SM - 11 Heating, Air Conditioning

Service
Workshop Manual
Audi A3 2013 ➤ ,
Audi A3 Cabriolet 2015 ➤ ,
Audi A3 Limousine 2014 ➤ ,
Audi A3 Limousine China 2014 ➤ ,
Audi A3 Sportback 2013 ➤ ,
Audi A3 Sportback China 2014 ➤ ,
Audi Q2 2016 ➤ , Audi Q2 China 2019 ➤
Heating, air conditioning
Edition 04.2019
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
80 - Heating
87 - Air conditioning system
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.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2019 Audi AG, Ingolstadt D3E804C6E50

Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A ...
Heating, air conditioning - Edition 04.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Identification of heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Type plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Notes on odours in vehicles without air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Notes on odours in vehicles with air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Notes on operation of auxiliary/supplementary heater on vehicles with diesel engine . . . . 8
2.5 Seat heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.6 Heated rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.7 Neck heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.8 Auxiliary air conditioner - vehicles with high-voltage system only . . . . . . . . . . . . . . . . . . . . 16
3 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1 Safety precautions when working on vehicles with high-voltage system . . . . . . . . . . . . . . 19
3.2 Safety precautions when working in the vicinity of high-voltage components . . . . . . . . . . 19
3.3 Safety precautions when handling refrigerants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.4 Safety precautions when working on air conditioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.5 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 21
3.6 Safety precautions when using testers and measuring instruments during a road test . . . . 21
3.7 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.4 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.5 Routing and attaching pipes and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.6 Installing radiators and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.7 Checking heating output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.8 Checking cooling output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.9 Discharging refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.10 Working on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.11 Paintwork repairs on vehicles with air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . 81
4.12 Refrigerant circuit seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.13 Notes on control motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.14 Notes on dust and pollen filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.15 Notes on high-voltage heater (PTC) Z115 (and high-voltage heater (PTC) control unit
J848 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.16 Notes on high-voltage components and potential equalisation lines . . . . . . . . . . . . . . . . . . 87
5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.1 Refrigerant capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.2 Approved refrigerant oils and refrigerant oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.3 Oil distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
80 - Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1 Overview of fitting locations - heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.1 Overview of fitting locations - components not located in passenger compartment . . . . . . 97
1.2 Overview of fitting locations - components in passenger compartment (front) . . . . . . . . . . 99
2 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2.1 Exploded view - heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2.2 Removing and installing fresh air blower V2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.3 Removing and installing fresh air blower control unit J126 . . . . . . . . . . . . . . . . . . . . . . . . 107
2.4 Removing and installing auxiliary air heater element Z35 . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Contents i
2.5 Removing and installing temperature flap control motor V68 with potentiometer G92 . . . . 108
2.6 Removing and installing air recirculation flap control motor V113 . . . . . . . . . . . . . . . . . . . . 108
2.7 Removing and installing air distribution flap control motor V428 with potentiometer G645
........................................................................ 108
2.8 Removing and installing dust and pollen filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2.9 Removing and installing heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.10 Removing and installing heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.11 Dismantling and assembling heater unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3 Air duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.1 Exploded view - routing of air flow and air distribution in passenger compartment . . . . . . 110
3.2 Removing and installing vents (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.3 Removing and installing fresh air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.4 Checking forced ventilation vents in passenger compartment . . . . . . . . . . . . . . . . . . . . . . 110
3.5 Removing and installing forced ventilation vents in passenger compartment . . . . . . . . . . 110
3.6 Checking plenum chamber water drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4 Operating and display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.1 Overview of fitting locations - operating and display unit . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.2 Removing and installing operating and display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
5 Further control components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.1 Removing and installing ambient temperature sensor G17 . . . . . . . . . . . . . . . . . . . . . . . . 113
5.2 Removing and installing continued coolant circulation pump V51 / auxiliary pump for heating
V488 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.3 Removing and installing coolant shut-off valve N82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

1 Overview of fitting locations - air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1.1 Overview of fitting locations - components not located in passenger compartment . . . . . . 114
1.2 Overview of fitting locations - components in passenger compartment (front) . . . . . . . . . . 127
2 Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2.1 System overview - refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2.2 Exploded view - condenser, air conditioner compressor, refrigerant lines and expansion
valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
2.3 Removing and installing pressure sender for refrigerant circuit G805 . . . . . . . . . . . . . . . . 160
2.4 Removing and installing refrigerant pressure and temperature sender G395 . . . . . . . . . . 161
2.5 Checking cut-in signal for air conditioner compressor regulating valve N280 . . . . . . . . . . 163
2.6 Removing and installing refrigerant shut-off valve for heater and air conditioner unit N541
........................................................................ 166
2.7 Removing and installing refrigerant shut-off valve for high-voltage battery heat exchanger
N542 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
2.8 Additional weight at refrigerant line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2.9 Removing and installing expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2.10 Detaching and attaching refrigerant lines at condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2.11 Removing and installing condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2.12 Removing and installing desiccant cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2.13 Removing and installing refrigerant lines with internal heat exchanger . . . . . . . . . . . . . . . . 189
2.14 Differences in service connections depending on refrigerant (R134a or R1234yf) . . . . . . 194
2.15 Removing and installing service connections (low and high-pressure sides) . . . . . . . . . . 197
2.16 Starting up air conditioner after charging refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . 199
3 Air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3.1 Exploded view - drive unit for air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3.2 Exploded view - pulley, mechanically driven air conditioner compressor . . . . . . . . . . . . . . 212
3.3 Detaching and attaching air conditioner compressor at bracket . . . . . . . . . . . . . . . . . . . . 216
3.4 Detaching and attaching refrigerant lines at air conditioner compressor . . . . . . . . . . . . . . 223
3.5 Removing and installing air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
3.6 Removing and installing pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
4 Control motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
ii Contents
4.1 Removing and installing temperature flap control motor V68 with potentiometer G92 . . . . 238
4.2 Removing and installing defroster flap control motor V107 with potentiometer G135 . . . . 240
4.3 Removing and installing air recirculation flap control motor V113 . . . . . . . . . . . . . . . . . . . . 242
4.4 Removing and installing left temperature flap control motor V158 with potentiometer G220
........................................................................ 245
4.5 Removing and installing right temperature flap control motor V159 with potentiometer G221
...................................................................... 246
4.6 Removing and installing fresh air/air recirculation, air flow flap control motor V425 with
potentiometer G644 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
4.7 Removing and installing actuator for fresh air/air recirculation, air flow flap . . . . . . . . . . . . 251
4.8 Removing and installing air distribution flap control motor V428 with potentiometer G645
........................................................................ 253
4.9 Removing and installing front air distribution flap control motor V426 with potentiometer G642
...................................................................... 255
4.10 Removing and installing actuator for air distribution flap . . . . . . . . . . . . . . . . . . . . . . . . . . 257
5 Front heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
5.1 Exploded view - heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
5.2 Exploded view - attachments for heater and air conditioning unit and air intake box . . . . . . 269
5.3 Exploded view - evaporator housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
5.4 Exploded view - flaps and partitions in air distribution housing . . . . . . . . . . . . . . . . . . . . . . 273
5.5 Removing and installing evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
5.6 Cleaning evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
5.7 Removing and installing evaporator output temperature sender G263 . . . . . . . . . . . . . . . . 286
5.8 Removing and installing vent temperature sender G150 / G151 . . . . . . . . . . . . . . . . . . . . 286
5.9 Removing and installing heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . 287
5.10 Removing and installing retainers for heater and air conditioning unit . . . . . . . . . . . . . . . . 290
5.11 Dismantling and assembling heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . 291
5.12 Removing and installing air distribution housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
5.13 Removing and installing dust and pollen filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
5.14 Removing and installing fresh air blower V2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
5.15 Removing and installing fresh air blower control unit J126 . . . . . . . . . . . . . . . . . . . . . . . . 297
5.16 Removing and installing footwell vent temperature sender G192 . . . . . . . . . . . . . . . . . . . . 297
5.17 Removing and installing auxiliary air heater element Z35 . . . . . . . . . . . . . . . . . . . . . . . . . . 298
5.18 Removing and installing heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
5.19 Removing and installing coolant pipes at heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . 310
5.20 Checking condensation drain hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
5.21 Removing and installing condensation drain hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
6 Air duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
6.1 Exploded view - routing of air flow and air distribution in passenger compartment . . . . . . 319
6.2 Removing and installing vents (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
6.3 Removing and installing vents (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
6.4 Removing and installing air ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
6.5 Removing and installing intake duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
6.6 Removing and installing drip rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
6.7 Removing and installing fresh air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
6.8 Checking forced ventilation vents in passenger compartment . . . . . . . . . . . . . . . . . . . . . . 329
6.9 Removing and installing forced ventilation vents in passenger compartment . . . . . . . . . . 332
6.10 Checking plenum chamber water drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
7 Operating and display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
7.1 Overview of fitting locations - operating and display unit . . . . . . . . . . . . . . . . . . . . . . . . . . 335
7.2 Removing and installing operating and display unit J65 / J301 / J255 . . . . . . . . . . . . . . . . 340
8 Coolant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
8.1 Incorporation of high-voltage heater (PTC) Z115 into coolant circuit . . . . . . . . . . . . . . . . . . 343
8.2 Incorporation of heat exchanger for high-voltage battery into coolant circuit of high-voltage
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
8.3 Removing and installing coolant valve for high-voltage battery N688 . . . . . . . . . . . . . . . . 350
Contents iii
8.4 Removing and installing coolant pump for high-voltage battery V590 . . . . . . . . . . . . . . . . 350
8.5 Removing and installing continued coolant circulation pump V51 . . . . . . . . . . . . . . . . . . 351
8.6 Removing and installing coolant shut-off valve N82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
8.7 Removing and installing coolant changeover valve 1 N632 . . . . . . . . . . . . . . . . . . . . . . . . 351
8.8 Removing and installing coolant changeover valve 2 N633 . . . . . . . . . . . . . . . . . . . . . . . . 351
8.9 Removing and installing heat exchanger for high-voltage battery . . . . . . . . . . . . . . . . . . . . 352
8.10 Removing and installing high-voltage heater (PTC) Z115 (with high-voltage heater (PTC)
control unit J848 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
9 Further control components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
9.1 Removing and installing sunlight penetration photosensor G107 . . . . . . . . . . . . . . . . . . . . 361
9.2 Removing and installing ambient temperature sensor G17 . . . . . . . . . . . . . . . . . . . . . . . . 362
9.3 Operation of air quality sensor G238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
9.4 Checking air quality sensor G238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
9.5 Operation of humidity sender in fresh air intake duct G657 . . . . . . . . . . . . . . . . . . . . . . . . 370
9.6 Removing and installing air quality sensor G238 / humidity sender in fresh air intake duct
G657 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
9.7 Removing and installing sensors G355 / G397 / G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
9.8 Removing and installing fuse for electrical air conditioner compressor . . . . . . . . . . . . . . . . 372
iv Contents
00 – Technical data
1 Identification
(ARL006396; Edition 04.2019)
⇒ “1.1 Identification of heater and air conditioning unit”,
page 1
1.1 Identification of heater and air condition‐

ing unit
⇒ “1.1.1 Identification of Valeo heater and air conditioning unit”,
page 1
⇒ “1.1.2 Identification of Denso heater and air conditioning unit”,
page 2
1.1.1 Identification of Valeo heater and air

conditioning unit
At the start of production, this vehicle was only fitted with “Valeo”
heaters and air conditioning units. Later this vehicle may also be
fitted with “Denso” heaters and air conditioning units (introduction
not yet finalised).
Note
When renewing the components, make sure they are correctly

allocated; the combination of components by different manufac‐
turers is not permitted ⇒ Electronic parts catalogue .
♦ The manufacturer's sticker -1- on the heater and air condition‐

ing unit -2- is visible only after the operating unit has been
removed.
♦ The coolant pipe separation point -arrows- is located directly
at the heat exchanger -1-.
1. Identification 1
1.1.2 Identification of Denso heater and air

conditioning unit
At the start of production, this vehicle was only fitted with “Valeo”
heaters and air conditioning units. Later this vehicle may also be
fitted with “Denso” heaters and air conditioning units (introduction
not yet finalised).
Note
When renewing the components, make sure they are correctly

allocated; the combination of components by different manufac‐
turers is not permitted ⇒ Electronic parts catalogue .
♦ The manufacturer's sticker -1- on the heater and air condition‐

ing unit -2- is visible only after the centre console has been
removed.
♦ The coolant pipe separation point -arrows- is integrated into
the coolant pipes.
2 Rep. gr.00 - Technical data

