vehicles with these display and control heads, and de‐
pending on the coding and adaptation, for example the display
on the screen for the “MMI” (Multi Media Interface), when using
the buttons and knobs, the display and control head no longer
switches to “A/C system”. The selected functions for the A/C
system appear in the display sequentially using the Vehicle
Diagnostic Tester in the "Guided Fault Finding" function, the
“Infotainment/MMI” Operating Instructions and the Owner's
Manual.
– Pay attention to the correct allocation, coding and adaptation
of the Climatronic Control Module - J255- display and control
head to the Front Information Display Control Head Control
Module - J523- to the Information Electronics Control Module
1 - J794- . Refer to the Parts Catalog and use the Vehicle Di‐
agnostic Tester in the "Guided Fault Finding" function. If the
allocation, coding or adaptation are incorrect, the A/C system
functions cannot be displayed or selected in the MMI.
Note

heads with the part number 8T1 820 043 up to index “S” are
installed on vehicles with a Front Information Display Control
Head Control Module - J523- .
heads with the part number 8T1 820 043 from index “T” may
be installed on vehicles with an Information Electronics Con‐
trol Module 1 - J794- . In order to be able to select and display
the different functions, the coding and adaptation must be cor‐
rect for the vehicle equipment level.

cific engines as optional equipment.
run on bioethanol (Flex Fuel Vehicles) were introduced

Note
♦ On vehicles with Start/Stop system, the Climatronic Control

Module - J255- display and control head prevents the Stop
function depending on the setting. If, for example, “defrost” is
selected, the stop function is not possible or will be interrupted
and the engine will start. The same applies in the case of
heating and cooling. The difference between the selected and
actual temperature exceeds a certain value using the Vehicle
♦ If the vehicle has a Start/Stop System, then only the Clima‐
tronic Control Module - J255- display and control head with the
part number 8T1 820 043 starting with index “AG” or with part
number 8K_ 820 043 may be installed. Refer to Parts Catalog
and use the Vehicle Diagnostic Tester in the "Guided Fault
Finding" function.
♦ The activation of an installed Coolant Recirculation Pump -
V50- ( Water Pump - V36- ) differs depending on the date of
manufacture and on the vehicle version. Make sure to use the
correct version of the Climatronic Control Module - J255- . Also
note the adaptation for the Coolant Recirculation Pump - V50-
( Water Pump - V36- ) activation on a Climatronic Control
Module - J255- with the part number 8T1 820 043 starting with
index “AG”. Refer to
Gasoline Engine”, page 625 and to using the Vehicle Diag‐
Refer to
page 506 . For vehicles with a gasoline engine, the electric
auxiliary heater (the Auxiliary Heater Heating Element - Z35- )
is activated by the Climatronic Control Module - J255- display
and control head via the local Data Bus (activated via the same
outlet and also via the Fresh Air Blower Control Module -
J126- ) on the Auxiliary Air Heater Control Module - J604- .
locations.
♦ If the vehicle has a gasoline engine that can run on bioethanol,
then only the Climatronic Control Module - J255- display and
control head with the part number 8T1 820 043 starting with
index “AG” or with part number 8K_ 820 043 may be installed.
Refer to Parts Catalog and use the Vehicle Diagnostic Tester
♦ Vehicles with a high voltage system (hybrid vehicles)

Note
♦ Only the Climatronic Control Module - J255- display and con‐

trol head with the part number 8R1 820 043 may be installed
on vehicles with a high voltage system (only for vehicles until
the version changeover) (from MY 2012 see below). Refer to
the Parts Catalog and use the Vehicle Diagnostic Tester in the
♦ Climatronic Control Module - J255- display and control head
with the part number 8R1 820 043 may only be installed on
vehicles with a high voltage system up to the vehicle version
changeover (from MY 2012 see below). After the vehicle ver‐
sion changeover, the Climatronic Control Module - J255- dis‐
play and control heads with the part number 8K_ 820 043 are
being installed in vehicles with a high voltage system. Pay at‐
tention to the part number index and coding. Refer to the Parts
♦ For vehicles built after the version changeover, only one Cli‐
matronic Control Module - J255- may be installed that are
available, so that the various functions necessary for vehicles
with a high voltage system can be performed by the Clima‐
tronic Control Module - J255- display and control head. A
Climatronic Control Module - J255- with part number 8K_ 820
043 and index “K or AA” through index “P or AE” does not have
the necessary functions needed by high voltage vehicles, for
example. These functions are integrated on a Climatronic
Control Module - J255- with part number 8K_ 820 043 from
index “Q or AF”. Instead of a Climatronic Control Module -
J255- with part number 8Kx 820 043 and index “Q”, the version
with index “AF” can be installed, for example (the existing
function for activating the A/C Clutch - N25- is not used). Refer
to the Parts Catalog. The coding of the Climatronic Control
Module - J255- turns off or activates the necessary functions
for the respective vehicle using the Vehicle Diagnostic Tester
♦ From MY 2012, as a running change (depending on the model

and version), a revised Climatronic Control Module - J255- is
being installed. Ensure the correct allocation. Refer to the
Parts Catalog.


Note
♦ From MY 2012, the changeover was made on the Audi A4 and

Audi A5 as a running change. Vehicles built before the
changeover may only have Climatronic Control Module - J255-
display and control head with part number 8T__ 820 043
installed (for vehicles with a high voltage system only the ver‐
sions with part number 8R1 820 043). Vehicles manufactured
after the changeover may only have the Climatronic Control
Module - J255- display and control head with part number 8K_
820 043 installed. Refer to the Parts Catalog and use the Ve‐
♦ When the “Comfort” A/C system is installed, the Climatronic
Control Module - J255- with part number 8T_ 820 043 (with
part number 8R1 820 043) -A-) and with part number 8K_ 820
043 -B- can be differentiated as follows: At the start of pro‐
duction of the Climatronic Control Module - J255- -A- (part
number 8T_ 820 043/8R1 820 043), the seat heating and ven‐
tilation are controlled by buttons -C- and the rotary switch.
From the vehicle version changeover (from MY 12 as a run‐
ning change), the installed Climatronic Control Module - J255-
-B- (part number 8K_ 820 043 ) has two separate buttons
-D and E- which operate the seat heating and seat ventilation.
The location of the buttons -F and G- is different between both
versions.
♦ The seat heating and seat ventilation can be adjusted sepa‐
rately to 3 settings via the respective buttons with the intro‐
duction of the Climatronic Control Module - J255- , version
-B-. Refer to the Owner's Manual.
♦ When installed on the “Basis” A/C system, the Climatronic
Control Module - J255- with part number 8T_ 820 043 (with
part number 8R1 820 043) -A-) and with part number 8K_ 820
043 -B- can be differentiated as follows, for example: Both
versions -A and B- can be differentiated by the rotary adjuster
(version -B- with a chrome ring) and by the seat heating but‐
tons. The seat symbols in the buttons -C and D- point in
different directions on the Climatronic Control Module - J255-
-A- installed from start of production. For the Climatronic Con‐
trol Module - J255- -B- installed from the vehicle version
changeover (from MY 2012 as a running change), the seat
symbols in the buttons -C and D- point in the same direction
♦ The seat heating can be adjusted to 3 settings via the respec‐
tive buttons with the introduction of the Climatronic Control
Module - J255- , version -B-. Refer to the Owner's Manual.
♦ Updated Fresh Air Blower Control Module - J126- , Fresh Air
Blower - V2- , Climatronic Control Module - J255- A/C display
and control head, Vehicle Electrical System Control Module -
J519- , Comfort System Central Control Module - J393- , Air
Quality Sensor - G238- and A/C units are being installed as a
running change from MY 2012 (depending on the vehicle ver‐
sion). Pay attention to the correct version and allocation of
these components. Refer to the Parts Catalog and use the
tion.


correctly. Refer to the Parts Catalog and use the Vehicle Di‐
♦ At the start of production, the Humidity Sensor - G355- was
only installed on the “Convenience” A/C system. Since the in‐
troduction of the Start/Stop System from MY 2010, the Hu‐
midity Sensor - G355- is also being installed in vehicles with
the “Basis” A/C system and this optional equipment.
♦ The Comfort System Central Control Module - J393- or the
Data Bus On Board Diagnostic Interface - J533- evaluates the
measured value from the Humidity Sensor - G355- for vehicles
manufactured before the version changeover (except for the
Audi Q5 hybrid). The Vehicle Electrical System Control Mod‐
ule - J519- evaluates the measured value from the Humidity
Sensor - G355- on vehicles manufactured from the product
changeover (and on all Audi Q5 hybrids). Refer to, Electrical
Equipment and use the Vehicle Diagnostic Tester in the "Gui‐
♦ Depending on time period of production (from MY 2012 as a
running change) and vehicle version, the Humidity Sensor -
G355- no longer operates as an individual part in the DTC
memory. On these vehicles, the Rain/Light Recognition Sen‐
sor - G397- is displayed as the fault location in the event of a
deviation on the Humidity Sensor - G355- .
Parts Catalog.
♦ As a running change from MY 2012, there are different ver‐
sions of the Coolant Recirculation Pump - V50- ( Water Pump
- V36- ) installed, depending on the vehicle version, on the
engine and on the time period of production. How these pumps
are activated is also different. From the start of MY 2012,
pumps, which were controlled by a 500 Hertz signal (500 pul‐
ses per second), are replaced by 100 to 500 Hertz signal
pumps. Pumps, controlled by a variable signal, also have a
diagnostic function and are controlled by the engine control
module. Check for the correct allocation using the Vehicle Di‐
agnostic Tester in the "Guided Fault Finding" function. Refer
tions and to the Parts Catalog.