2 General notes
⇒ “2.1 Type plates”, page 3
⇒ “2.2 Notes on odours in vehicles without air conditioner”, page
5
⇒ “2.3 Notes on odours in vehicles with air conditioner”,
page 6
⇒ “2.4 Notes on operation of auxiliary/supplementary heater on
vehicles with diesel engine”, page 8
⇒ “2.5 Seat heating”, page 10
⇒ “2.6 Heated rear window”, page 12
⇒ “2.7 Neck heating”, page 14
⇒ “2.8 Auxiliary air conditioner - vehicles with high-voltage system
only”, page 16
2.1 Type plates

The type plate indicating the type of refrigerant and the refrigerant
capacity is located on the top right of the bumper cover.
Note
♦ The label indicates the type of refrigerant used and the quan‐
tity of refrigerant and refrigerant oil with which the system was
charged during production.
♦ Symbols on the label indicate the hazards which may be en‐
countered when handling the refrigerant or working on the
refrigerant circuit.
♦ For all air conditioners up to 06/2016, the refrigerant circuit is
charged with refrigerant R134a. From 06/2016 onwards (grad‐
ual introduction), refrigerant R134a or R1234yf may be used,
depending on the country version and vehicle model ⇒ Air
conditioners with refrigerant R1234yf - General information;
Rep. gr. 00 ; Laws and regulations .
♦ Standards and regulations may also be listed, such as certain
SAE standards applicable in the USA. SAE J639 specifies the
safety warnings for air conditioners in passenger cars. SAE
J842 specifies that all components and materials must be ap‐
proved for use with refrigerant R1234yf; SAE J2845 states that
only trained and certified individuals may perform repairs and
service on the refrigerant circuit of the air conditioner.
♦ Depending on the version and production period, the GWP
(global warming potential) value may be included for the re‐
frigerant used.
♦ The capacities and type of refrigerant oil listed on the label
apply to the status at the time of the vehicle's production. Al‐
ways refer to the vehicle-specific Workshop Manual for the
current applicable values ⇒ “5 Technical data”, page 88 , ⇒
Air conditioner with refrigerant R134a; Rep. gr. 87 ; Capacities
for refrigerant R134a/refrigerant oil and approved refrigerant
oils , or ⇒ Air conditioners with refrigerant R1234yf - General
notes; Rep. gr. 00 ; Technical data .
2. General notes 3
Version 1
1- Refrigerant designation, e.g. R134a or R1234yf (depending
on production date and version)
2- Refrigerant capacity
3- Refrigerant oil designation, in this case PAG oil; for further
details refer to ⇒ Air conditioner with refrigerant R134a;
Rep. gr. 87 ; Capacities for refrigerant R134a/refrigerant oil
and approved refrigerant oils , or ⇒ Air conditioner with re‐
frigerant R1234yf - General notes; Rep. gr. 00 ; Technical
and physical principles .
Note
♦ For refrigerant R134a and refrigerant oil capacities, as well as

approved refrigerant oils, refer to ⇒ Air conditioner with re‐
frigerant R134a; Rep. gr. 87 ; Capacities for refrigerant
R134a/refrigerant oil and approved refrigerant oils .
♦ For refrigerant R1234yf and refrigerant oil capacities as well
as approved refrigerant oils, refer to
⇒ “5 Technical data”, page 88 , and ⇒ Air conditioners with
refrigerant R1234yf - General information; Rep. gr. 00 ; Tech‐
nical data .
Version 2
1- Refrigerant oil designation, in this case PAG oil (for further
information, refer to
⇒ “5.2 Approved refrigerant oils and refrigerant oil capaci‐
ties”, page 90 ).
2- Refrigerant designation, e.g. R134a or R1234yf (depending
on production date and version). Depending on the type
plate version and vehicle production period, the GWP (glob‐
al warming potential) value may be included for the refrig‐
erant used ⇒ Air conditioner with refrigerant R134a; Rep.
gr. 87 ; General information on air conditioning systems
(“Refrigerant R134a”, “Environmental aspects for refriger‐
ant R134a”), ⇒ Air conditioner with refrigerant R134a; Rep.
gr. 87 ; General information on air conditioning systems , or
⇒ Air conditioner with refrigerant R1234yf - General notes;
Rep. gr. 00 ; Technical and physical principles .
3- Refrigerant capacity
Note
♦ For refrigerant R134a and refrigerant oil capacities, as well as

approved refrigerant oils, refer to ⇒ Air conditioner with re‐
frigerant R134a; Rep. gr. 87 ; Capacities for refrigerant
R134a/refrigerant oil and approved refrigerant oils .
♦ For refrigerant R1234yf and refrigerant oil capacities as well
as approved refrigerant oils, refer to
⇒ “5 Technical data”, page 88 , and ⇒ Air conditioners with
refrigerant R1234yf - General information; Rep. gr. 00 ; Tech‐
nical data .

Version 3
Note
Explanation of information on label -A- ⇒ page 4 .
2.2 Notes on odours in vehicles without air

conditioner
Odours emanating from the heater can have various causes; not
all these odours originate in the heater.
Type of odour Possible cause and remedy
Smell of burnt oil ♦ Usually originates in engine compartment due to leak(s) in engine or gearbox
– Eliminate leak(s) in engine or gearbox.
Sulphurous smell of ex‐ ♦ Leak(s) in exhaust system
haust gas
♦ Exhaust gas entering passenger compartment (e.g. when reversing through
a cloud of exhaust fumes)
– Eliminate leak(s) in exhaust system.
Fishy smell of coolant ♦ Leak(s) in engine cooling system or heat exchanger for heater
– If fishy odour occurs in both fresh air and air recirculation mode, check heat
exchanger for leaks.
Scorched clutch smell ♦ Clutch linings worn or clutch operated incorrectly
– Check clutch.
Other odours ♦ Floor mats, retrofitted protective seat covers etc.
– Check and renew or clean floor mats or protective covers.
Mouldy smell from front end ♦ Water can enter fresh air intake via drip rail if plenum chamber cover is dam‐
of vehicle aged or not installed properly.
– Check fresh air intake of heater unit ⇒ page 329 .
♦ Deposits (leaves, pine needles etc.) may have accumulated in plenum cham‐
ber.
– Check plenum chamber for deposits ⇒ page 333 .
♦ Water may not be able to drain out of plenum chamber.
– Check water drains ⇒ page 333 .
Odour from heater ♦ Odours originating in the heater are usually perceptible in both fresh air mode
and air recirculation mode. If an odour problem occurs only in fresh air mode
or only in air recirculation mode, the heater is usually not the cause of the
problem.
♦ If a heat exchanger is leaking, the odour of the escaping coolant will be per‐
ceptible in both fresh air and air recirculation mode. However, the odour may
be less noticeable in the “cold” setting of the heater control unit - J65- than
in heating mode. Reason: Not all the air flows through the heat exchanger
constantly; however, there is a constant flow of coolant through the heat ex‐
changer.
♦ Old or severely contaminated dust and pollen filter
– Check dust and pollen filter ⇒ page 293 .
2. General notes 5
2.3 Notes on odours in vehicles with air con‐

ditioner
Odours coming from the air conditioner can have various causes.
Not all of these odours originate in the evaporator of the air con‐
ditioning unit and can therefore be eliminated by cleaning the
evaporator.
Type of odour Possible cause and remedy
Smell of burnt oil ♦ Usually originates in engine compartment due to leak(s) in engine or gearbox
– Eliminate leak(s) in engine or gearbox.
Sulphurous smell of ex‐ ♦ Leak(s) in exhaust system
haust gas
♦ Exhaust gas entering passenger compartment (e.g. when reversing through
a cloud of exhaust fumes)
– Eliminate leak(s) in exhaust system.
Fishy smell of coolant ♦ Leak(s) in engine cooling system or air conditioner heat exchanger
– If fishy odour occurs in both fresh air and air recirculation mode, check air
conditioner heat exchanger for leaks.
Scorched clutch smell ♦ Clutch linings worn or clutch operated incorrectly
– Check clutch.
Other odours ♦ Floor mats, retrofitted protective seat covers etc.
– Check and renew or clean floor mats or protective covers.
Mouldy smell from front end ♦ Water can enter fresh air intake via drip rail if plenum chamber cover is dam‐
of vehicle aged or not installed properly.
– Check fresh air intake of air conditioning unit ⇒ page 329
♦ Deposits (leaves, pine needles etc.) may have accumulated in plenum cham‐
ber.
– Check plenum chamber for deposits ⇒ page 333 .
♦ Water may not be able to drain out of plenum chamber.
– Check water drains ⇒ page 333 .
Odour from air conditioning ♦ Too much water condensation in air conditioning unit
unit
– Check condensation drain ⇒ page 313 .
♦ Old or severely contaminated dust and pollen filter
– Check dust and pollen filter ⇒ page 293 .
♦ Deposits on evaporator fins
– Clean evaporator ⇒ page 277 .

Note
♦ Cleaning with the ultrasound A/C cleaner - VAS 6189A- or a

pressure-feed spray gun - V.A.G 1538- will only eliminate the
odour if it originates in the evaporator.
♦ There are numerous evaporator cleaning methods with differ‐
ent effects available on the market. Cleaning the evaporator
using the ultrasound A/C cleaner - VAS 6189A- or a suction-
feed spray gun - V.A.G 1538- is one of the methods currently
checked and approved by Audi. Other methods checked and
approved by Audi and the corresponding information can be
found e.g. on the “Audi Partner Portal” or the “Audi Service‐
Net” (⇒ table).
♦ The following procedures are examples of how to access “Audi
ServiceNet”. Depending on the country, “Air conditioner clean‐
ing” may be found, for example, in the “Genuine parts” sub-
menu. For precise details on how to find the instructions on
“Air conditioner cleaning”, follow the instructions provided on
the “Audi Partner Portal” or on “Audi ServiceNet”.
– Select path:
Audi ServiceNet
Products
Maintenance and wear
Air conditioner cleaning
Or
Audi ServiceNet
AGP/AGA
Product information
Information according to categories
Maintenance and wear
Air conditioner cleaning
♦ ⇒ “5.6 Cleaning evaporator”, page 277
2. General notes 7
2.4 Notes on operation of auxiliary/supple‐

mentary heater on vehicles with diesel
engine
⇒ “2.4.1 Notes on supplementary heater ( auxiliary air heater el‐
ement Z35 )”, page 8
⇒ “2.4.2 Checking activation of supplementary heater ( auxiliary
air heater element Z35 )”, page 8
2.4.1 Notes on supplementary heater ( auxili‐

ary air heater element - Z35- )
♦ An auxiliary heater fitted as an optional extra is currently not
activated as a supplementary heater ⇒ Auxiliary/supplemen‐
tary heater; Rep. gr. 82 ; Auxiliary/supplementary heater
control; Functional description .
♦ An electric supplementary heater is currently only available for
vehicles with a TDI engine (without high-voltage system); in‐
troduction for vehicles with petrol engine (without high-voltage
system) not yet finalised.
♦ Currently a supplementary heater is not available for vehicles
with petrol engine without a high-voltage system.
♦ On vehicles with a TDI engine (without high-voltage system),
the electric supplementary heater ( auxiliary air heater element
- Z35- ) is activated via the engine control unit (introduction
and activation not yet finalised for vehicles with petrol engine
without high-voltage system). The control units exchange the
relevant information via the data bus ⇒ Vehicle diagnostic
tester, “Guided Fault Finding” function and ⇒ Current flow di‐
agrams, Electrical fault finding and Fitting locations.
♦ Vehicles with high-voltage system are currently not fitted with
an auxiliary air heater element - Z35- ; on these vehicles, the
high-voltage heater (PTC) - Z115- (with high-voltage heater
(PTC) control unit - J848- ) assumes the function of the auxil‐
iary air heater element
⇒ “4.15 Notes on high-voltage heater (PTC) Z115 (and high-
voltage heater (PTC) control unit J848 )”, page 85 .
♦ The auxiliary air heater element - Z35- -item 2- is installed in
the vicinity of the heat exchanger -1- for heater ⇒ page 298 .
♦ Checking operation and resistance value of auxiliary air heater
element -Z35- ⇒ Vehicle diagnostic tester (“Guided Fault Find‐
ing”)
2.4.2 Checking activation of supplementary

heater ( auxiliary air heater element -
Z35- )
Components involved in activation of supplementary heater:
Heat energy is added to the air after it leaves the heat exchanger
for the heater via the auxiliary air heater element - Z35- ⇒ Vehicle
diagnostic tester (“Guided Fault Finding”). This is only the case if
there is a request from the operating unit ( heater control unit -
J65- on vehicles without air conditioner / air conditioning system
control unit - J301- on vehicles with manually controlled air con‐
ditioner / Climatronic control unit - J255- on vehicles with auto‐
matically controlled air conditioner).

Note
♦ To protect the battery - A- on vehicles with start/stop system,

the activation of the auxiliary heater element -Z35- is switched
off while the stop function is active. -Z35- is activated again as
soon as the engine has been re-started via the start function
⇒ Vehicle diagnostic tester (“Guided Fault Finding”).
♦ Vehicles with high-voltage system are currently not fitted with
an auxiliary air heater element - Z35- ; on these vehicles, the
high-voltage heater (PTC) - Z115- (with high-voltage heater
(PTC) control unit - J848- ) assumes the function of the auxil‐
iary air heater element
Cut-in criteria for activation of supplementary heater ( -Z35- )

• The cut-in criteria must be met in the operating unit ( -J65- , -
J301- or -J255- ) and in the engine control unit.
The following conditions must be met for the operating unit ( -
J65- , -J301- or -J255- ) to transmit a request for the activation of
the supplementary heater to the engine control unit:
• “Automatic supplementary heating” function not deactivated
(on radio or MMI display) ⇒ Owner's Manual
• Engine running for at least 8 seconds and engine speed above
500 rpm
• Engine temperature below 75 °C
• Calculated ambient temperature below 6 °C
• Stop function of start/stop system not active
• Electrical system voltage above 12.2 V and onboard supply
control unit - J519- not transmitting any request preventing
activation
• No fault stored in operating unit ( -J65- , -J301- or -J255- )
• No faults stored in engine control unit, and load of alternator -
C- below 30 ... 77 % (depending on version of engine control
unit) ⇒ Vehicle diagnostic tester (“Guided Fault Finding”)
• Due to the setting and the measured temperatures, the oper‐
ating unit ( -J65- , -J301- or -J255- ) has calculated that
additional heating output is required to reach the temperature
specified for the passenger compartment.
• More than 90 % of the air (position of temperature flaps) is
being routed through the heat exchanger for the left or right
side.
Note
The engine control unit activates the auxiliary air heater element
- Z35- via the low heat output relay - J359- and the high heat
output relay - J360- so that the load of the alternator -C- does not
exceed 95%. The next stage is only switched on if the load of the
alternator is below 30 ... 77 %, depending on the engine speed
⇒ Vehicle diagnostic tester (“Guided Fault Finding”) and ⇒ Cur‐
rent flow diagrams, Electrical fault finding and Fitting locations.
2. General notes 9
Shut-off criteria for activation of supplementary heater
Note
Activation is switched off as soon as the “Automatic supplemen‐

tary heating” function is deactivated (on radio or MMI display), a
cut-in criterion in the operating unit ( -J65- , -J301- or -J255- ) or
in the engine control unit is no longer met or one of the shut-off
criteria is detected.
The operating unit ( -J65- , -J301- or -J255- ) deactivates the re‐

quest for activation of the electric supplementary heater under the
following conditions:
• One of the cut-in criteria is no longer met.
• The calculated ambient temperature is above approx. 8 ℃.
• The load of the alternator -C- is above 95 %.
• Less than 60 % of the air is being routed through the heat
exchanger for the left and right sides (position of temperature
flaps).
• Stop function of start/stop system active
2.5 Seat heating

⇒ “2.5.1 Checking front seat heating”, page 10
2.5.1 Checking front seat heating
Note
♦ Currently seat ventilation is not available for this vehicle.

♦ Information on rear seat heating ⇒ General body repairs, in‐
terior; Rep. gr. 74 ; Covers and padding on front seats ,
⇒ Vehicle diagnostic tester (“Guided Fault Finding” function for
onboard supply control unit - J519- ) and ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations.
Components involved in activation of seat heating:

The operating unit ( heater control unit - J65- on vehicles without
air conditioner / air conditioning system control unit - J301- on
vehicles with manually controlled air conditioner / Climatronic
control unit - J255- on vehicles with automatically controlled air
conditioner) transmits the request for activation of the seat heat‐
ing via the data bus. The onboard supply control unit - J519- then
activates the seat heating elements directly ⇒ Vehicle diagnostic
tester (“Guided Fault Finding”) and ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
Checking operation and activation of seat heating ⇒ Vehicle di‐
agnostic tester (“Guided Fault Finding” function for onboard sup‐
ply control unit - J519- )

Procedure
The seat heating setting is selected using buttons -1 and 3- on
the operating unit -J65- / -J301- -item A- or -J255- -item B-.
♦ When the seat heating is switched on, the function indicator
lamps in buttons -1 and 3- light up ⇒ Owner's Manual .
♦ If it is not possible to switch on the seat heating due to a shut-
off criterion detected by -J519- , -J519- transmits a corre‐
sponding signal back to the operating unit via the data bus,
and the function indicator lamps in buttons -1 and 3- either do
not light up or go out.
♦ The seat heating setting is selected on the operating unit ( -
J65- , -J301- or -J255- ). The specified temperatures for the
different seat heating settings are stored in the onboard supply
control unit - J519- . Depending on the version of -J519- , the
specified seat heating temperature may therefore differ al‐
though the setting is the same on the operating unit ⇒ Vehicle
diagnostic tester (“Guided Fault Finding”) and ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.
♦ The seat heating setting for the driver's seat can be stored for
a specific key in the operating unit ( -J65- , -J301- or -J255- ).
The settings selected before the ignition is switched off are
called up again the next time the vehicle is driven ⇒ Owner's
Manual .
♦ Depending on the vehicle and operating unit ( -J65- , -J301-
or -J255- ), the seat heating setting may be reduced automat‐
ically by one level after a certain time (e.g. after 10 minutes)
⇒ Vehicle diagnostic tester (“Guided Fault Finding”) and ⇒
Owner's Manual .
♦ On vehicles with start/stop system, the seat heating may be
switched off while the stop function is active to protect the bat‐
tery - A- . However, the setting for activation of the seat heating
remains stored in the operating unit ( -J65- , -J301- or -J255- ).
The seat heating is switched on again as soon as the engine
is restarted via the start function ⇒ Vehicle diagnostic tester
(“Guided Fault Finding” function for onboard supply control
unit - J519- ).
♦ On vehicles with no seat occupied sensor for the front pas‐
senger's seat, the seat heating is currently not deactivated
automatically by the operating unit ( -J65- , -J301- or -J255- )
if a seat is not occupied while the vehicle is being driven. How‐
ever, if the ignition is switched off and not switched on again
within approx. 10 minutes, the setting for activation of the seat
heating is deleted ⇒ Owner's Manual .
♦ If e.g. the voltage measured at the onboard supply control unit
- J519- at terminal 30 drops below a value stored in -J519- ,
the seat heating output is reduced or the seat heating is
switched off completely to relieve the load on the alternator -
C- ⇒ Vehicle diagnostic tester (“Guided Fault Finding” function
for onboard supply control unit - J519- ).
♦ Conditions preventing the activation of the driver's or front
passenger's seat heating (e.g. open circuit in power supply to
corresponding control unit etc.) are stored as faults in -J519- .
On such vehicles, the information that the event memory in the
corresponding control unit has to be read out may not be
transmitted via the data bus to the control unit ( -J65- , -J301-
or -J255- ) ⇒ Vehicle diagnostic tester (“Guided Fault Find‐
ing”). If there are problems with seat heating, you should
therefore first read out the event memories of the control units
which can influence activation of the seat heating (e.g. on‐
board supply control unit - J519- ).
2. General notes 11
♦ Depending on the model and vehicle equipment, the various

pieces of information on the activation of the seat heating (set‐
ting transmitted by the operating unit -J65- / -J301- / -J255- ,
specified and actual seat temperature, etc.) are displayed dif‐
ferently in the various measured value blocks in the different
control units ⇒ Vehicle diagnostic tester (“Guided Fault Find‐
ing”).
♦ The “Read measured values” function of the “Guided Fault
Finding” routine for the operating unit ( -J65- , -J301- or -J255- )
indicates which seat heating setting has been selected. De‐
pending on the vehicle version and equipment, the activation
of the seat heating, the actual and specified temperatures in
the seat and the actual current flowing via the seat heating etc.
are displayed in the “Read measured values” function for -
J519- ⇒ Vehicle diagnostic tester (“Guided Fault Finding”).
♦ Description of how to check the operation and activation of the
seat heating ⇒ Vehicle diagnostic tester (“Guided Fault Find‐
ing” function for onboard supply control unit - J519- ).
Note
Checking operation of seat heating and servicing ⇒ General body

repairs, interior; Rep. gr. 74 ; Covers and padding on front seats
and ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations.
2.6 Heated rear window

⇒ “2.6.1 Checking heated rear window Z1 ”, page 12
2.6.1 Checking heated rear window - Z1-

Components involved in activation of heated rear window:
The operating unit ( heater control unit - J65- on vehicles without
air conditioner / air conditioning system control unit - J301- on
vehicles with manually controlled air conditioner / Climatronic
control unit - J255- on vehicles with automatically controlled air
conditioner) transmits the request for activation of the heated rear
window via the data bus. The onboard supply control unit - J519-
then activates the heated rear window - Z1- via the heated rear
window relay - J9- if there is no criterion preventing the activation
in -J519- ⇒ Vehicle diagnostic tester (“Guided Fault Finding”) and
⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐
tions.