Note
♦ The A/C clutch turns off the A/C compressor drive completely
under certain conditions (for example “ECON”). The correct
Climatronic Control Module - J255- version must be installed
and coded correctly so that the A/C Clutch - N25- can be ac‐
tivated by the Climatronic Control Module - J255- display and
control head. Refer to the Parts Catalog and use the Vehicle
♦ So that the A/C Clutch - N25- can be activated by the Clima‐
tronic Control Module - J255- display and control head, only
one Climatronic Control Module - J255- must be installed on
these vehicles that has the necessary functions to activate the
A/C Clutch - N25- ( Climatronic Control Module - J255- with
part number 8K_ 820 043 and index “K” cannot, for example,
activate an A A/C Clutch - N25- ). A Climatronic Control Mod‐
ule - J255- with part number 8K_ 820 043 and index “AA” can,
for example, activate the A/C Clutch - N25- . Instead of a Cli‐
matronic Control Module - J255- with part number 8K_ 820
043 and index “K”, a version with index “AA” (existing function
for activating the A/C Clutch - N25- is not used) or a version
with index “AF” (existing functions for activating the A/C Clutch
- N25- or for vehicles with a high voltage system are not used)
can be installed. Refer to the Parts Catalog. The coding of the
Climatronic Control Module - J255- turns off or activates the
necessary functions for the respective vehicle using the Vehi‐
cle Diagnostic Tester in the "Guided Fault Finding" function.
♦ In MY 2014 and from MY 2015, a revised Climatronic Control

Module - J255- display and control head is being installed as
a running change (introduction depending on model and ver‐
sion). Pay attention to the allocation. Refer to the Parts Cata‐
log.
Note
Exact launch date is open. The Climatronic Control Module -

J255- is differentiated, for example, by the button AC (part number
8K_ 820 043 up to index “AL”) or the button A/C (part number
8K_ 820 043 starting with index “AM” or “BA”). Refer to the Parts
Catalog.
8.2 Display and Control Head, Removing

and Installing
The Climatronic Control Module - J255-
Note
In both versions (“Basis” or “Convenience”) the Climatronic Con‐

trol Module - J255- A/C display and control head is removed and
installed in the same way.
Removing
– Check the coding and adaptation for the Climatronic Control
Module - J255- A/C display and control head using the “Re‐
place control module” function of the Guided Fault Finding (if
head should be replaced) using the Vehicle Diagnostic Tester

Caution
♦ To prevent damage to the Climatronic Control Module -

J255- A/C display and control head and center console
when removing, do not pull too hard.
♦ Do not damage surface of center console when removing
(cover it if necessary).

– Attach the T-Handle Hook - 3438- -A- in one of the openings
-B or C- of the Climatronic Control Module - J255- A/C display
and control head as illustrated.
– Carefully pull the Climatronic Control Module - J255- A/C dis‐
play and control head in the direction of -arrow- out of center
console.
Note
The Climatronic Control Module - J255- A/C display and control

head is held in the center control brackets with clamps (left and
right).
Remove the Connectors from the Climatronic Control Module -

J255- A/C Display and Control Head.
– Loosen the harness connector release catch -C- for the con‐
nectors -A and B- by pulling the direction of the -arrow- .
– Press the connector release catch -D- -arrow- and remove the
connectors -A and B-.
Installing
following.
♦ When replacing a Climatronic Control Module - J255- A/C dis‐
play and control head, pay attention to the exact allocation.
Refer to
⇒ “8.1 Display and Control Head Location”, page 629 and
Parts Catalog.
Mount the Trim on the Display and Control Head on the Audi Q5.

– Clean the adhesive surface -D- on the display and control

head -A-, for example, with cleaning solution D 009 401 04.
– Install the display and control head -A-.
Note
♦ The trim piece -B- is supplied with a two-sided adhesive strip

already installed -C- Parts Catalog
♦ If the trim -B- is going to be re-used when replacing the display
and control unit, the Climatronic Control Module - J255- -A- is
also reused. Remove the adhesive strip -C- from the trim -B-.
Clean the adhesive surface on the trim -B- as described in the
instructions which came with the adhesive strip. Affix to the
trim piece -B- a strip (dimension: 204 mm x 10 mm) of the two-
sided adhesive tape -C- with material strength approximately
1.2 mm (for example with adhesive tape D 438 515 A1. Refer
to the Parts Catalog).
– Mount the trim piece -B- with the adhesive tape -C- onto the
adhesive surface -D- of the display and control head -A- and
then align it -B-.
– Press the trim piece -B- onto the surface -D-.
♦ After replacing/installing the Climatronic Control Module -
J255- A/C display and control head, always perform the follow
work using the Vehicle Diagnostic Tester in the "Guided Fault
Finding" function):
– Re-code (or check the coding) of the Climatronic Control Mod‐
ule - J255- A/C display and control head.
– Perform the basic setting for the Climatronic Control Module -
J255- A/C display and control head (correct the cause for any
malfunctions displayed) and erase.
J255- A/C display and control head and correct if necessary.
– Perform the output diagnostic test mode for the Climatronic
Control Module - J255- A/C display and control head (depend‐
ing on the type of complaint).

8.3 Interior Temperature Sensor Fan, Re‐

Note
♦ The same Interior Temperature Sensor Fan - V42- -B- is cur‐

rently installed in both versions of the Climatronic Control
Module - J255- A/C display and control heads (“Basis” -E- and
“Convenience” -F-). The blowers run at different RPMs (ap‐
proximately 2,500 to 3,200 RPM on the “Basis” version and
approximately 2,800 to 3,500 RPM on the “Convenience” ver‐
sion) due to the different component location in the display and
control head using the Vehicle Diagnostic Tester in the "Gui‐
J255- A/C display and control head, there may be a molded
seal -C-. Re-install it if necessary.
Removing
– Remove the Climatronic Control Module - J255- A/C display
and control head. Refer to
page 636 .
– Pull the Interior Temperature Sensor Fan - V42- -B- out of the
head.
Installing
following.
– When installing the Interior Temperature Sensor Fan - V42- ,
do not press on the fan wheel -D-, but rather hold the blower
firmly at the housing.

9 Additional Components for Control

and Regulation
⇒ “9.1 Sunlight Photo Sensor G107 , Removing and Installing”,
page 640
⇒ “9.2 Air Quality Sensor G238 , Function”, page 642
⇒ “9.3 Air Quality Sensor G238 , Checking”, page 645
⇒ “9.4 Air Quality Sensor G238 / Humidity Sensor In Fresh Air
Intake Duct G657 , Removing and Installing”, page 655
⇒ “9.5 Outside Air Temperature Sensor G17 , Removing and
⇒ “9.6 Center Vent Temperature Sensor G191 , Removing and
⇒ “9.7 Footwell Vent Temperature Sensor G192 / Left Footwell
Vent Temperature Sensor G261 , Removing and Installing”, page
660
⇒ “9.8 Right Footwell Vent Temperature Sensor G262 , Remov‐
ing and Installing”, page 661
⇒ “9.9 Evaporator Vent Temperature Sensor G263 , Removing
⇒ “9.10 Humidity Sensor G355 , Removing and Installing”, page
663
⇒ “9.11 Rain/Light Recognition Sensor G397 , Removing and
⇒ “9.12 Left Front Upper Body Vent Temperature Sensor G385 ,
Removing and Installing”, page 667
⇒ “9.13 Right Front Upper Body Vent Temperature Sensor G386 ,
Removing and Installing”, page 667
⇒ “9.14 Humidity Sensor In Fresh Air Intake Duct G657 Function”,
page 669
⇒ “9.15 Humidity Sensor in Fresh Air intake Duct G657 , Check‐
ing”, page 670
9.1 Sunlight Photo Sensor - G107- , Remov‐

ing and Installing
Note
♦ There are different versions of the Sunlight Photo Sensor -

G107- , therefore make sure the allocation is correct. Refer to
the Parts Catalog. If a Sunlight Photo Sensor - G107- is in‐
stalled that is not designated for that vehicle (there is a differ‐
ent signal than the one designated in this Climatronic Control
Module - J255- A/C display and control head), the Climatronic
Control Module - J255- A/C display and control head cannot
evaluate the signal from the Sunlight Photo Sensor - G107-
and the A/C system is not regulated correctly.
Q5, etc. the location of the components varies slightly. Re‐
moving and installing the components is the same as descri‐
bed for the Audi A5 Coupé.

Removing
– Carefully pry the Sunlight Photo Sensor - G107- -A- out of the
defroster vent -B- (for the windshield) using a small screw‐
driver. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instrument
Panel; Overview - Instrument Panel .
Note
While doing so, do not damage the surface of the cover for the
Sunlight Photo Sensor - G107- -A- and the defroster vent -B-.
– Disconnect the connector -C- .

Installing
following.
Control Module - J255- display and control head and erase
any displayed malfunctions, if necessary using the Vehicle Di‐
9. Additional Components for Control and Regulation 641

9.2 Air Quality Sensor - G238- , Function
Note
♦ There are different versions depending on the vehicle date of

manufacture and the A/C system version (“Basis” or “Conven‐
ience”) is installed. The “Basis” A/C system does not have a
humidity sensor in the Humidity Sensor in Fresh Air intake
Duct - G657- / Air Quality Sensor - G238- until the MY 2012
changeover. From MY 2012 it has a humidity sensor in Hu‐
midity Sensor in Fresh Air intake Duct - G657- without an Air
Quality Sensor - G238- (black housing). From MY 2012, the
“Convenience” A/C system has an Air Quality Sensor - G238-
without a Humidity Sensor in Fresh Air intake Duct - G657- .
From this change, a Humidity Sensor in Fresh Air intake Duct
- G657- is installed with an Air Quality Sensor - G238- (brown
housing).
♦ Only vehicles with the “Convenience” A/C system have an Air
Quality Sensor - G238- without a Humidity Sensor in Fresh Air
intake Duct - G657- (from start of production up the change‐
over) Refer to the Parts Catalog.
♦ From MY 2012, the vehicle version was changed-over as a
running change beginning with Audi A4 and Audi A5. Refer to
⇒ “8.1 Display and Control Head Location”, page 629 . Vehi‐
cles, built before the changeover and with the “Convenience”
A/C system, have an Air Quality Sensor - G238- (not installed
on the “Basis” version). For vehicles built since this change‐
over (and for the Audi Q5 Hybrid), a Humidity Sensor in Fresh
Air intake Duct - G657- is installed on the “Basis” version and
a Humidity Sensor in Fresh Air intake Duct - G657- with the
Air Quality Sensor - G238- is installed on vehicles with the
“Convenience” version.
♦ The different versions can be differentiated as follows: For the
Humidity Sensor in Fresh Air intake Duct - G657- version with
the Air Quality Sensor - G238- , the housing is brown (running
change from MY 2012). For the Humidity Sensor in Fresh Air
intake Duct - G657- version without the Air Quality Sensor -
G238- , the housing is black (running change from MY 2012).
For the Air Quality Sensor - G238- version without a Humidity
Sensor in Fresh Air intake Duct - G657- , the housing is black
and the Humidity Sensor in Fresh Air intake Duct - G657- -3-
is not present (gradual discontinuation from MY 2012).
♦ There are different versions of the Air Quality Sensor - G238-

-2-. This vehicle has an Air Quality Sensor - G238- that deter‐
mines the NOx percentage (nitrogen) and CO percentage
(carbon monoxide) of the air flowing by via a sensor. In addi‐
tion, the Air Quality Sensor - G238- installed on this vehicle
exchanges information with the Vehicle Electrical System
Control Module - J519- via a local Data Bus. Therefore, note
the exact allocation of the Air Quality Sensor - G238- . Refer
ates the measured value from the Air Quality Sensor - G238-
-1- and transmits it to the Climatronic Control Module - J255-
display and control head via the Data Bus. The Climatronic
Control Module - J255- display and control head switches to
recirculating air mode when requested, if there is no Shut-Off
condition present using the Vehicle Diagnostic Tester in the
♦ The Air Quality Sensor - G238- requires approximately two
minutes to reach its operating temperature after the ignition is
switched on. During the warm-up phase, the function of the Air
Quality Sensor - G238- is limited.