Procedure
The rear window heating is switched on via button -2- on the op‐
erating unit -J65- / -J301- -item A- or -J255- -item B-.
♦ When button -2- is pressed with the ignition switched on, the
onboard supply control unit - J519- is activated by the operat‐
ing unit ( -J65- , -J301- or -J255- ) via the data bus. As soon
as -J519- switches the rear window heating on (on vehicles
without high-voltage system; only with engine running), the in‐
dicator lamp in button -2- lights up ( -J519- sends feedback
signal via data bus). The rear window heating is switched off
by pressing the button again and switching off the ignition ⇒
Owner's Manual , ⇒ Vehicle diagnostic tester (“Guided Fault
Finding”) and ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations.
♦ On vehicles without a high-voltage system, -Z1- is only acti‐
vated via -J9- by -J519- when the engine is running. If the
engine is not running on vehicles without high-voltage system,
there is no activation and no feedback from -J519- and the
indicator lamp in the button either is not on or goes out again
shortly after the button is pressed ⇒ Owner's Manual and
♦ On vehicles with high-voltage system, the rear window heating
is activated irrespective of the engine when the vehicle's drive
system is active. In electric mode with the engine stopped, it
is activated just as it is on vehicles without high-voltage system
with the engine running.
♦ -Z1- is switched off automatically by -J519- at ambient tem‐
peratures above 0 °C after the operating time stored in -J519-
(approx. 10 minutes) ⇒ Vehicle diagnostic tester (“Guided
Fault Finding”).
♦ At ambient temperatures below 0 °C, -Z1- remains switched
on until the ignition is switched off (it can be switched off and
on again manually at any time). If the temperature rises above
0 °C while the vehicle is being driven, -Z1- is switched off after
the operating time stored in -J519- (approx. 10 minutes).
♦ If the button for rear window heating remains pressed for sev‐
eral seconds when the rear window heating is switched on, the
rear window heating will remain switched on until the button is
pressed again or the ignition is switched off ⇒ Owner's Man‐
ual .
- J519- at terminal 30 drops below a value stored in -J519- or
in the operating unit ( -J65- , -J301- or -J255- ), the rear window
heating output is reduced or the rear window heating is switch‐
ed off completely to relieve the load on the alternator -C-
♦ If the activation of -Z1- has to be shut off by -J519- due to
undervoltage, the indicator lamp in the button for rear window
heating in the operating unit ( -J65- , -J301- or -J255- ) stays
on. However, if it is shut off for a lengthy period, -J519- deac‐
tivates the request for activation of the indicator lamp in the
button of the operating unit, and the indicator lamp in the but‐
ton goes out.
♦ On vehicles with start/stop system, the rear window heating
may be switched off while the stop function is active to protect
the battery - A- . However, the setting for activation of -Z1-
remains stored. The rear window heating is switched on again
as soon as the engine is restarted via the start function ⇒ Ve‐
hicle diagnostic tester (“Guided Fault Finding” function for
onboard supply control unit - J519- ).
2. General notes 13
♦ The “Read measured values” function of the Guided Fault

Finding routine for the operating unit ( -J65- , -J301- or -J255- )
indicates that the rear window heating is switched on or why
there is no activation although there is a corresponding re‐
quest ⇒ Vehicle diagnostic tester (“Guided Fault Finding”).
♦ Checking activation signal from heated rear window ⇒ Vehicle
diagnostic tester, “Guided Fault Finding” function for onboard
supply control unit - J519-
2.7 Neck heating

⇒ “2.7.1 Checking neck heating”, page 14
2.7.1 Checking neck heating
Note
♦ The neck heating function is currently only available in the Audi

A3 Cabriolet. You can identify vehicles with neck heating e.g.
by the vent -A- in the seat ⇒ General body repairs, interior;
Rep. gr. 72 ; Front seats .
♦ For further information on the neck heating function, see ⇒
General body repairs, interior; Rep. gr. 72 ; Front seats ,
⇒ Vehicle diagnostic tester, “Guided Fault Finding” function
(for onboard supply control unit - J519- ) and ⇒ Current flow
Components involved in activation of neck heating:

The operating unit ( Climatronic control unit - J255- on vehicles
with automatically controlled air conditioner) transmits a request
for the activation of the neck heating (left and/or right) via the data
bus. The onboard supply control unit - J519- then activates the
control unit for left neck heating - J846- and/or the control unit for
right neck heating - J847- via a data line ⇒ Vehicle diagnostic
Checking operation and activation of neck heating ⇒ Vehicle di‐
agnostic tester (“Guided Fault Finding” function for onboard sup‐
ply control unit - J519- )

Procedure
The neck heating setting is selected using buttons -1 and 2- on
the operating unit -J255- -item A-.
♦ When the neck heating is switched on, the function indicator
lamps in buttons -1 and 2- light up ⇒ Owner's Manual .
♦ If it is not possible to switch on the neck heating due to a shut-
off criterion detected by -J519- , -J519- transmits a corre‐
sponding signal back to the operating unit via the data bus,
and the function indicator lamps in buttons -1 and 2- either do
not light up or go out.
♦ When the ignition is switched on but the engine is not running,
the neck heating is only activated if -J519- has calculated that
the battery - A- is sufficiently charged. If -J519- has calculated
that the neck heating cannot be activated because the battery
- A- is not sufficiently charged, the function indicator lamps in
buttons -1 and 2- may still remain on (depending on version of
-J519- ) ⇒ Vehicle diagnostic tester (“Guided Fault Finding”
function for onboard supply control unit - J519- ).
♦ The neck heating setting is selected on the operating unit -
J255- . The selected settings for the neck heating (left and
right) are transmitted via -J519- to the control unit for left neck
heating - J846- and control unit for right neck heating - J847- .
The specified temperatures and speeds for the blower for left
neck heating - V450- and blower for right neck heating - V451-
for the various neck heating levels are stored in -J846- and -
J847- . Depending on the versions of -J846- and -J847- , the
specified neck heating temperature may therefore differ al‐
though the setting is the same on the operating unit -J255-
⇒ Vehicle diagnostic tester (“Guided Fault Finding”) and
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations.
♦ The neck heating setting for the driver's seat can be stored for
a specific key in the operating unit -J255- . The settings se‐
lected before the ignition is switched off can be called up again
the next time the vehicle is driven ⇒ Owner's Manual .
♦ On vehicles with start/stop system, the neck heating might be
switched off while the stop function is active to protect the bat‐
tery - A- . However, the setting for the activation of the neck
heating remains stored in the operating unit -J255- . The neck
heating is switched on again as soon as the engine is restarted
via the start function ⇒ Vehicle diagnostic tester (“Guided Fault
Finding” for onboard supply control unit - J519- ).
♦ On vehicles with no seat occupied sensor for the front pas‐
senger's seat, the neck heating is currently not deactivated
automatically by the operating unit -J255- if a seat is not oc‐
cupied while the vehicle is being driven. However, if the igni‐
tion is switched off and not switched on again within approx.
10 minutes, the setting for activation of the neck and seat
heating may be deleted ⇒ Owner's Manual .
- J519- at terminal 30 drops below a value stored in -J519- ,
the neck heating output is reduced or the neck heating is
switched off completely to relieve the load on the alternator -
C- ⇒ Vehicle diagnostic tester (“Guided Fault Finding” function
for onboard supply control unit - J519- ).
2. General notes 15
♦ Conditions preventing the activation of the driver's or front

passenger's neck heating (e.g. open circuit in power supply to
corresponding control unit etc.) are stored as faults in -J519- .
On such vehicles, the information that the event memory in the
corresponding control unit has to be read out may not be
transmitted via the data bus to the control unit -J255- ⇒ Vehicle
diagnostic tester (“Guided Fault Finding”). If there are prob‐
lems with the neck heating function, you should therefore first
read out the event memories of the control units which can
influence activation of the neck and seat heating (e.g. onboard
supply control unit - J519- ).
♦ Depending on the model and vehicle equipment, the various
pieces of information on the activation of the neck and seat
heating (settings transmitted by the operating unit -J255- ) are
displayed differently in the various measured value blocks in
the different control units ⇒ Vehicle diagnostic tester (“Guided
Fault Finding”).
♦ The “Read measured values” function of the “Guided Fault
Finding” routine for the operating unit -J255- indicates which
neck heating setting has been selected. The activation of the
neck heating, the actual and specified temperatures and blow‐
er speeds for -V450- and -V451- , the actual current flowing
via the control units -J846- and -J847- etc. are displayed in the
“Read measured values” function of -J519- depending on the
vehicle version and equipment ⇒ Vehicle diagnostic tester
(“Guided Fault Finding”).
♦ Description of how to check the operation and activation of the
neck heating ⇒ Vehicle diagnostic tester (“Guided Fault Find‐
ing” function for onboard supply control unit - J519- ).
Note
Checking operation of neck heating and servicing ⇒ General

body repairs, interior; Rep. gr. 72 ; Front seats and ⇒ Current flow
2.8 Auxiliary air conditioner - vehicles with

high-voltage system only
⇒ “2.8.1 Notes on auxiliary air conditioner”, page 16
2.8.1 Notes on auxiliary air conditioner