♦ During the warm-up phase, the Air Quality Sensor - G238-

malfunctions may occur under certain ambient influences.
Only replace the Air Quality Sensor - G238- if the Air Quality
Sensor - G238- is registered continually as faulty. If the mal‐
function indicator for the Air Quality Sensor - G238- changes
from “static” to “sporadic” after turning the ignition off and then
on again (waiting at least two minutes each time), then the Air
Quality Sensor - G238- is OK and it is no longer necessary to
observe the DTC memory using the Vehicle Diagnostic Tester
♦ The Air Quality Sensor - G238- recognizes the pollutants in
the surrounding air (mostly gasoline and/or diesel exhaust
gases) and prompts the Climatronic Control Module - J255-
display and control head to switch the A/C system to recircu‐
lating air mode.
head recognizes the type and intensity of the air pollutant on
the signal from the sensor. The Climatronic Control Module -
J255- display and control head then makes the decision de‐
pending on the exterior temperature and the intensity of the
air pollutant using the Vehicle Diagnostic Tester in the "Guided
– At an exterior temperature above approximately 2 °C (35.6 °
F), the recirculating air mode is switched on upon request from
the Air Quality Sensor - G238- when there is only a slight in‐
crease in the pollutant concentration.
– If the exterior temperature goes below -1 °C (30 °F) and in
“ECON mode” (the A/C compressor is switched off and the
indicator lamp in the AC or A/C button is off) the switch-over
takes place first when there is a sharp increase in the pollutant
concentration and only for approximately 15 seconds. If there
is another increase in the pollutant concentration within ap‐
proximately two minutes, then the Climatronic Control Module
- J255- display and control head does not switch into the “au‐
tomatic recirculating air mode”.
If the A/C compressor is switched off (for example, “ECON” is on
and the indicator lamp in the AC or A/C button is off), the Clima‐
tronic Control Module - J255- ) display and control head limits the
maximum duration of the “automatic recirculating air mode” to
approximately 15 seconds (so that the windows do not fog up).
– If the concentration decreases, the A/C system switches to the
fresh air mode.
– The duration of the “automatic recirculating air mode” depends
on the version of the Climatronic Control Module - J255- dis‐
play and control head. If the outside air temperature is below
10 °C (50 °F), then the system will stay on for approximately
30 seconds in “automatic recirculating air”. After this, it
switches back to fresh air mode. If, within approximately two
minutes, an increase in the pollutant concentration occurs
again, the Climatronic Control Module - J255- display and
control head does not switch to “automatic recirculating air
mode” during this time.
♦ “Automatic recirculating air mode” can be switched off at any
time. If the function is active, the A/C compressor is switched
on with a request for “automatic recirculating air mode” and
also when the outside air temperature is below 2 °C (36 °F). If
the temperature is below -5 °C (23 °F), then it is not possible
to use the A/C compressor.
♦ At setting “automatic recirculating air mode” in the MMI (Multi
Media Interface), the A/C compressor can also be switched on
when the recirculating air mode is manually switched on (using
the “recirculation button”) up to a temperature of approximate‐
ly - 5°C (23 °F).

♦ To ensure that the A/C system does not operate constantly in

the recirculating air mode in areas with a consistently higher
pollution, the Air Quality Sensor - G238- is self-learning (it ad‐
justs its sensitivity to the environmental conditions).
♦ If outside air pollution load remains high for longer period of
time, the Air Quality Sensor - G238- starts to adapt itself to the
changing environmental condition through an adaptation pro‐
gram (learning program), the air recirculation request in evenly
polluted ambient air is therefore generally shorter than 12 mi‐
nutes. If a succession of peaks in the polluted air is detected,
the A/C system can operate over a longer period of time in
recirculating air mode.
♦ A certain amount of time is required for repositioning of the air
conditioning system doors. In the event that a sudden increase
in pollutants is encountered (for example when driving through
a diesel exhaust cloud) gaseous pollutants can be taken in
with the fresh air into the passenger compartment until the
door can be closed. For this reason, on vehicles equipped with
an Air Quality Sensor - G238- a dust and pollen filter is installed
with a charcoal layer. A filter that is saturated with pollutants
is no longer effective and needs to be replaced .
♦ In order to avoid frequent switching of the back pressure/fresh
air door and the air recirculation door, a slight increase of pol‐
lutants in the surrounding air will not allow for immediate
switching (the Air Quality Sensor - G238- does not send a re‐
quest to the Climatronic Control Module - J255- display and
control head). The filtering of the activated charcoal insert in
the dust and pollen filter will be sufficient.
♦ In order to avoid frequent switching of the back pressure/fresh
air door and the air recirculation doors, the request from the
Air Quality Sensor - G238- for “Automatic recirculating air
mode” remains for at least 25 seconds (minimum duration pe‐
riod), even if the pollutant concentration in the air is so far
reduced that the recirculating air mode is no longer necessary.
♦ So that the fogged windows are cleared as quickly as possible,
head does not permit the recirculating air mode when “Defrost”
mode is on (a request from the Air Quality Sensor - G238- is
not processed).
♦ The Air Quality Sensor - G238- requires approximately 30
seconds to become operational once the ignition has been
switched on (warm-up time). During this time there is no re‐
quest from the Air Quality Sensor - G238- to the Climatronic
Control Module - J255- display and control head for “automatic
recirculating air mode”.
♦ The Air Quality Sensor - G238- contains a highly sensitive
electronic component which can be damaged if it comes in
direct contact with solvents, fuels or chemicals. For this rea‐
son, do not install sensors that may have come into contact
with these substances.
♦ Under certain ambient influences, when switching on the ig‐
nition (for example, when the air pollution is high), if a fault on
the Air Quality Sensor - G238- is stored in the Vehicle Electri‐
cal System Control Module - J519- during the Air Quality
Sensor - G238- warm-up time, even though the sensor is OK,
proceed as follows:
– Switch off the ignition for a minimum of two minutes.
– Switch on the ignition and wait at least two minutes.

– Read the DTC memory of the Vehicle Electrical System Con‐

trol Module - J519- . If the Air Quality Sensor - G238- still
displays a static malfunction, perform Guided Fault Finding
ing" function. If the Air Quality Sensor - G238- is no longer
displayed as a malfunction or the malfunction was sporadic,
then the Air Quality Sensor - G238- is OK (and no longer needs
to be observed). Erase the DTC memory.
9.3 Air Quality Sensor - G238- , Checking
Note
♦ Different versions depending on the vehicle date of manufac‐

ture and A/C system version (“Basis” or “Convenience”). Refer
to ⇒ “9.2 Air Quality Sensor G238 , Function”, page 642 .
♦ The Air Quality Sensor - G238- is only installed on vehicles
with the “Convenience” A/C system.
♦ The Air Quality Sensor - G238- and the Humidity Sensor in
Fresh Air intake Duct - G657- need approximately two minutes
until they reach their operating temperature after turning on
the ignition. The function of the Air Quality Sensor - G238- and
the Humidity Sensor in Fresh Air intake Duct - G657- is limited
during the warm-up phase.
♦ During the warm-up phase, the Air Quality Sensor - G238-
malfunctions may occur under certain ambient influences.
Only replace the Air Quality Sensor - G238- if the Air Quality
Sensor - G238- is repeatedly appearing as faulty. If the mal‐
function indicator for the Air Quality Sensor - G238- changes
from “static” to “sporadic” after switching the ignition off and
then on again (waiting at least two minutes each time), then
the Air Quality Sensor - G238- is OK and the DTC memory
entry no longer needs to be monitored (erase the DTC mem‐
ory) using the Vehicle Diagnostic Tester in the "Guided Fault
Finding" function.
Special Tools and Equipment

♦ Vehicle Diagnostic Tester with the Vehicle Diagnosis System
- Updated Cable - 3m - VAS5051/5A-
♦ Commercially available gas lighter (for checking the Air Qual‐
ity Sensor - G238- )
Test Requirements:
♦ Vehicle standing in a clean atmosphere (away from running
engines, exhaust vents, etc.)
♦ Engine compartment and the plenum chamber are clean (not
contaminated with oil or fuel)
♦ The engine compartment and the plenum chamber were not
sprayed with cleaning agents or preservatives containing sol‐
vents
♦ “Automatic recirculating air mode” is switched on.
Note
It is possible to switch the “automatic recirculating air mode” on

or off via the “A/C System” in the “Car” menu in the MMI (Multi
Media Interface). Refer to the Infotainment/MMI Operating In‐
structions.

Air Quality Sensor - G238- , Checking Function

General Warnings .
WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.

cover -B-. Refer to
Warnings .
General Warnings .
nition turned on
DANGER!


ning engine.

Note
to be active.
Manual.
Module - J285- ).


Note
Installing .
All Vehicles
– With the ignition switched off, connect the Vehicle Diagnostic
Tester with the Vehicle Diagnosis System - Updated Cable -
3m - VAS5051/5A- to the vehicle diagnostic connection and
initiate the Guided Fault Finding using the Vehicle Diagnostic
– Turn on the ignition (vehicles with the high voltage system).
– Start the engine (vehicles without the high voltage system).
Note
The vehicle electrical system may turn off the engine on a vehicle
with the Start/Stop System.

J255- display and control head using the Vehicle Diagnostic
– Set the “Auto” mode on the Climatronic Control Module - J255-
display and control head (“Convenience” version).
– Via the MMI (Multi Media Interface), set the “automatic recir‐
culating air mode” on the Climatronic Control Module - J255-
display and control head. Refer to Infotainment/MMI Operating
Instructions.
– Wait two minutes. (warm-up time for the Air Quality Sensor -
G238- ).
– Via the Vehicle Diagnostic Tester , select the “read measured
values block” function and then read the measured values for
the Air Quality Sensor - G238- using the Vehicle Diagnostic

Note
♦ The NOx- portion (nitrogen oxide) and the CO- portion (carbon
monoxide) in the air measured by the Air Quality Sensor -
G238- is displayed in the measured values block. For an
explanation for possible displays using the Vehicle Diagnostic
Tester in the "Guided Fault Finding" function
♦ The measured value of the Air Quality Sensor - G238- is not
directly displayed on all versions of the display control head
for the Climatronic Control Module - J255- . Depending on the
version of the Climatronic Control Module - J255- as the meas‐
ured value only the status of the heating and A/C system mode
“fresh or recirculating air mode” is displayed using the Vehicle
Diagnostic Tester .
– Turn the Air Quality Sensor - G238- -A- approximately 90° to

the left and remove it from the fresh air intake -C- .

– Allow a little bit of gas from a lighter -B- to flow past from the
top area -A- of the Air Quality Sensor - G238- .
Note
If the Air Quality Sensor - G238- comes in contact with cigarette

smoke or with gas from a lighter, it will react since butane gas is
heavier than air; therefore, remove the Air Quality Sensor -
G238- .
– Select and read the measured value block with the Air Quality
Sensor - G238- measured values using the Vehicle Diagnostic
Specified values:
♦ The measured values increase contrary to the initial value in
the display fields and show that both sensors in the Air Quality
Sensor - G238- are working correctly and the Air Quality Sen‐
sor - G238- electronics are evaluating the measured values
properly.
– Wait a short period of time (approximately one minute, de‐
pending on amount of test gas flowing into the sensor).
– Read the Air Quality Sensor - G238- measured values.
Specified Values:
♦ The measured values will return to the output values and by
doing so, show that both sensors are working correctly, and
that the sensor electronics evaluated the measured values
correctly.
Note
Due to changed pollution values, it is possible that different values

can be displayed than those by the first measuring.
– Read the display with the measured values for the A/C oper‐
ating status (recirculation/fresh air operation).
Specified Values:
♦ The display field will show that the A/C is working in the fresh
air mode.
Note
♦ If a deviating value from the “fresh air mode” is displayed in

the measured values block, then there is already a request for
recirculating air mode (for example, due to the request for
“maximum cooling output” or “manual recirculating air mode)”.
Select a setting that does not require recirculating air mode.
♦ If is appears in the measured values block that the Air Quality
Sensor - G238- is already requesting automatic recirculating
air mode, then, if necessary, clean the plenum chamber or
move the vehicle into an area where the surrounding air is
cleaner using the Vehicle Diagnostic Tester in the "Guided

– Allow a little bit of gas from a lighter -B- to flow past from the
top area -A- of the Air Quality Sensor - G238- .
– Read the recirculation/fresh air mode display.
Specified Values:
♦ In the measured values block, it will be displayed that a request
for air recirculation is present and that the A/C system is work‐
ing in the air recirculation mode.
Note
♦ If is shows in the measured values block that the Air Quality

Sensor - G238- has requested automatic recirculating air
mode, this request will not be performed based on a Shut-Off
condition from the Climatronic Control Module - J255- display
and control head. Repair the cause for this Shut-Off condition,
if necessary using the Vehicle Diagnostic Tester in the "Gui‐
ded Fault Finding" function
♦ In order to avoid frequent shifting of the recirculated air/fresh
air doors and the recirculation doors, the requirement of the
Air Quality Sensor - G238- for “Automatic air recirculation”
mode remains for at least 25 seconds (minimum duration pe‐
riod), even if the pollutant concentration is so far reduced that
recirculated air mode is no longer necessary.
– Wait a short period of time (approximately one minute, de‐

pending on amount of test gas flowing into the sensor).
♦ If the measured value block shows that there is no longer a
request for air recirculation, then the A/C system is working
again in the fresh air mode.
If the function of Air Quality Sensor - G238- is OK for this test and
there is a customer complaint continue as follows:
– Check the dust and pollen filter for soiling. Refer to
556 .
– With the ignition switched off, connect the Vehicle Diagnostic
Tester with the Vehicle Diagnosis System - Updated Cable -
3m - VAS5051/5A- to the vehicle diagnostic connection and
use the Vehicle Diagnostic Tester in the "Guided Fault Find‐
ing" function.
– Using the Vehicle Diagnostic Tester , select the “Read meas‐
ured values block” function using the Vehicle Diagnostic Test‐
Note
A second person is required to read out the values displayed while

driving.
Always pay attention to the safety instructions using the Vehicle

Diagnostic Tester in the "Guided Fault Finding" function
– Read the displays in the measured values block for the Air
Quality Sensor - G238- measured values and the recirculation/
fresh air mode request.
– Drive the vehicle into an area with a relatively clean atmos‐
phere (system in fresh-air mode).
– Then drive vehicle into an area where the atmosphere is pol‐
luted (for example, onto an uphill road with truck traffic).

– Read the displays in the different display fields. The displays

in the different display fields must change; for example, when
driving through a Diesel exhaust cloud.
Note
Also pay attention to the descriptions. Refer to

page 556 (Dust and Pollen Filter, Removing and Installing) and
⇒ “9.2 Air Quality Sensor G238 , Function”, page 642 .

9.4 Air Quality Sensor - G238- / Humidity

Sensor In Fresh Air Intake Duct - G657- ,
Note

♦ The Air Quality Sensor - G238- is only installed on vehicles
with the “Convenience” A/C system.
♦ The Humidity Sensor in Fresh Air intake Duct - G657- is only
installed on vehicles from MY 2012 as a running change. Refer
♦ The Air Quality Sensor - G263- / Humidity Sensor in Fresh Air
intake Duct - G657- are highly sensitive electronic compo‐
nents that can get damaged if they come in direct contact with
solvents, fuels or chemicals (for example, impurities may enter
through area -A-). Therefore, never install an Air Quality Sen‐
sor - G238- / Humidity Sensor in Fresh Air intake Duct - G657-
that was stored, for example, in a tool box.
♦ Following removal, do not set down the Air Quality Sensor -
G238- / Humidity Sensor in Fresh Air intake Duct - G657- in
areas where it could come into contact with solvents, fuels or
certain chemical compounds (liquids or vapors).
♦ There are different versions of the Air Quality Sensor - G238- /
Humidity Sensor in Fresh Air intake Duct - G657- with different
functions, therefore pay attention to the correct version. Refer

General Warnings .
WARNING

voltage system.

WARNING

connector.
DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.

cover -B-. Refer to
Warnings .
General Warnings .
– Switch off ignition.
Note
Installing .
All Vehicles

– Rotate the Air Quality Sensor - G238- / Humidity Sensor in

Fresh Air intake Duct - G657- -A- approximately 90° to the left
and remove it from the fresh air intake -C-.
– Remove the connector -B- from the Air Quality Sensor -
G238- / Humidity Sensor in Fresh Air intake Duct - G657- .
Terminal assignment in connector -B-
1 - B+ (terminal “15”)
2 - Ground (terminal “31”)
3 - Signal wire to the Vehicle Electrical System Control Module -
J519- . Refer to ⇒ Wiring diagrams, Troubleshooting & Compo‐
nent locations.
Note
♦ The signal from the Air Quality Sensor - G238- / Humidity

Sensor in Fresh Air intake Duct - G657- cannot be evaluated
by workshop equipment.
ates the data from the Air Quality Sensor - G238- / Humidity
Sensor in Fresh Air intake Duct - G657- and then transmits it
to the Climatronic Control Module - J255- display and control
head via the Data Bus.
♦ There are different versions of the air intake shroud for the
fresh air intake -C- (with and without a mount for the Air Quality
Sensor - G238- / Humidity Sensor in Fresh Air intake Duct -
G657- -A-, front mount or on the side). To ensure the correct
version. Refer to the Parts Catalog.
♦ The measured values for the Air Quality Sensor - G238- / Hu‐
midity Sensor in Fresh Air intake Duct - G657- are displayed
in the measured value block for the Climatronic Control Mod‐
ule - J255- display and control head and in the measured value
block for the Vehicle Electrical System Control Module -
J519- . For the explanatory notes of the displays using the
tion

9.5 Outside Air Temperature Sensor -

Note
♦ The measured value of the Outside Air Temperature Sensor -

G17- is evaluated by the Vehicle Electrical System Control
Module - J519- and is transmitted via the Data Bus to the Cli‐
(and the Instrument Cluster Control Module - J285- ) using the
tion.
♦ The illustration shows the allocation of the Outside Air Tem‐
perature Sensor - G17- -A- on the Audi A5 Coupe, the Audi
A5 Sportback, the Audi A4, Audi Q5, etc. The allocation can
vary.
♦ If the vehicle has an Outside Air Temperature Sensor - G17-
-A- with the bracket -B- installed on the air intake grille above
the impact member, it is possible that a higher temperature
may register due to the component location of the Outside Air
Temperature Sensor - G17- under certain operating conditions
(because the radiator and condenser are radiating heat, for
example on MY 2008 vehicles). In MY 2009, the component
location of the Outside Air Temperature Sensor - G17- -A- has
been moved as a running change. The Outside Air Tempera‐
ture Sensor - G17- with the new bracket -C- have been move
slightly forward (closer to the radiator grille) and is under the
impact member -D-. Refer to the Parts Catalog.
♦ If there is a complaint because the measured value is too high
because the vehicle has the Outside Air Temperature Sensor
- G17- -A- with the bracket -B- installed on the air intake grille
above the impact member, then install an Outside Air Tem‐
perature Sensor - G17- -A- with the revised bracket -C- slightly
forward (closer to the radiator grille) and under the impact
member -D-. The wire connections may have to be length‐
ened. Refer to the Parts Catalog. The bracket -C- is clipped
into the impact member -D-. It may be necessary to drill a 7
mm hole into the impact member -D-.
.
Removing and Installing:
– Disconnect the connector -E- on the temperature sensor -A-
and remove the temperature sensor from the bracket (-B- or
-D-).
Note
Depending on the vehicle equipment level, it may be necessary

to remove the bumper in order to remove the Outside Air Tem‐
perature Sensor - G17- -A- from the bracket -C- installed under
the impact member -D- (if, for example, the Outside Air Temper‐
ature Sensor - G17- is not accessible from above on vehicles with
additional radiators).