♦ On vehicles with high-voltage system, you will find the function
“Auxiliary air conditioner” on the Multi Media Interface (MMI),
where you can display and select the various functions of the
auxiliary heater (via the high-voltage heater (PTC) - Z115- ),
the auxiliary ventilation and the cooling for the passenger
compartment (via the air conditioner) ⇒ Owner's Manual and
⇒ Infotainment/MMI Operating Manual .
♦ On vehicles with high-voltage system which do not feature an
auxiliary heater as an optional extra, the passenger compart‐
ment can be ventilated, heated with the high-voltage heater
(PTC) - Z115- or cooled with the air conditioner when ambient
temperatures are high via the “Auxiliary air conditioner” func‐
tion ⇒ Owner's Manual and ⇒ Infotainment/MMI Operating
Manual .
♦ On vehicles with high-voltage system which feature an auxili‐
ary heater as an optional extra, the passenger compartment
can be heated with the high-voltage heater (PTC) - Z115- or
the auxiliary heater via the “Auxiliary air conditioner” function.
As a general rule, the auxiliary heater is only activated at am‐
bient temperatures below -10 °C. If the ambient temperature

is above -10 °C, the air conditioner operating unit -J255- usu‐
ally determines that the heating output of -Z115- is sufficiently
high to heat up the passenger compartment ⇒ Auxiliary/sup‐
plementary heater; Rep. gr. 00 ; General notes , ⇒ Owner's
Manual and ⇒ Infotainment/MMI Operating Manual .
♦ If the “Auxiliary air conditioner” function is activated and the air
conditioner control unit -J255- determines that heat output
mode is necessary, various control units are interrogated by -
J255- via the data bus, e.g. the battery regulation control unit
- J840- (fitted in hybrid battery unit - AX1- ) and the control unit
for high-voltage battery charging unit - J1050- (fitted in power
and control electronics for electric drive - JX1- ). If -J255- is
informed that the hybrid battery unit - AX1- is charged suffi‐
ciently, that enough energy is available to operate the high-
voltage heater (PTC) (PTC) - Z115- and that there is enough
fuel in the fuel tank, -J255- activates -Z115- or the auxiliary
heater, depending on the ambient temperature.
♦ To ensure that the vehicle always operates correctly after the
passenger compartment has been heated, ventilated or
cooled via the “Auxiliary air conditioner” function, there must
be enough fuel in the fuel tank (also on vehicles without aux‐
iliary heater as optional extra) so that the “Auxiliary air condi‐
tioner” function for heating, ventilating or cooling the passen‐
ger compartment is activated by the air conditioner control unit
-J255- . Reason: Energy is drawn from the hybrid battery unit
- AX1- via the “Auxiliary air conditioner” function. It must be
possible to start the engine so that the vehicle can be moved
safely even after the charge level of -AX1- has been reduced
⇒ Owner's Manual and ⇒ Infotainment/MMI Operating Man‐
ual .
♦ So that the passenger compartment can be heated or venti‐
lated via the “Auxiliary air conditioner” function or cooled via
the air conditioner if ambient temperatures are high, the air
conditioner operating unit -J255- starts up and activates fur‐
ther components (e.g. the fresh air blower - V2- , various air
conditioner control motors, the high-voltage heater (PTC) -
Z115- or the auxiliary heater (if fitted) for heating the passen‐
ger compartment and the electrical air conditioner compressor
- V470- for cooling the passenger compartment).
♦ So that the coolant heated up by -Z115- is conveyed through
the air conditioner heat exchanger, the coolant pump for high-
temperature circuit - V467- , the coolant changeover valve 2 -
N633- and the coolant valve for gearbox - N488- must also be
activated (by the corresponding engine control unit). To en‐
sure that the coolant flows in the right direction, the non-return
valves fitted in the coolant circuit must also be installed cor‐
rectly and they must operate correctly. For further information,
refer to ⇒ page 343 , ⇒ Rep. gr. 19 ; Cooling system/coolant;
Connection diagram - coolant hoses , ⇒ Vehicle diagnostic
♦ If -J255- is informed that the hybrid battery unit - AX1- is not
sufficiently charged and therefore that not enough energy is
available for the operation of the high-voltage heater (PTC) -
Z115- , or that there is not enough fuel in the fuel tank, -J255-
does not activate the “Auxiliary air conditioner” function (this
means that -Z115- and the “Auxiliary heater” function are also
not activated) ⇒ Vehicle diagnostic tester (“Guided Fault Find‐
ing”), ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations, ⇒ Owner's Manual and ⇒ Infotainment/MMI
Operating Manual .
♦ On vehicles with high-voltage system which feature “Audi con‐
nect services” as an optional extra, the “Auxiliary air condi‐
tioner” function can also be switched on and off using a mobile
phone (and control unit 1 for information electronics - J794- )
⇒ Communication; Rep. gr. 91 ; Telephone system; Layout -
2. General notes 17
telephone , ⇒ Current flow diagrams, Electrical fault finding

and Fitting locations, ⇒ Owner's Manual and ⇒ Infotainment/
MMI Operating Manual .

3 Safety precautions
⇒ “3.1 Safety precautions when working on vehicles with high-
voltage system”, page 19
⇒ “3.2 Safety precautions when working in the vicinity of high-
voltage components”, page 19
⇒ “3.3 Safety precautions when handling refrigerants”,
page 20
⇒ “3.4 Safety precautions when working on air conditioners”, page
21
⇒ “3.5 Safety precautions when working on vehicles with start/
stop system”, page 21
⇒ “3.6 Safety precautions when using testers and measuring in‐
struments during a road test”, page 21
⇒ “3.7 Safety precautions when working on the cooling system”,
page 22
3.1 Safety precautions when working on vehicles with high-voltage system

Electric and magnetic fields can cause fatal injury.
The high-voltage system generates electric and magnetic fields.
Danger of severe or fatal injuries caused by malfunctioning of ac‐
tive implants (e.g. pacemakers, insulin pumps).
– Persons with active implants must not perform work on the
high-voltage system.
Risk of injury - engine may start unexpectedly

It is difficult to determine whether the drive system of an electric
vehicle or hybrid vehicle is active. Moving parts can trap or draw
in parts of the body.
– Switch off ignition.
– Place ignition key outside vehicle.
Risk of injury if auxiliary air conditioner is activated

On electric and hybrid vehicles, the auxiliary air conditioner can
switch itself on if it has been activated. The radiator fans can start
up automatically and trap or draw in parts of the body.
– Deactivate auxiliary air conditioner.
3.2 Safety precautions when working in the vicinity of high-voltage components

High voltage can cause fatal injury.
The voltage levels in the high-voltage system constitute a safety
hazard. Danger of severe or fatal injuries from electric shock or
3. Safety precautions 19
electric arcs if high-voltage components or high-voltage wiring are

damaged.
– Carry out a visual check of high-voltage components and high-
voltage wiring.
– Never use cutting/forming tools or other sharp-edged imple‐
ments in the vicinity of high-voltage components and high-
voltage wires.
– Never perform work using welding, brazing, thermal bonding
or hot air in the vicinity of high-voltage components or high-
voltage wires.
Risk of damage to high-voltage wiring

Incorrect handling may result in damage to the insulation of high-
voltage wires or high-voltage connectors.
– Never use high-voltage wiring or high-voltage connectors as
a support.
– Never prop tools against high-voltage wiring or high-voltage
connectors.
– High-voltage cables must not be excessively bent or kinked.
– Pay attention to coding when connecting high-voltage con‐
nections.
3.3 Safety precautions when handling refrigerants

Danger of asphyxiation and poisoning from refrigerant
Refrigerant vapour can cause dry coughs, nausea and even as‐
phyxiation or poisoning.
– Never inhale refrigerant vapour.
– Always perform work on the refrigerant circuit and keep re‐
frigerant vessels in well ventilated areas.
– Never work in cellars, near cellar entrances or in or near other
underground areas.
– Switch on extraction systems.
Risk of frostbite from refrigerant

Pressurised refrigerant can escape during work on the air condi‐
tioner. Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up refrig‐
erant circuit.
– Extract/drain refrigerant again if more than 10 minutes have
passed since initial extraction and refrigerant circuit has not

been opened up. Renewed evaporation has created pressure

in the refrigerant circuit.
3.4 Safety precautions when working on air conditioners

Risk of explosion due to ignition sources - risk of death!
Danger to life and risk of explosion if ignition sources are close to
air conditioners and refrigerant vessels. Escaping refrigerant may
ignite and cause an explosion. Danger of severe or fatal injuries
due to explosion.
– Always keep ignition sources away from air conditioners or
refrigerant vessels.
– Avoid electrostatic discharge, sparks from the striking of tools
and hot surfaces.
Risk of irreparable damage to refrigerant lines

Risk of irreparable damage to refrigerant lines if the inside film is
torn.
– Never bend refrigerant lines which have a radius smaller than
r = 100 mm.
3.5 Safety precautions when working on vehicles with start/stop system

Risk of injury - engine may start unexpectedly
The engine can start unexpectedly if the vehicle's start/stop sys‐
tem is activated. A message in the instrument cluster indicates
whether the start/stop system is activated.
– To deactivate the start/stop system, switch off the ignition.
3.6 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury if test equipment is not secured
If an accident occurs and the front passenger's airbag is triggered,
test equipment which is not secured adequately may be catapul‐
ted through the vehicle with potentially serious consequences.
– Secure test equipment on the rear seat with a strap.
Or
– Have a second mechanic operate test equipment on the rear
seat.
3. Safety precautions 21
3.7 Safety precautions when working on the cooling system

Risk of scalding as hot coolant can escape
The cooling system is under pressure when the power unit is hot.
Risk of scalding due to hot steam and hot coolant.
– Put on protective gloves.
– Put on safety goggles.
– Cover filler cap on expansion tank with a cloth and open care‐
fully to release pressure.

4 Repair instructions
⇒ “4.1 Rules for cleanliness”, page 23
⇒ “4.2 General notes”, page 23
⇒ “4.3 General repair instructions”, page 24
⇒ “4.4 Contact corrosion”, page 25
⇒ “4.5 Routing and attaching pipes and wiring”, page 26
⇒ “4.6 Installing radiators and condensers”, page 26
⇒ “4.7 Checking heating output”, page 27
⇒ “4.8 Checking cooling output”, page 49
⇒ “4.9 Discharging refrigerant circuit”, page 78
⇒ “4.10 Working on refrigerant circuit”, page 79
⇒ “4.11 Paintwork repairs on vehicles with air conditioning sys‐
tem”, page 81
⇒ “4.12 Refrigerant circuit seals”, page 81
⇒ “4.13 Notes on control motors”, page 82
⇒ “4.14 Notes on dust and pollen filter”, page 83
⇒ “4.15 Notes on high-voltage heater (PTC) Z115 (and high-volt‐
age heater (PTC) control unit J848 )”, page 85
4.1 Rules for cleanliness

Even small quantities of dirt can lead to defects. Therefore it is
important to observe the following rules for cleanliness when
working on the air conditioner:
♦ Immediately seal off open lines and connections with clean
plugs, e.g. from engine bung set - VAS 6122- .
♦ Place removed parts on a clean surface and cover them. Use
only lint-free cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use parts
that have been stored without their packaging (e.g. in toolbox‐
es).
♦ Do not work with compressed air when the system is open.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
4.2 General notes

♦ For the applicable current flow diagrams, refer to ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.
♦ A label in the engine compartment indicates the capacity and
the refrigerant used ⇒ page 3 .
♦ For further information on performing repair work on vehicles
with air conditioning systems and on handling refrigerant, refer
to ⇒ Air conditioner with refrigerant R134a; Rep. gr. 87 ;
General information on air conditioning systems , or ⇒ Air
conditioner with refrigerant R1234yf - General notes; Rep. gr.
00 ; Repair instructions; Refrigerant and refrigerant oil .
4. Repair instructions 23
4.3 General repair instructions