Control Module - J255- display and control head (and the In‐
strument Cluster Control Module - J285- ) and erase any
faults, if necessary using the Vehicle Diagnostic Tester in the
9.6 Center Vent Temperature Sensor -

Note
The Center Vent Temperature Sensor - G191- is only installed on

vehicles equipped with the “Basis” A/C system.
Removing
– Remove the Radio - R- of the CD changer (depending on the
vehicle equipment level). Refer to ⇒ Communication; Rep.
Gr. 91 ; Radio; Radio, Removing and Installing or ⇒ Com‐
munication; Rep. Gr. 91 ; DVD/CD Changer; CD Changer,
– Reach through the installation shaft and disconnect the con‐
nector -A- .
– Turn the sensor -B- 90° and remove it from the air guide chan‐
nel leading the “center” instrument panel vents.
Installing
following.
– Check the seal -C- for damage and proper seating.
9.7 Footwell Vent Temperature Sensor -

G192- / Left Footwell Vent Temperature
Sensor - G261- , Removing and Instal‐
ling
The Footwell Vent Temperature Sensor - G192- Is Installed on
Vehicles Equipped with the “Basis” A/C system.
The Left Footwell Vent Temperature Sensor - G261- Is Installed
on Vehicles Equipped with the “Convenience” A/C system.
Note
Different names of the currently identical sensor, depending on

the A/C system version. Refer to ⇒ “4 Actuators”, page 388 (A/C
unit components)
Removing


– Turn the sensor -B- 90° and remove it from the left (driver side)
footwell vent.
Installing
following.
9.8 Right Footwell Vent Temperature Sen‐

sor - G262- , Removing and Installing
Note
The Right Footwell Vent Temperature Sensor - G262- is only in‐

stalled on vehicles equipped with the “Convenience” A/C system.
Removing
– Remove the right footwell vent (front passenger side) -C-. Re‐
fer to
– Turn the sensor -D- 90° and remove it from the right footwell
vent -C- .
Installing
following.
– Check the seal -E- for damage and proper seating.

9.9 Evaporator Vent Temperature Sensor -

Removing
to
– Loosen the Evaporator Vent Temperature Sensor - G263-
-B- from the A/C unit mount -C-.
– Turn the Evaporator Vent Temperature Sensor - G263- -B-
180° and remove it from the A/C unit.
Note
The Evaporator Vent Temperature Sensor - G263- -B- is installed

so that the temperature sensor -D- is facing the evaporator. To
remove and install it when the air intake housing is installed, it
must be turned it its mount 180º out of installation position after
loosening or before tightening.
Installing
following.
– Insert the Evaporator Vent Temperature Sensor - G263- -B-
into the A/C unit mount -C-.
– Turn the Evaporator Vent Temperature Sensor - G263- -B-
180° and then secure it in the mount.

9.10 Humidity Sensor - G355- , Removing

and Installing
⇒ “9.10.1 Humidity Sensor G355 , Removing and Installing, Ve‐
hicles without High Beam Assist”, page 663
⇒ “9.10.2 Humidity Sensor G355 , Removing and Installing, Ve‐
hicles with High Beam Assist”, page 664
9.10.1 Humidity Sensor - G355- , Removing

and Installing, Vehicles without High
Beam Assist
WARNING

voltage system.
Note

memory. For these vehicles, if there is a difference on the Hu‐
midity Sensor - G355- , the Rain/Light Recognition Sensor -
G397- is displayed as the faulty location using the Vehicle
♦ Starting from MY 2010, there is a running change of the Hu‐
midity Sensor - G355- version. Refer to Parts Catalog. Re‐
moving and installing is different depending on the version of
the Humidity Sensor - G355- . The version “1” (installed
through MY 2009 and discontinued as a running change) is
removed and installed as described in the following. The ver‐
sion “2” (installed from MY 2010 with a running change) is
removed and installed as described in the repair manual “Elec‐
trical Equipment”. Refer to ⇒ Electrical Equipment; Rep. Gr.
92 ; Windshield Wiper System; Rain/Light Recognition Sen‐
sor, Removing and Installing .
Removing (Version “1”)

– Remove the interior rearview mirror. Refer to ⇒ Body Interior;
Rep. Gr. 68 ; Interior Rearview Mirror; Interior Rearview Mir‐
ror, Removing and Installing .
– Spread the cover -1- on both sides slightly -arrows- and re‐
move it from the interior rearview mirror base -2-.


– Using a small screwdriver -3-, carefully press the Humidity
Sensor - G355- -4- off of the cover -1- -arrow- and at the same
time remove it upward.
Installing (Version “1”)
– Carefully insert the Humidity Sensor - G355- into the side
guides.
Note
If the Humidity Sensor - G355- is not inserted correctly, the cover

cannot be installed.
– Install the interior rearview mirror. Refer to ⇒ Body Interior;

9.10.2 Humidity Sensor - G355- , Removing

and Installing, Vehicles with High Beam
Assist
WARNING

voltage system.
Note

♦ Starting from MY 2010, there is a running change of the Hu‐
midity Sensor - G355- version. Refer to Parts Catalog. Re‐
moving and installing is different depending on the version of
the Humidity Sensor - G355- . The version “1” (installed
through MY 2009 and discontinued as a running change) is
removed and installed as described in the following. The ver‐
sion “2” (installed from MY 2010 with a running change) is
removed and installed as described in the repair manual “Elec‐
trical Equipment”. Refer to ⇒ Electrical Equipment; Rep. Gr.
92 ; Windshield Wiper System; Rain/Light Recognition Sen‐
sor, Removing and Installing .

Removing (Version “1”)

– Remove the interior rearview mirror. Refer to ⇒ Body Interior;
– Release the retaining tabs -1 and 2- using a screwdriver -3-.
– Disengage the rear cover -4-.
– Release the retaining tabs in direction of -arrows- and carefully

fold the upper cover -2- slightly upward.
– Disengage the retaining tab -1- on the front cover -3-.
– Remove the upper cover.
– Disengage the hooks in the direction of the -arrow- and re‐

move the front cover -2- downward from the guide braces on
the rearview mirror base -1-.

– Release the clips -2- in direction of -arrows- and remove the

Humidity Sensor - G355- -4- from the rearview mirror base
-1-.
Installing (Version “1”)
– Install the interior rearview mirror. Refer to ⇒ Body Interior;
9.11 Rain/Light Recognition Sensor - G397- ,

WARNING

voltage system.
Note

♦ Starting from MY 2010, there is a running change for the ver‐
sion of the Humidity Sensor - G355- (with or without Rain/Light
Recognition Sensor - G397- ). Refer to Parts Catalog. Re‐
moving and installing is different for both versions. Depending
on the date of manufacture and the vehicle version, version
“1” (discontinued as a running change through MY 2009) or
version “2” (running change from MY 2010) can be installed.
Removing and Installing (Version “1”)

– Removing and installing the interior rearview mirror. Refer to
⇒ Body Interior; Rep. Gr. 68 ; Interior Rearview Mirror; Interior
Rearview Mirror, Removing and Installing .
– Removing and installing the Humidity Sensor - G355- / Rain/
Light Recognition Sensor - G397- . Refer to
⇒ “9.10 Humidity Sensor G355 , Removing and Installing”,
page 663 .
Removing and Installing (Version “2”)
– Removing and installing the Humidity Sensor - G355- / Rain/
Light Recognition Sensor - G397- . Refer to ⇒ Electrical
Equipment; Rep. Gr. 92 ; Windshield Wiper System; Rain/
Light Recognition Sensor, Removing and Installing .

9.12 Left Front Upper Body Vent Tempera‐

ture Sensor - G385- , Removing and
Installing
Note
The Left Front Upper Body Vent Temperature Sensor - G385- is

only installed on vehicles with a “Convenience” A/C system.
Removing
– Remove the storage compartment on driver side. Refer to ⇒
Body Interior; Rep. Gr. 68 ; Storage Compartments and Cov‐
ers; Driver Side Instrument Panel Cover, Removing and In‐
stalling .
– Disconnect the connector -A- from the temperature sensor.
– Turn the Left Front Upper Body Vent Temperature Sensor -
G385- -B- 90° and remove it from the mount in the air guide
channel -D- .
Installing
following.
9.13 Right Front Upper Body Vent Tempera‐

ture Sensor - G386- , Removing and
Installing
Note
The Right Front Upper Body Vent Temperature Sensor - G386-

is only installed on vehicles with a “Convenience” A/C system.
Removing

– Disconnect the connector -A- from the temperature sensor.

– Turn the Right Front Upper Body Vent Temperature Sensor -
G386- -B- approximately 90° and remove it from the mount in
the air guide channel -D- .
Installing
following.

9.14 Humidity Sensor In Fresh Air Intake

Duct - G657- Function
Note
♦ There are different versions depending on the vehicle date of

manufacture and the A/C system version (“Basis” or “Conven‐
ience”) is installed. The “Basis” A/C system does not have a
humidity sensor in the Humidity Sensor in Fresh Air intake
Duct - G657- / Air Quality Sensor - G238- until the MY 2012
changeover. From MY 2012 it has a humidity sensor in Hu‐
midity Sensor in Fresh Air intake Duct - G657- without an Air
Quality Sensor - G238- (black housing). From MY 2012, the
“Convenience” A/C system has an Air Quality Sensor - G238-
without a Humidity Sensor in Fresh Air intake Duct - G657- .
From this change, a Humidity Sensor in Fresh Air intake Duct
- G657- is installed with an Air Quality Sensor - G238- (brown
housing).
♦ Only vehicles with the “Convenience” A/C system have an Air
Quality Sensor - G238- without a Humidity Sensor in Fresh Air
intake Duct - G657- (from start of production up the change‐
over) Refer to the Parts Catalog.
♦ From MY 2012, the vehicle version was changed-over as a
running change beginning with Audi A4 and Audi A5. Refer to
⇒ “8.1 Display and Control Head Location”, page 629 . Vehi‐
cles, built before the changeover and with the “Convenience”
A/C system, have an Air Quality Sensor - G238- (not installed
on the “Basis” version). For vehicles built since this change‐
over (and for the Audi Q5 Hybrid), a Humidity Sensor in Fresh
Air intake Duct - G657- is installed on the “Basis” version and
a Humidity Sensor in Fresh Air intake Duct - G657- with the
Air Quality Sensor - G238- is installed on vehicles with the
“Convenience” version.
♦ This is how to tell the difference: the Humidity Sensor In Fresh
Air Intake Duct - G657- with an Air Quality Sensor - G238- has
a brown housing (running change from MY 12). For the Hu‐
midity Sensor in Fresh Air intake Duct - G657- version without
the Air Quality Sensor - G238- , the housing is black (running
change from MY 2012). For the Air Quality Sensor - G238-
version without a Humidity Sensor in Fresh Air intake Duct -
G657- , the housing is black and the Humidity Sensor in Fresh
Air intake Duct - G657- -3- is not present (gradual discontinu‐
ation from MY 2012).
♦ The Humidity Sensor in Fresh Air intake Duct - G657- -3- with
the Air Quality Sensor - G238- -1- is installed in the same
housing -2- (housing color “brown”) on vehicles with the “Con‐
venience” A/C system.
♦ If the vehicle has the “Basis” A/C system, then only the Hu‐
midity Sensor in Fresh Air intake Duct - G657- -3- is present.
The Air Quality Sensor - G238- -1- is not installed in the hous‐
ing -2- (housing color “black”).
♦ The Humidity Sensor In The Fresh Air Intake Duct - G657- is
a highly sensitive electronic component that can be damaged
if it comes in direct contact with fluids, solvents, fuels and cer‐
tain chemical compounds.
♦ The function of the Humidity Sensor In The Fresh Air Intake
Duct - G657- can be severely affected by direct contact with
water so that correct moisture values can no longer be meas‐
ured (briefly or permanently depending on the composition of
the fluid). For this reason, do not install sensors that may have
come into contact with these substances.

♦ The Humidity Sensor In The Fresh Air Intake Duct - G657-

determines the temperature and the moisture in the air flowing
by and exchanges the information with the Vehicle Electrical
System Control Module - J519- via the Data Bus.
♦ The measured value for the Humidity Sensor In The Fresh Air
Intake Duct - G657- is evaluated by the Vehicle Electrical Sys‐
tem Control Module - J519- and is transmitted via the Data Bus
to the Climatronic Control Module - J255- control head.
♦ The Climatronic Control Module - J255- uses the measured
values to calculate the current relative humidity of the drawn-
in fresh air. The calculated humidity value is used to detect
whether there is a risk of the windshield, rear window, and door
windows fogging up on the inside. If that is the case, the Cli‐
matronic Control Module - J255- changes various character‐
istic curves to counteract this. This can be performed, for
example, by lowering the evaporator temperature (by activat‐
ing the A/C compressor), by raising the response thresholds
for the request for “automatic recirculating air mode”, by pre‐
venting engine Shut-Off via the start-stop function, etc.
♦ The Humidity Sensor in Fresh Air intake Duct - G657- needs
about two minutes until it has reached its operating tempera‐
ture after the ignition is switched on. During the warm-up
phase, the function of the Humidity Sensor in Fresh Air intake
Duct - G657- is limited.
9.15 Humidity Sensor in Fresh Air intake Duct

- G657- , Checking
Note

♦ The Humidity Sensor in Fresh Air intake Duct - G657- is only
installed on vehicles from MY 2012 as a running change. Refer
♦ The Air Quality Sensor - G238- and the Humidity Sensor in
Fresh Air intake Duct - G657- need approximately two minutes
until they reach their operating temperature after turning on
the ignition. The function of the Air Quality Sensor - G238- and
the Humidity Sensor in Fresh Air intake Duct - G657- is limited
during the warm-up phase.
♦ The function of the Humidity Sensor in Fresh Air intake Duct -
G657- can only be checked via the “Guided Fault Finding”. The
measured values of the Humidity Sensor in Fresh Air intake
Duct - G657- are evaluated there via the “read measured val‐
ues” function and are compared to the temperature and hu‐
midity measured at the component location of the Humidity
Sensor in Fresh Air intake Duct - G657- using the Vehicle Di‐
agnostic Tester in the "Guided Fault Finding" function
Check the function of the Humidity Sensor in Fresh Air intake Duct
- G657- using the Vehicle Diagnostic Tester in the "Guided Fault
Finding" function.

10 Battery Cooling Module

ment”, page 671
⇒ “10.2 Overview - Components Inside Rear Passenger Com‐
partment”, page 675
⇒ “10.3 Overview - Battery Cooling Module”, page 678
⇒ “10.4 Overview - Air Intake, Air Vent and Air Guide on the Bat‐
tery Cooling Module”, page 682
⇒ “10.5 Overview - Air Guide”, page 684
⇒ “10.6 Hybrid Battery Refrigerant Shut-Off Valve 1 N516 , Re‐
⇒ “10.7 Traction Battery A2 Rear Outlet Air Guide, Removing and
⇒ “10.8 Traction Battery A2 Front Outlet Air Guide, Removing
⇒ “10.9 Traction Battery A2 Inlet Air Guide, Removing and In‐
⇒ “10.10 Left and Right Air Guides on Traction Battery A2 , Re‐
⇒ “10.11 Battery Cooling Module, Bringing into Service Position”,
page 701
⇒ “10.12 Battery Cooling Module, Removing and Installing”, page
704
⇒ “10.13 Battery Fan 1 V457 , Removing and Installing”,
page 708
⇒ “10.14 Temperature Sensor before Hybrid Battery Evaporator
G756 , Removing and Installing”, page 711
⇒ “10.15 Temperature Sensor after Hybrid Battery Evaporator
G757 , Removing and Installing”, page 713
page 715
⇒ “10.17 Condensation Water Drain, Checking”, page 718
10.1 Overview - Components Outside of Pas‐

senger Compartment
General Warnings .
WARNING

voltage system.
10. Battery Cooling Module 671

WARNING

connector.
DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.

Note
♦ Components on the outside of the vehicle interior for vehicles with and without a high voltage system. Refer
to ⇒ “1.1 Overview - Components Outside of Passenger Compartment”, page 120
1 - Coolant Fan - V7- and Cool‐

ant Fan 2 - V177-
❑ For additional informa‐
tion. Refer to
⇒ “1.1 Overview - Com‐
ponents Outside of Pas‐
senger Compartment”,
page 120 .
2 - Outside Air Temperature
Sensor - G17-
tion. Refer to
page 120 .
3 - Information Label
❑ With specifications for
type of refrigerant and
designated fill capacity.
Refer to
⇒ “4 Technical Data”,
page 110 and ⇒ Refrig‐
erant R134a Servicing;
Rep. Gr. 87 ; Refriger‐
ant R134a Capacities,
Refrigerant Oil and Ap‐
proved Refrigerant Oils .
4 - Fresh Air Intake with Intake
Grille
tion. Refer to
page 120 .
5 - Air Quality Sensor - G238- /
Humidity Sensor In Fresh Air Intake Duct - G657-
❑ For additional information. Refer to
⇒ “1.1 Overview - Components Outside of Passenger Compartment”, page 120 .
6 - Condensation Water Drain
7 - Plenum Chamber Water Drain
8 - Electric Drive Power and Control Electronics - JX1-
❑ Read and follow all of the supplemental warnings for all work performed on the Electric Drive Power And
Control Electronics - JX1- and vehicles with the high voltage system. Refer to

⇒ “2.2 High Voltage Vehicles Safety Precautions”, page 36 and ⇒ Electrical System Hybrid; Rep. Gr.
93 ; High Voltage System General Warnings .
9 - Climatronic Coolant Shut-Off Valve - N422- / Coolant Shut-Off Valve - N82-
On certain vehicles (depending on the engine), vacuum-controlled coolant Shut-Off valves were installed on
vehicles without a “parking heater” from start of production. Shut-Off valves that are directly activated were
introduced as a later time as a running change. This valve may be referred to as the Climatronic Coolant Shut-
Off Valve - N422- or the Coolant Shut-Off Valve - N82- depending on the engine version and when the vehicle
was produced. Refer to
⇒ “7.1 Coolant Shut-Off Valve N82 / Climatronic Coolant Shut-Off Valve N422 Location, Activation and Func‐
tion”, page 619 .
Note
On vehicles with an engine with a

regulated coolant circuit (for exam‐
ple, with a regulated coolant pump
and a Cylinder Head Coolant Valve
- N489- ), no Climatronic Coolant
Shut-Off Valve - N422- / Coolant
Shut-Off Valve - N82- is currently in‐
stalled. On an engine with a regula‐
ted coolant pump, the engine con‐
trol module activates the coolant
pump, and in doing so regulates the
coolant circuit. Refer to ⇒ Rep. Gr.
19 ; Coolant Pump/Thermostat .
10 - Plenum Chamber Water Drain

11 - Coolant Recirculation Pump - V50-
12 - Refrigerant Line Connections to the Evaporator Inside the Battery Cooling Module
WARNING
The
discharged.

❑ Check using the Vehicle Diagnostic Tester in the "Guided Fault Finding" function.
Note

Shut-Off Valve 1 - N516- is activa‐
ted, for example, if it is necessary to
cool the battery and no cooling is
desired in the passenger compart‐
ment (open without activation).

14 - Electrically-Driven A/C Compressor

❑ With A/C Compressor Control Module - J842- and Electrical A/C Compressor - V470-
❑ Removing A/C Compressor from bracket and reinstalling in vehicles with 4 cylinder. Engine. Refer to
⇒ “3.3.3 A/C Compressor, Removing and Installing on Bracket, Electrically-Driven A/C Compressor”,
page 304 . 1)
Note

ley, etc.).
10.2 Overview - Components Inside Rear

Passenger Compartment
Vehicles with a High Voltage System (Hybrid Vehicles)


General Warnings .
WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
Note
♦ Refer to
⇒ “10.4 Overview - Air Intake, Air Vent and Air Guide on the Battery Cooling Module”, page 682
♦ Refer to ⇒ “10.3 Overview - Battery Cooling Module”, page 678
WARNING
♦ The bolts of the connection point may only be loosened

when the refrigerant circuit has been discharged.

1 - Hybrid Battery Recircula‐

tion Door Positioning Motor 1 -
V479- :
ling. Refer to
⇒ “4.13 Hybrid Battery
Recirculation Door Po‐
sitioning Motor 1 V479 ,
ling”, page 431 .
2 - Expansion Valve with Hy‐
brid Battery Refrigerant Shut-
Off Valve 2 - N517-
ling. Refer to
⇒ “2.16 Rear Expansion
Valve with Hybrid Bat‐
tery Refrigerant Shut-
Off Valve 2 N517 , Re‐
page 248 .
3 - Opening for Refrigerant
Lines
ling. Refer to
⇒ “2.11 Refrigerant Line
Pass-Through in Lug‐
gage Compartment, Re‐
moving and Installing ”,
page 210 .
4 - Battery Fan 1 - V457-
ling. Refer to
⇒ “10.13 Battery Fan 1
V457 , Removing and
5 - Hybrid Battery Recircula‐
tion Door Positioning Motor 2 - V480-
⇒ “4.14 Hybrid Battery Recirculation Door Positioning Motor 2 V480 , Removing and Installing”,
page 434 .
6 - Temperature Sensor before Hybrid Battery Evaporator - G756-
⇒ “10.14 Temperature Sensor before Hybrid Battery Evaporator G756 , Removing and Installing”, page
711 .
7 - Temperature Sensor after Hybrid Battery Evaporator - G757-
⇒ “10.15 Temperature Sensor after Hybrid Battery Evaporator G757 , Removing and Installing”,
page 713 .
10.3 Overview - Battery Cooling Module

General Warnings .

WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
Note
♦ The Battery Regulation Control Module - J840- activates the

attachments using the Vehicle Diagnostic Tester in the "Gui‐
ded Fault Finding" function
♦ For this model line, only vehicles with a high-voltage system
were manufactured that had the refrigerant circuit charged
with refrigerant R134a.


1 - Condensation Water Drain

❑ Checking. Refer to
⇒ “10.17 Condensation
Water Drain, Checking”,
page 718 .
ling. Refer to
⇒ “10.16 Condensation
Water Drain, Removing
and Installing”,
page 715 .
2 - Bonded Rubber Bushing
3 - Nut
❑ 9 Nm
4 - Battery Cooling Module
❑ Bringing into service po‐
sition. Refer to
⇒ “10.11 Battery Cool‐
ing Module, Bringing in‐
to Service Position”,
page 701 .
ling. Refer to
⇒ “10.12 Battery Cool‐
ing Module, Removing
and Installing”,
page 704 .
5 - Bolt
❑ 10 Nm. Refer to
⇒ “2.16 Rear Expansion
Valve with Hybrid Bat‐
tery Refrigerant Shut-
Off Valve 2 N517 , Re‐
page 248 .
⇒ “2.16 Rear Expansion Valve with Hybrid Battery Refrigerant Shut-Off Valve 2 N517 , Removing and
7 - Seals
❑ Always replacing
8 - Clamp
9 - Screw
❑ 1.5 Nm
10 - Hybrid Battery Recirculation Door Positioning Motor 1 - V479- :
page 431 .
11 - Screw
❑ 1.5 Nm
12 - Hybrid Battery Recirculation Door Positioning Motor 2 - V480-
page 434 .

13 - Temperature Sensor before Hybrid Battery Evaporator - G756-

⇒ “10.14 Temperature Sensor before Hybrid Battery Evaporator G756 , Removing and Installing”, page
711 .
14 - Battery Fan 1 - V457-
⇒ “10.13 Battery Fan 1 V457 , Removing and Installing”, page 708 .
15 - Screw
❑ 1.5 Nm
16 - Temperature Sensor after Hybrid Battery Evaporator - G757-
⇒ “10.15 Temperature Sensor after Hybrid Battery Evaporator G757 , Removing and Installing”,
page 713 .
Bonded Rubber Bushing - Installed Position

• The collar -arrow- on the bonded rubber bushing -1- faces up‐
ward.
10.4 Overview - Air Intake, Air Vent and Air

Guide on the Battery Cooling Module
General Warnings .
WARNING

voltage system.

WARNING

connector.
DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.

Note
Air guides, removing and installing. Refer to ⇒ “10.5 Overview - Air Guide”, page 684 .
1 - Air Guide to the Battery

Cooling Module
❑ Air inlet from the area
underneath the luggage
compartment base plate
2 - Left air guide to the Traction
Battery - A2-
3 - Right air guide to the Trac‐
tion Battery - A2-
4 - Front outlet air guide for the
Traction Battery - A2-
❑ To the battery cooling
module
6 - Rear Outlet Air Guide from
the Battery Cooling Module
❑ For the vehicle forced
air extraction
10.5 Overview - Air Guide

General Warnings .

WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
Additional Work
– Remove the luggage compartment floor (different versions).
Refer to ⇒ Body Interior; Rep. Gr. 70 ; Luggage Compartment
Trim Panels; Overview - Luggage Compartment Floor .
♦ Perform a visual inspection of the high voltage components
and cables after removing the luggage compartment floor and
“Read and follow the High Voltage Electrical System General
Warnings”. Refer to ⇒ Electrical System Hybrid; Rep. Gr. 93 ;
High Voltage System General Warnings .
♦ When working near the high voltage components and cables,
make sure that they are not damaged.
♦ Perform a visual inspection of the high voltage components
and cables after finishing work on and before installing the
luggage compartment floor panel.

1 - Inlet Air Guide for the Trac‐

tion Battery
ling. Refer to
⇒ “10.9 Traction Battery
A2 Inlet Air Guide, Re‐
page 696 .
❑ Attach the air guide to
the battery cooling mod‐
ule using one bolt and to
the air guide using sev‐
eral bolts if the retainers
no longer hold or one of
the tabs breaks off.
2 - Front Outlet Air Guide for
the Traction Battery
ling. Refer to
⇒ “10.8 Traction Battery
A2 Front Outlet Air
Guide, Removing and
❑ Use several bolts to at‐
tach the air guide to the
battery cooling module if
the retainer no longer
holds or one of the tabs
breaks off.
3 - Left Air Duct
ling. Refer to
⇒ “10.10 Left and Right
Air Guides on Traction
Battery A2 , Removing
and Installing”,
page 699 .
❑ Use an additional bolt to attach the air guide if the retainers no long hold. Remove the traction battery to
do this. Refer to ⇒ Electrical System Hybrid; Rep. Gr. 93 ; High Voltage Battery Unit; High Voltage
4 - Bolt
❑ Use an additional bolt to attach the air guide if the retainers no longer hold. Remove the traction battery
to do this. Refer to ⇒ Electrical System Hybrid; Rep. Gr. 93 ; High Voltage Battery Unit; High Voltage
5 - Traction Battery - A2-
❑ Work on the Traction Battery - A2- such as removing and installing, disabling the vehicle high voltage
system, etc. Refer to ⇒ Electrical System; Rep. Gr. 93 ; High Voltage Battery Unit; High Voltage Battery,
7 - Right Air Guide
⇒ “10.10 Left and Right Air Guides on Traction Battery A2 , Removing and Installing”, page 699 .
❑ Use an additional bolt to attach the air guide if the retainers no long hold. Remove the traction battery to
do this. Refer to ⇒ Electrical System Hybrid; Rep. Gr. 93 ; High Voltage Battery Unit; High Voltage
8 - Bolt
❑ Use an additional bolt to attach the air guide if the retainers no longer hold.
9 - Bolt


11 - Bolt
12 - Rear Outlet Air Guide for the Traction Battery
⇒ “10.7 Traction Battery A2 Rear Outlet Air Guide, Removing and Installing”, page 691 .
❑ Use several bolts to attach the air guide to the battery cooling module if one of the tabs breaks off.
10.6 Hybrid Battery Refrigerant Shut-Off

Valve 1 - N516- , Removing and Instal‐
ling
General Warnings .
WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
Note
erant R134a.
Removing
tion).

– Free up the clip -2- for the wiring harness on the refrigerant
pipe.
– Remove the bolt -3- and separate the refrigerant pipe -4-.
Note
Ignore items -1, 5 and 6-.

– Disconnect and remove the connector -3- from the bracket.

– Remove the union nuts -1 and 2- while counterholding on the
connection and remove the Hybrid Battery Refrigerant Shut-
Off Valve 1 - N516- .
Installing
following.
Note

– Replace the O-ring seals. For the correct version. Refer to the
Parts Catalog.
– Install the union nuts -1 and 2- all the way by hand and then
tighten them.
♦ Union nut tightening specification -1 and 2-: 16.5 Nm
Note
Make sure when tightening the union nuts that the refrigerant lines
are not tensioned.

Station).
Finding" function.
fer to
Note

10.7 Traction Battery - A2- Rear Outlet Air

Guide, Removing and Installing


General Warnings .
WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
Removing
– Remove the left and right bolts -2-, if equipped.
– Open the left and right retainers in direction of -arrow- and
remove the rear outlet air guide toward the right.

Installing
following.
Note
Use several bolts -3- to attach the air guide to the battery cooling
module -1- if one of the tabs -4- breaks off.
– Push the air guide -2- onto the battery cooling module -1-. The
tabs -4- on the left and right must click into place.
10.8 Traction Battery - A2- Front Outlet Air

Guide, Removing and Installing
General Warnings .
WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
Removing
– Disconnect the connectors -1- and free up the wiring harness
-arrows-.

– Remove the left and right bolts -1 and 5-, if equipped.

– Open the left and right tabs -2- and remove the front outlet air
guide -3- from the battery cooling module -8-.
– Unclip and remove the front outlet air guide from the retainers
-6- on the air guides -4 and 7-.
Installing
following.
Note
Use bolts -2, 3 and 4- to attach the air guide to the battery cooling
module -7- if the retainers -6- do not hold any longer or one of the
tabs -1 and 5-.
– Clip the front outlet air guide inside the battery cooling module
-7- -arrow B- first, then install the left -1- and right -5- air guides
in direction of -arrows A-.
– Reinstall all of the previously removed components.
10.9 Traction Battery - A2- Inlet Air Guide,

General Warnings .

WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
Removing
– Remove the rear outlet air guide for the traction battery. Refer
to
⇒ “10.7 Traction Battery A2 Rear Outlet Air Guide, Removing
– Remove the front outlet air guide for the traction battery. Refer
to

– Remove the left and right bolts -3 and 7-, if equipped.

– Release the front and rear tabs -8- and remove the inlet air
guide -1- from the battery cooling module -6-.
– Unclip and remove the inlet air guide carefully from the retain‐
ers -4- on the left -2- and right -5- air guides.
Installing
following.
Note
Use a bolt -5- to attach the air guide to the battery cooling module
-6- and use bolts -2 and 3- to attach the left -1- and right -4- air
guides if the retainers no longer hold or if one of the tabs breaks
off.
– Clip the inlet air guide inside the battery cooling module -6- in
direction of -arrow B- first, then install the left -1- and right
-4- air guides in direction of -arrows A-.
10.10 Left and Right Air Guides on Traction

Battery - A2- , Removing and Installing
General Warnings .
WARNING

voltage system.

WARNING

connector.
DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.