Vehicles with high-voltage system (hybrid vehicles)
For all work on vehicles with high-voltage system, note additional
warnings for working on such vehicles
voltage system”, page 19 .
For the following steps, work in the vicinity of high-voltage com‐
ponents is necessary (Safety precautions when working in the
vicinity of high-voltage components
voltage components”, page 19 ).
Working with ignition switched on or high-voltage system active
– To minimise the number of automatic engine starts when the
vehicle's drive system is active during test and measurement
work, charge the vehicle batteries e.g. with the battery
charger 60A - VAS 5904- in battery standby mode ⇒ Electrical
system; General information; Rep. gr. 27 ; Battery; Charging
battery and ⇒ 4-cylinder direct injection engine (1.2, 1.4 ltr. 4-
valve TFSI EA 211); Rep. gr. 00 ; Safety precautions; Safety
precautions when working on vehicles with high-voltage sys‐
tem .
– For test and measurement work that requires the vehicle's
drive system to be active (READY) or the ignition to be switch‐
ed on, move the selector lever to position “P”, activate the
parking brake and take care to keep well clear of the engine
when it is running. Set up any tools needed so that they cannot
come into contact with moving parts.
Note
♦ Also move the selector lever to position “P” and activate the
parking brake before performing test and measurement work
for which the ignition must be switched on but where the ve‐
hicle's drive system does not need to be active (READY).
♦ The status of the drive system (READY) is shown by the con‐
trol unit in dash panel insert - J285- via the “power meter” ⇒
Owner's Manual .
♦ Activating and deactivating drive system ⇒ Owner's Manual
(note display of control unit in dash panel insert - J285- ).
– On vehicles with high-voltage system, switch off (deactivate)

auxiliary air conditioner function ⇒ Owner's Manual and ⇒
Infotainment/MMI Operating Manual .
All vehicles
Caution
Remove the relevant fuse(s) before working on electrical wir‐

ing.
Note
Disconnect battery before starting electric welding work on vehi‐

cle ⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
connecting battery .

The air conditioner refrigerant circuit may only be discharged and

opened:
♦ If this is required by the safety precautions
( ⇒ “3.3 Safety precautions when handling refrigerants”, page
20 ).
♦ If this is necessary for the removal of other components.
♦ If components of the air conditioner refrigerant circuit have to
be removed or renewed.
The air conditioner refrigerant circuit must remain closed during
all other normal vehicle repair steps.
Note
The connections for the senders/switches described in this Work‐

shop Manual are fitted with a valve which closes automatically
when the switches are unscrewed. These switches can therefore
be renewed at any workshop without discharging the refrigerant
circuit.
If it is necessary for certain repair measures of the heater and air

conditioner to discharge and open the air conditioner refrigerant
circuit, the steps involved are described in the corresponding work
procedure. Specific tools are required for discharging the refrig‐
erant circuit; such work may only be performed by appropriately
qualified personnel ⇒ Air conditioner with refrigerant R134a; Rep.
gr. 87 ; Refrigerant circuit (Working with the air conditioner serv‐
ice station), and ⇒ Air conditioners with refrigerant R1234yf -
General information; Rep. gr. 87 ; Working with the air conditioner
service station .
Note
It is not permissible to perform servicing work on the air condi‐

tioner refrigerant circuit which involves discharging and opening
the refrigerant circuit without the necessary tools and expertise.
The vehicle may have to be taken to a workshop which is equip‐
ped with the necessary tools and at which the work can be
performed by appropriately qualified personnel. There the refrig‐
erant circuit can be discharged and opened in the specified
manner ⇒ Air conditioner with refrigerant R134a; Rep. gr. 87 ;
General information on air conditioning systems , or ⇒ Air con‐
ditioner with refrigerant R1234yf - General notes; Rep. gr. 00 ;
Laws and regulations .
4.4 Contact corrosion

Contact corrosion can occur if unsuitable fasteners are used (e.g.
bolts, nuts, washers, etc.).
For this reason, only fasteners with a special surface coating are
fitted.
In addition, all rubber and plastic parts and all adhesives are made
of non-conductive materials.
Always fit new components if you are not sure that the old com‐
ponents are suitable ⇒ Electronic parts catalogue .
Please note:
♦ We recommend using only genuine replacement parts; these
have been tested and are compatible with aluminium.
♦ We recommend using Audi Genuine Accessories.
♦ Damage caused by contact corrosion is not covered by the

warranty.
4.5 Routing and attaching pipes and wiring

♦ To avoid interchanging components and to make sure the
components are re-installed in the original positions, mark e.g.
fuel lines, hydraulic fluid lines, vacuum lines, activated char‐
coal filter system lines and electrical wiring before removing
them. Make sketches or take photographs if necessary.
♦ To avoid damaging lines and wires, it is important to make sure
there is enough clearance from all moving or hot components
in the engine compartment due to the confined space.
♦ After attaching, check routing of refrigerant lines. They must
be inserted in brackets provided and should not make contact
with other components.
4.6 Installing radiators and condensers

♦ Even if fitted correctly, there may be slight pressure marks on
the radiator and condenser fins. This does not mean that the
components are damaged. If the fins are only very slightly dis‐
torted, this does not justify renewal of the radiator or the
condenser.
♦ If the condenser and radiator are no longer parallel as a result
of slight deformation at the securing lugs on the sides of the
condenser (e.g. following an accident), this can be corrected
by bending the lugs back into position, provided that the con‐
denser is still functioning properly and that there is no leakage.
If the lugs are slightly deformed, the condenser does not have
to be renewed.
♦ Slight bending of the condenser (up to 4 mm) is not a problem
as long as there is enough of a gap (at least 4 mm) between
the condenser and the radiator, the condenser is still function‐
ing properly and there is no leakage. If there are slight defor‐
mations, the condenser does not have to be renewed.

4.7 Checking heating output

⇒ “4.7.1 Notes on checking heating output and tools required”,
page 27
⇒ “4.7.2 Checking heating output (and actuation of temperature
flaps) - vehicles without air conditioner”, page 29
flaps) - vehicles with manually controlled air conditioner”,
page 32
flaps) - vehicles with automatically controlled air conditioner (with‐
out high-voltage system)”, page 35
flaps) - vehicles with automatically controlled air conditioner (with
high-voltage system)”, page 40
4.7.1 Notes on checking heating output and

tools required
Note
This Workshop Manual only gives a general outline of the check‐

ing procedure. Perform the functional check of the heater as
described in the "Guided Fault Finding" routine ⇒ Vehicle diag‐
nostic tester (“Guided Fault Finding”).
Special tools and workshop equipment required

♦ Vehicle diagnostic tester
♦ Commercially available thermometer (for measuring temper‐
ature; if applicable use thermometer with 2 probes for simul‐
taneous measurement of temperature e.g. on right and left)
Note
If the coolant circuit is not completely bled after filling, air may
accumulate in the heat exchanger and thus reduce the heating
output. In addition, there may be problems with noises or with
differences in the temperature of the air from the vents.
Remedy if there is poor heating output or noise from the coolant

circuit
• On vehicles without a high-voltage system, perform a road test
at a fairly high engine speed (for at least 10 minutes, engine
speed above 2500 rpm). Select a low gear when doing so to
avoid excessive road speeds.
• If a customer complains about poor heating output at certain
engine speeds, check the connections between the heat ex‐
changer and the engine coolant circuit ⇒ Engine, mechanics;
Rep. gr. 19 ; Cooling system/coolant; Connection diagram -
coolant hoses .
• If a customer complains about poor heat output on a vehicle
with a high-voltage system, check the connections between
the heat exchanger and the coolant circuit as well as the acti‐
vation and operation of the shut-off valves, coolant pumps and
high-voltage heater (PTC) - Z115-
⇒ “8.1 Incorporation of high-voltage heater (PTC) Z115 into
coolant circuit”, page 343 before checking the heating output
⇒ Engine, mechanics; Rep. gr. 19 ; Cooling system/coolant;
Connection diagram - coolant hoses and ⇒ Vehicle diagnostic
tester (“Guided Fault Finding” for air conditioner and engine

control unit).
Note
♦ On vehicles without an air conditioner, but with a start/stop

system, the stop function may be disabled depending on the
setting on the operating unit ( heater control unit - J65- ), e.g.
in heating mode. The engine is started as soon as there is a
request for heating.
♦ On vehicles with a manually controlled air conditioner and a
start/stop system, the stop function may be disabled depend‐
ing on the setting on the operating unit ( air conditioning
system control unit - J301- ), e.g. in heating mode. The engine
is started as soon as there is a request for heating. In cooling
mode, there are no limitations for the stop function via the air
conditioning system control unit - J301- .
♦ On vehicles with air conditioning system control unit - J301- ,
no humidity sender - G355- is installed. The permissible stop
time is calculated using characteristic curves which are influ‐
enced by the measured outside temperature, the function “air
recirculation mode” and the status of the windscreen wipers.
In order for -J301- to allow the stop function, the time calcula‐
ted must be greater than approx. 20 seconds. To prevent the
front and door windows from misting up, the stop time may be
reduced at low outside temperatures when the air recirculation
mode is active or if it is raining. If the time calculated for the
stop function is less than approx. 20 seconds, this will be pre‐
vented.
♦ On vehicles with an automatically controlled air conditioner
and a start/stop system, the stop function is disabled depend‐
ing on the setting on the operating unit ( Climatronic control
unit - J255- ). For example, the stop function is not possible,
or the stop function is interrupted and the engine is switched
on as soon as the “defrost” mode is selected. This also applies
if the difference between the set specified temperature and the
measured actual temperature exceeds a certain value in heat‐
ing and cooling mode ⇒ Vehicle diagnostic tester (“Guided
Fault Finding”).
♦ On vehicles with a high-voltage system, the coolant flowing
through the heat exchanger in the air conditioning unit is either
heated by the engine or by the high-voltage heater (PTC) -
Z115- depending on various conditions
coolant circuit”, page 343 , ⇒ Engine, mechanics; Rep. gr.
19 ; Cooling system/coolant; Connection diagram - coolant
hoses and ⇒ Vehicle diagnostic tester (“Guided Fault Finding”
for air conditioner and engine control unit).
♦ Depending on the engine version, the coolant circuit may be

fitted with a continued coolant circulation pump - V51- / auxil‐
iary pump for heating - V488- (different designations depend‐
ing on engine version) to assist the engine coolant pump on
vehicles without high-voltage system ⇒ Engine, mechanics;
coolant hoses and ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations. On vehicles with a start/stop sys‐
tem, -V51- / -V488- may be activated in “stop mode” (engine
stopped), e.g. if the engine is cold, to maintain the flow of
coolant through the heat exchanger.
♦ Depending on the engine version, a coolant shut-off valve -
N82- may be installed in the coolant circuit on vehicles without
high-voltage system ⇒ Engine, mechanics; Rep. gr. 19 ;
Cooling system/coolant; Connection diagram - coolant hoses

locations. -N82- is activated by the engine control unit - J623-

if e.g. no heating output is being requested by -J65- / -J301- /
-J255- and the engine is still cold ⇒ Vehicle diagnostic tester,
“Guided Fault Finding” function (for engine control unit). No
heated coolant can flow through the heat exchanger when -
N82- is activated.
♦ Various shut-off valves, coolant pumps and a high-voltage
heater (PTC) - Z115- are fitted in the coolant circuit of vehicles
with a high-voltage system. These components ensure that
the passenger compartment can be heated when the vehicle
is in electric mode (engine stopped)
coolant circuit”, page 343 .
4.7.2 Checking heating output (and actuation

of temperature flaps) - vehicles without
air conditioner
page 27
Test requirements
• Coolant circuit bled as specified ⇒ Engine, mechanics; Rep.
gr. 19 ; Cooling system/coolant; Draining and filling cooling
system
• All air ducts, covers and seals OK and properly installed
• Seal between engine compartment, bonnet and plenum cham‐
ber OK and fitted correctly; checking ⇒ General body repairs,
exterior; Rep. gr. 50 ; Bulkhead; Exploded view - plenum
chamber cover
• If fitted: Operation of continued coolant circulation pump -
V51- / auxiliary pump for heating - V488- (different designa‐
tions depending on engine version) and coolant shut-off valve
-N82- OK.
• Air flow in dust and pollen filter not impaired by dirt; checking
⇒ page 293
• Air intake of heater (in fresh air and air recirculation mode) not
impeded by dirt or retrofitted components
• Vehicle not exposed to sunlight
• Engine warm: coolant temperature above 80 °C
• Event memory of operating unit ( heater control unit - J65- )
interrogated and erased, basic setting performed in ⇒ Vehicle
diagnostic tester (“Guided Fault Finding”).
• Encoding and adaption of operating unit ( heater control unit -
J65- ) checked ⇒ Vehicle diagnostic tester (“Guided Fault
Finding”).
• Vehicles with TDI engine: Activation and operation of auxiliary
air heater element -Z35- OK ⇒ Vehicle diagnostic tester (“Gui‐
ded Fault Finding”)
• Vehicles with petrol engine and -Z35- (introduction not yet fi‐
nalised): activation and operation of auxiliary air heater ele‐
ment -Z35- OK ⇒ Vehicle diagnostic tester (“Guided Fault
Finding”)
• Vehicles with auxiliary heater: Activation and operation of aux‐
iliary heater OK ⇒ Vehicle diagnostic tester (“Guided Fault
Finding”).
Checking
– Close bonnet, doors, windows and sunroof.
– Open all dash panel vents.

– Start the engine and make the following settings on the oper‐
ating unit ( heater control unit - J65- ):
• Set rotary temperature control -1- to “cold” stop.
• Set rotary control -4- for air distribution to “Dash panel vents”.
• Set rotary control -5- for fresh air blower to maximum speed.
– Measure the ambient temperature.
– Use a thermometer to measure temperature of air emerging
from dash panel vents (left and right).
Specifications:
• After 5 minutes the measured values must not be more than
15 °C higher than the measured ambient temperature.
• The difference between the temperatures measured on the left
and right sides should be less than 8 °C.
Check the following if readout does not match specifications:
♦ Check and if necessary repair seal between engine compart‐
ment, bonnet and plenum chamber ⇒ General body repairs,
chamber cover .
♦ Repeat the test using one of the two temperature sensors to
measure the temperature of the air drawn in via the heater
fresh air intake in the plenum chamber with the bonnet closed.
Permissible increase in temperature of air in heater (between
air entering fresh air intake and air emerging from dash panel
vents): max. 10 °C.
Check the following if the temperature in the heater has increased
by more than 10 °C:
♦ Activation and operation of temperature flap control motor -
V68- ⇒ Vehicle diagnostic tester (“Guided Fault Finding”)
♦ Operation of temperature flap in heater ⇒ page 273
♦ Foam seal at heat exchanger for heater ⇒ page 299

– Set the highest possible temperature.

• Set rotary temperature control -1- to “warm” stop.
Specifications at an engine temperature of approx. 90 °C:
• The temperature of the air emerging from the dash panel vents
should increase above 55 °C.
♦ Coolant circuit bled properly ⇒ Engine, mechanics; Rep. gr.
19 ; Cooling system/coolant; Draining and filling cooling sys‐
tem .
♦ Incorporation of heat exchanger into coolant circuit ⇒ Engine,
mechanics; Rep. gr. 19 ; Cooling system/coolant; Connection
diagram - coolant hoses .
♦ Engine thermostat The engine coolant may not become prop‐
erly warm if the thermostat is defective ⇒ Engine, mechanics;
Rep. gr. 19 ; Coolant pump/thermostat assembly; Checking
thermostat , or ⇒ Vehicle diagnostic tester (depending on en‐
gine).
♦ Engine coolant pump ⇒ Engine, mechanics; Rep. gr. 19 ;
Coolant pump/thermostat assembly; Exploded view - coolant
pump .
♦ If fitted: Check operation of continued coolant circulation pump
- V51- / auxiliary pump for heating - V488- (different designa‐
- N82- ⇒ Vehicle diagnostic tester (“Guided Fault Finding”).
Note
♦ On vehicles without -V51- / -V488- (different designations de‐

pending on engine version), set the engine speed to approx.
2000 rpm and repeat the test if necessary. If the temperature
of the air increases to over 55 °C when the test is repeated
with a higher engine speed, this indicates that not enough
coolant is flowing through the heat exchanger for the heater.
Cause: Delivery rate of engine coolant pump too low with en‐
gine idling or heat exchanger not incorporated into coolant
circuit as specified ⇒ Engine, mechanics; Rep. gr. 19 ; Cool‐
ing system/coolant; Connection diagram - coolant hoses .
♦ The required heating output is not attained if insufficient heat‐
ed coolant flows through the heat exchanger for the heater.
– Set the lowest possible temperature.

Specifications:
• After 5 minutes the measured values must not be more than
15 °C higher than the measured ambient temperature.
♦ Measured value for evaporator output temperature sender -
G263- ⇒ Vehicle diagnostic tester (“Guided Fault Finding”)

of temperature flaps) - vehicles with
manually controlled air conditioner
page 27
Test requirements
system
chamber cover
-N82- OK.
⇒ page 293
• Air intake of air conditioning unit (in fresh air and air recircu‐
lation mode) not impeded by dirt or retrofitted components
• Cooling output of air conditioner checked and OK
⇒ page 54
• Event memory of operating unit ( air conditioning system con‐
trol unit - J301- ) interrogated and erased, basic setting per‐
formed ⇒ Vehicle diagnostic tester (“Guided Fault Finding”).
• Encoding and adaption of operating unit ( air conditioning sys‐
tem control unit - J301- ) checked ⇒ Vehicle diagnostic tester


ded Fault Finding”).
Finding”)
Finding”).
Checking
– Close bonnet, doors, windows and sunroof.
– Start the engine and select the following settings on the oper‐
ating unit:
• Air conditioner compressor on: Lamp in AC or A/C button
-5- on
– With the engine running, operate the air conditioner for several
minutes at maximum cooling output.
– Compare measured values to measured value displayed for
evaporator output temperature sender - G263- ⇒ Vehicle di‐
agnostic tester (“Guided Fault Finding”).
Specifications:
• The measured values for the temperature of the air emerging
from the vents (left and right) must not be lower than the
measured value for -G263- ; after 5 minutes they must not be
over 7 ℃ higher than this measured value ⇒ Vehicle diagnostic
tester (“Guided Fault Finding”).
• The difference in the measured temperature of the air emerg‐
ing from the vents (left and right) should be less than 8 °C.
♦ Operation of temperature flap in air conditioning unit
⇒ page 293
– Set the highest possible temperature.

• Set rotary temperature control -1- to “warm” stop.
• The temperature of the air emerging from the dash panel vents
should increase above 55 °C.
tem .
⇒ page 293
gine).
pump .
Note


– Set the lowest possible temperature.

– Compare measured values to measured value displayed for
evaporator output temperature sender - G263- ⇒ Vehicle di‐
agnostic tester (“Guided Fault Finding”).
Specifications:
• The measured values must not be lower than the measured
value for -G263- ; after 5 minutes they must not be over 7 °C
higher than this measured value ⇒ Vehicle diagnostic tester
• The difference in the measured temperature of the air emerg‐
ing from the vents (left and right) should be less than 8 °C.
⇒ page 293

of temperature flaps) - vehicles with au‐
tomatically controlled air conditioner
(without high-voltage system)
page 27
Test requirements
system
chamber cover
⇒ page 293
lation mode) not impeded by dirt or retrofitted components.
- N82- OK.
⇒ page 59
• Event memory of operating unit ( Climatronic control unit -
J255- ) interrogated and erased, basic setting performed ⇒ Ve‐
hicle diagnostic tester (“Guided Fault Finding”).
• Encoding and adaption of operating unit ( Climatronic control

unit - J255- ) checked ⇒ Vehicle diagnostic tester (“Guided
Fault Finding”).
Finding”)
Finding”).
Checking
– Close doors, bonnet, windows, sunroof and rear lid.
– Start engine.
Note
Vehicles with start/stop system: Should the engine not start or

should it be switched off via the “start/stop function”, try starting
the engine by changing the temperature setting on the operating
unit -J255- e.g. to “LO” and activating the “A/C” function.
– Engine running (or started after changing setting):

• Set temperature to “cold” using rotary controls -1 and 7-: “LO”

display for driver and passenger side in display -3- of -J255- .
• Press buttons -5 and 6- for dash panel vents and footwell
vents.
-8- on
• “eco” mode not activated: display -3- of -J255- blank.
– With the engine running, operate the air conditioner for several
minutes at maximum cooling output.
– “Read measured values” for vent temperature senders -
G150- / -G151- and evaporator output temperature sender -
G263- ⇒ Vehicle diagnostic tester (“Guided Fault Finding”).
– Compare measured values for vent temperature senders -
G150- / -G151- / -G192- to measured value for -G263- .
Specifications:
• The measured values for the vent temperature senders -
G150- / -G151- / -G192- must not be lower than the value for
-G263- ; after 5 minutes they must not be over 7 °C higher than
this measured value ⇒ Vehicle diagnostic tester (“Guided Fault
Finding”).
• The difference between the two measured values for the vent
temperature senders -G150- / -G151- must not be more than
8 °C.
Note
Check by hand to establish whether air is actually emerging from

the activated vents.
– Set the highest possible temperature for the driver side.

• Set temperature to “warm” using rotary control -1-: “HI” display
for driver side in display -3- of -J255- .
G150- / -G151- / -G192- .
• The temperature should increase to above 55 °C in the display
zone with the measured value for -G150- / -G192- .
• The temperature should increase by less than 10 °C in the
display zone with the measured value for -G151- .
Note
Applies to LHD vehicles only; on RHD vehicles -G192- is fitted in

the right footwell vent duct.

tem .
♦ Activation and operation of left temperature flap control motor
- V158- and right temperature flap control motor - V159- ⇒ Ve‐
hicle diagnostic tester (“Guided Fault Finding”)
♦ Measured values for vent temperature senders -G150- / -
G151- / -G192- ⇒ Vehicle diagnostic tester (“Guided Fault
Finding”)
♦ Operation of temperature flaps for left and right side in air con‐
ditioning unit ⇒ page 293
gine).
pump .