Removing
Note
Remove the traction battery when removing the air guide for ve‐
hicles with additional bolted connections -1 and 3-.
Vehicles with Additional Bolted Connections for the Air Guides:

– Remove the traction battery. Refer to ⇒ Electrical System;
– Remove the bolts -1, 2 and 3- and the air guides.
Vehicles without Additional Bolted Connections for the Air
Guides:
– Remove the corresponding front bracket for the luggage com‐
partment floor. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Luggage
Compartment Trim Panels; Overview - Luggage Compartment
Floor .
– Remove the bolts -2- and carefully unclip the air guides from
the retainers.
Installing
following.
Caution
If the retainers for the air guides no longer hold, the air guides
must be secured with additional bolts -1 and 3-. Remove the
traction battery to do this. Refer to ⇒ Electrical System Hybrid;
10.11 Battery Cooling Module, Bringing into

Service Position
General Warnings .

WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
Bring the Battery Coolant Module into the Service Position

– Remove the rear outlet air guide for the traction battery. Refer
to
⇒ “10.7 Traction Battery A2 Rear Outlet Air Guide, Removing
– Remove the front outlet air guide for the traction battery. Refer
to
– Remove the air guide for the battery coolant module. Refer to
⇒ “10.9 Traction Battery A2 Inlet Air Guide, Removing and

– Disconnect and free up the connectors -1 and 2-.

– Remove the nuts -arrows-.
– Cover the Traction Battery - A2- for example, with a Fender

Protector - Audi - VAG1917A- -2-.
– Remove the battery coolant module -1- and lay it on the un‐
covered battery module as illustrated.
Caution

Installing
following.
– Reinstall the previously removed component.
10.12 Battery Cooling Module, Removing and

Installing
General Warnings .

WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
Note
erant R134a.
Removing
tion).
– Remove the air duct air inlet for the traction battery. Refer to
⇒ “10.9 Traction Battery A2 Inlet Air Guide, Removing and


-1 and 4-.
Note
– Disconnect and free up the connectors -1 and 2-.

– Remove the nuts -arrows- and remove the battery cooling
module.
Installing
following.
Note


the Parts Catalog.
them for damage.
Station).
fer to
Note

10.13 Battery Fan 1 - V457- , Removing and

Installing
General Warnings .

WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
Note
♦ Voltage is supplied via the Fan Activation Relay - J937- . Refer

tions.
♦ Activated by the Battery Regulation Control Module - J840-
ing" function.
Removing
– Bring the battery cooling module in the service position. Refer
to
⇒ “10.11 Battery Cooling Module, Bringing into Service Posi‐
tion”, page 701 .

– Turn the boot -1- on the connector upright and disconnect the
connector.
– Remove the bolts -arrows-, and remove the Battery Fan 1 -
V457- .
Installing
following.
10.14 Temperature Sensor before Hybrid Bat‐

tery Evaporator - G756- , Removing and
Installing
General Warnings .
WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.

to
tion”, page 701 .


– Turn the temperature sensor counterclockwise in direction of
-arrow- and remove.
Installing
following.
– Check that the current seals are not damaged and in their cor‐
rect positions.
10.15 Temperature Sensor after Hybrid Bat‐

tery Evaporator - G757- , Removing and
Installing
General Warnings .
WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.

to
tion”, page 701 .


– Loosen the Temperature Sensor after Hybrid Battery Evapo‐
rator - G757- out of the retainer by moving it back and forth in
direction of -arrows- and then remove it.
Installing
following.
– Check that the current seals are not damaged and in their cor‐
rect positions.
10.16 Condensation Water Drain, Removing

and Installing
General Warnings .
WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
Removing
to
tion”, page 701 .

– Remove the nuts -2 and 3- and move the heat shield slightly
to the left.
– Unlock the plastic ring -arrows- and push the condensation
water drain into the battery cavity.
– Remove the condensation water drain from the bracket.
Installing
following.
Note
♦ Replace the condensation water drain if the plastic ring is

damaged.
♦ Caulk the plastic ring with silicon if it is loose.
– Note the installed location when attaching the plastic ring:

• The plastic ring tab -1- must be positioned between both of the
condensation water drain markings -arrows-.
– Attach the condensation water drain in direction of -arrow A-

so that the tab -1- engages in the opening -2- in the retaining
bracket.
– Install the grommet in the opening in the battery cavity. Insert
the top tab -4- first and then lock the bottom one.
Note
♦ If the grommet on the battery cavity is not completely caulked,

caulk this position with for example Silicone Adhesive - D 176
001 A3- . Refer to the Parts Catalog.
♦ The adhesive surface must be clean and free of grease when
applying the silicone adhesive.
– Check that the condensation water drain is in the correct po‐

sition.
• The tab -2- must face the seam -1- in the bracket.

10.17 Condensation Water Drain, Checking

General Warnings .
WARNING

voltage system.
WARNING

connector.

DANGER!

components.
thermal glue.
ginning.
ment.
ment.
zation cables.
spection:
age.
formations.
ing label.
Checking
to
tion”, page 701 .

– Check the condensation water drain -3- for debris and make
sure it is installed correctly.
– Check that the condensation water drain is in the correct po‐

sition.
• The tab -2- must face the seam -1- in the bracket.

11 Special Tools
♦
♦ Hose Clamps - Up To 40mm - 3093-
♦ Hose Clamps - Up To 25mm - 3094-
♦ T-Handle Hook - 3438-

♦ A/C Pipe Pliers - T40147-
♦ Air Conditioner Couplings Release Tool - T40149-
♦ Retaining Ring - T40232-
♦ Cooling System Tester - VAG1274B-
♦ Ultrasound A/C Cleaner - VAS6189B- .
♦ Ultrasound A/C Cleaner - Airco-Clean Fluid - VAS6189/1-
11. Special Tools 721

12 Revision History
DRUCK NUMBER: A005A500121
Fac‐ Edit Job Fee Notes Quality
tory Edi‐ Type dba Checke
Edi‐ tion ck d By
tion
11.2 11/2 Lo‐ 129 “set to DEF” step added to Tom
017 8/20 cal 858 Heater and A/C Unit, Re‐ Perry
17 Fac‐ 3 moving and Installing
tory
Feed
back
11.2 11/1 Fac‐ N/A Eric P.
017 3/20 tory
17 Up‐
date
10.2 10/1 Fac‐ N/A Performed Factory update. Juan S.
017 2/20 tory
17 Up‐
date
06.2 02/0 Lo‐ 123 Correction to Overview - Tom
016 8/20 cal 352 Heater and A/C Unit Air In‐ Perry
17 Feed 0 take Housing
back
06.2 06/0 Fac‐ 117 Fix typo in “Cooling Output, Tom
016 7/20 tory 479 Checking, Vehicles without Perry
16 Up‐ 9 High Voltage System”
date
6.20 04/0 Feed 116 Changes made to metada‐ Tom
14 4/20 back 186 ta for S and RS model des‐ Perry
16 8 ignations
06.2 08/1 Cor‐ Checked all metadata. Mi‐ Tom
014 9/20 rec‐ nor changes made to met‐ Perry
15 tion adata for S and RS model
designations
06.2 08/1 Lo‐ 111 Fixed broken links for S5 Tom
014 8/20 cal 737 Perry
15 Feed 3,
back 111
737
7
06.2 5/6/2 Link Jim H.
014 015 Chec
king
06.2 09/0 Fac‐ Tom
014 8/20 tory Perry
14 Up‐
date
07/1 Fac‐ 101 New Format & Feedback Tom
6/20 tory 600 Perry
14 Up‐ 9
date
02/2 Lo‐ 997 Metadata changes made Tom
6/20 cal 956 Perry
14 Feed
back

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Service

Service Department. Technical Information

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

80 - Heating, Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

87 - Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

2.7 A/C Pressure/Temperature Sensor G395 , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

00 – General, Technical Data

⇒ “1.1 Type Labels”, page 2

1.1 Type Labels

♦ The information label provides information about the type of

2 Rep. Gr.00 - General, Technical Data

The Refrigerant and Capacity Type Plate Is Located at the Lower

♦ Refrigerant R134a and refrigerant oil as well as approved re‐

Explanations about the specifications on the information label

1.2 Odors in Vehicles with A/C System

♦ The odor can only be removed by cleaning with the if it origi‐

4 Rep. Gr.00 - General, Technical Data

♦ The odor can be removed by cleaning with the Ultrasound A/

1.3 Front Seat Heating and Ventilation

Various vehicle electrical components (for example, Rear Win‐

Components Which Participate in the Control of the Seat Heating

♦ From MY 2010, this vehicle has a Start/Stop System for spe‐

♦ The activation of the Right Front Seat Ventilation Control Mod‐

6 Rep. Gr.00 - General, Technical Data

♦ If there is a condition, where the heating or ventilation of the

8 Rep. Gr.00 - General, Technical Data

♦ If installed, the recognizable differences on the “Convenience”

♦ The specified temperature for the seat depends on the selec‐

10 Rep. Gr.00 - General, Technical Data

♦ The activation of the seat ventilation is controlled by different

1.4 Rear Window Defogger

♦ Various vehicle electrical components (for example, Rear Win‐

12 Rep. Gr.00 - General, Technical Data

♦ The rear window defogger is switched off at an outside tem‐

1.5 Notes on A/C System Control and Reg‐

♦ If there is a malfunction in the A/C system, first check the DTC

♦ Perform the following work after completing repairs, using the

– Check the DTC memory of Climatronic Control Module - J255-

1.6 Notes on A/C System Control and Reg‐

1.6.1 Notes on Components Outside Passen‐

♦ If there is a malfunction in the A/C system, first check the DTC

14 Rep. Gr.00 - General, Technical Data

♦ Perform the following work after completion of repair opera‐

♦ Components on the outside of the passenger compartment,

16 Rep. Gr.00 - General, Technical Data

1.6.2 Notes on Components Outside Passen‐

♦ If there is a malfunction in the A/C system, first check the DTC

♦ Perform the following work after completion of repair opera‐

Risk of unintended engine start

Handling high voltage cables:

18 Rep. Gr.00 - General, Technical Data

There is a risk of electrocution from damaged high voltage

1.7 Notes on Refrigerant Circuit

Risk of unintended engine start

Handling high voltage cables:

There is a risk of electrocution from damaged high voltage

If it is necessary to perform work in the vicinity of high voltage

20 Rep. Gr.00 - General, Technical Data

age Components and Cables”, page 41 and ⇒ Electrical Sys‐

The A/C Compressor Control Module - J842- integrated in the

For Vehicles without a High Voltage System

♦ The A/C compressor without an A/C Clutch - N25- is always

♦ No refrigerant may be added to the refrigerant circuit (dis‐

22 Rep. Gr.00 - General, Technical Data