Note

– Set the highest possible temperature for the front passenger

side.
for passenger side in display -3- of -J255- .
G150- / -G151- / -G192- .
zone with the measured value for -G151- .
• The difference between the display zones for the measured
values for -G150- / -G151- / -G192- should be less than 8 °C.
If the readings do not match the specifications, check the com‐
ponents as described above ⇒ page 38 .
– Set the lowest possible temperature for the driver and pas‐
senger side.
G150- / -G151- / -G192- and evaporator output temperature
sender - G263-
Specifications:
Finding”).
• The difference between the measured values for the vent tem‐
perature senders -G150- / -G151- / -G192- must not be more
than 8 °C.
♦ Check measured values for vent temperature senders -
sender - G263- ⇒ Vehicle diagnostic tester (“Guided Fault
Finding”).

of temperature flaps) - vehicles with au‐
tomatically controlled air conditioner
(with high-voltage system)
In the following steps, work near high-voltage system compo‐
nents is necessary (Safety precautions when working in the vi‐
cinity of high-voltage system components
voltage components”, page 19 and ⇒ 4-cyl. direct injection engine
(1.2, 1.4 ltr. 4-valve TFSI EA211); Rep. gr. 93 ; High-voltage
components ).

DANGER!
When working on a vehicle with the ignition switched on or

while the drive system is active, the engine can start unex‐
pectedly and exhaust fumes can cause a health hazard in
closed rooms. Moving parts can trap or draw in parts of the
body and/or clothing (safety hazard).
Before switching on the ignition, perform the following steps:
♦ Move selector lever to position P
♦ Activate parking brake
♦ Switch off ignition
♦ Open bonnet
♦ Connect battery charger (e.g. battery charger - VAS
5095A- ) to jump-start connections of 12 V electrical sys‐
tem
♦ Switching on ignition

tem .
Note
Owner's Manual .

page 27
Test requirements
system

chamber cover
⇒ “5.13 Removing and installing dust and pollen filter”,
page 293
lation mode) not impeded by dirt or retrofitted components.
• Operation of the various shut-off valves, coolant pumps and
high-voltage heater (PTC) - Z115- OK
coolant circuit”, page 343 and ⇒ Vehicle diagnostic tester
(“Guided Fault Finding” for air conditioner and engine control
unit).
⇒ “4.8.4 Checking cooling output - vehicles with automatically
controlled air conditioner (without high-voltage system)”, page
59
Note
♦ On vehicles with high-voltage system, the engine does not

necessarily run when the vehicle's drive system is active. If the
engine is too cold and the charge level of the hybrid battery
unit - AX1- is such that the engine does not started, try starting
and running the engine by changing the setting for the function
“e-tron mode” in the “Car”/“Car systems” menu of the Multi
Media Interface (MMI) e.g. to “Increase battery charge”, or by
releasing the bonnet (with vehicle's drive system ready - see
display in “power meter” in dash panel insert) ⇒ Owner's Man‐
ual and ⇒ Infotainment/MMI Operating Manual .
♦ The engine is not always started if the hybrid battery unit - AX1-
is sufficiently charged. If the coolant in the engine is colder
than approx. 70 ℃, the coolant flowing through the heat ex‐
changer is first heated by the high-voltage heater (PTC) -
Z115- and then delivered by the coolant pump for high-
temperature circuit - V467- . In order for the coolant to flow
through the heat exchanger correctly, it is important that not
only -V467- , the coolant changeover valve 2 - N633- and the
coolant valve for gearbox - N488- are activated correctly, but
that the non-return valves are correctly installed in the coolant
circuit and function correctly ⇒ page 343 and ⇒ Rep. gr. 19 ;
Cooling system/coolant; Connection diagram - coolant hoses .
♦ If the temperature of the coolant in the engine exceeds 75 ℃,
-Z115- is no longer activated. The coolant pump for high-tem‐
perature circuit - V467- is activated when the engine is stopped
so that the coolant flows through the heat exchanger. In order
for the coolant to flow through the heat exchanger correctly, it
is important that not only -V467- , the coolant changeover
valve 2 - N633- and the coolant valve for gearbox - N488- are
activated correctly, but that the non-return valves are correctly
installed in the coolant circuit and function correctly
⇒ page 343 and ⇒ Rep. gr. 19 ; Cooling system/coolant;
Connection diagram - coolant hoses .
• Event memory of operating unit ( Climatronic control unit -

J255- ) and of engine control unit (e.g. engine control unit -
J623- ) interrogated and erased, basic setting performed

• Encoding and adaption of operating unit ( Climatronic control

unit - J255- ) checked ⇒ Vehicle diagnostic tester (“Guided
Fault Finding”).
Finding”).
Checking
– Switch on ignition.
DANGER!

♦ Open bonnet
tem
– Activate vehicle's drive system (engine does not have to start

at this point).
– Change “e-tron mode” setting on Multi Media Interface (MMI)
or release bonnet; engine will start and run.
Note
♦ On vehicles with high-voltage system, the engine does not

necessarily run when the vehicle's drive system is active. If the
engine is too cold and the charge level of the hybrid battery
unit - AX1- is such that the engine does not start, try starting
and running the engine by changing the setting for the function
“e-tron mode” in the “Car”/“Car systems” menu of the Multi
Media Interface (MMI) e.g. to “Increase battery charge”, or by
releasing the bonnet (with vehicle's drive system ready - see
display in “power meter” in dash panel insert) ⇒ Owner's Man‐
ual and ⇒ Infotainment/MMI Operating Manual .
♦ With vehicle's drive system ready and temperature set to
“warm” on air conditioner operating unit ( Climatronic control
unit - J255- - “HI” on display), the flow of coolant through the
heat exchanger of the air conditioning unit is maintained by the
coolant pump for high-temperature circuit - V467- when the
engine is stopped
coolant circuit”, page 343 and ⇒ Engine, mechanics; Rep. gr.
19 ; Coolant pump/thermostat assembly; Exploded view -
coolant pump .
♦ Engine running (or started after changing setting):

Note
Vehicles with high-voltage system: Depending on the setting on

the operating unit ( Climatronic control unit - J255- ), the coolant
temperature, the charge level of the hybrid battery unit - AX1- etc.,
the engine may be running or switched off.

• Press buttons -5 and 6- for dash panel vents and footwell
vents.
• Air conditioner compressor on: Lamp in A/C button -8- is on.
– With the vehicle's drive system ready, operate the air condi‐
tioner for several minutes at maximum cooling output.
G150- / -G151- and evaporator output temperature sender -
G150- / -G151- / -G192- to measured value for evaporator
output temperature sender - G263- .
Specifications:
the evaporator output temperature sender - G263- ; after 5
minutes they must not be over 7 °C higher than this measured
value ⇒ Vehicle diagnostic tester (“Guided Fault Finding”).
• The difference between the two measured values for the vent
temperature senders -G150- / -G151- must not be more than
8 °C.
Note
Check by hand to establish whether air is actually emerging from

the activated vents.
– Set the highest possible temperature for the driver side.

for driver side in display -3- of -J255- .
G150- / -G151- / -G192- .
zone with the measured value for -G150- / -G192- .
• The temperature should increase by less than 10 °C in the
display zone with the measured value for -G151- .
Note
Applies to LHD vehicles only; on RHD vehicles -G192- is fitted in

the right footwell vent duct.

tem .
♦ Measured values for vent temperature senders -G150- / -
G151- / -G192- ⇒ Vehicle diagnostic tester (“Guided Fault
Finding”)
gine).
♦ Activation and operation of high-voltage heater (PTC) - Z115- ,
coolant pump for high-temperature circuit - V467- etc.
coolant circuit”, page 343 as well as connections between
these components and coolant circuit ⇒ Vehicle diagnostic
tester (“Guided Fault Finding”) and ⇒ Engine, mechanics;
coolant hoses .
pump .

Note
♦ So that the coolant heated up by -Z115- or the engine is con‐

veyed through the air conditioner heat exchanger, the coolant
pump for high-temperature circuit - V467- , the coolant
changeover valve 2 - N633- and the coolant valve for gearbox
- N488- must also be activated (by the corresponding engine
control unit). To ensure that the coolant flows in the right di‐
rection, the non-return valves fitted in the coolant circuit must
also be installed correctly, and they must operate correctly.
For further information, refer to
hoses , ⇒ Vehicle diagnostic tester (“Guided Fault Finding”)
locations.
– Set the highest possible temperature for the front passenger

side.
for passenger side in display -3- of -J255- .
G150- / -G151- / -G192- .
zone with the measured value for -G151- .
• The difference between the display zones for the measured
values for -G150- / -G151- / -G192- should be less than 8 °C.
If the readings do not match the specifications, check the com‐
ponents as described above ⇒ page 46 .
– Set the lowest possible temperature for the driver and pas‐
senger side.
sender - G263-
Specifications:
Finding”).
• The difference between the measured values for the vent tem‐
perature senders -G150- / -G151- / -G192- must not be more
than 8 °C.
♦ Check measured values for vent temperature senders -
Finding”).

4.8 Checking cooling output

⇒ “4.8.1 Notes on checking cooling output and tools required”,
page 49
⇒ “4.8.2 Test requirements”, page 50
⇒ “4.8.3 Checking cooling output - vehicles with manually con‐
trolled air conditioner”, page 54
controlled air conditioner (without high-voltage system)”,
page 59
controlled air conditioner (with high-voltage system)”, page 64
⇒ “4.8.6 Fault Finding if results do not match specifications”, page
74
⇒ “4.8.7 Fault Finding if temperature increases downstream of
evaporator”, page 75
⇒ “4.8.8 Fault finding if ice forms at evaporator”, page 76
4.8.1 Notes on checking cooling output and

tools required
Note


♦ Commercially available thermometer (for measuring temper‐
ature; if applicable use thermometer with 2 probes for simul‐
taneous measurement of temperature e.g. on right and left)
Note
♦ On vehicles with start/stop function, the stop function may be

disabled depending on the setting on the operating unit ( air
conditioning system control unit - J301- ), e.g. in heating mode.
The engine is started as soon as there is a request for heating.
In cooling mode, there are no limitations for the stop function
via the air conditioning system control unit - J301- ⇒ Vehicle
♦ On vehicles with air conditioning system control unit - J301- ,
no humidity sender - G355- is installed. The permissible stop
time is calculated using characteristic curves which are influ‐
enced by the measured outside temperature, the function “air
recirculation mode” and the status of the windscreen wipers.
In order for -J301- to allow the stop function, the time calcula‐
ted must be greater than approx. 20 seconds. To prevent the
front and door windows from misting up, the stop time may be
reduced at low outside temperatures when the air recirculation
mode is active or if it is raining. If the time calculated for the
stop function is less than approx. 20 seconds, this will be pre‐
vented.
♦ On vehicles with a start/stop system, the stop function is dis‐
abled depending on the setting on the operating unit ( Clima‐
tronic control unit - J255- ). For example, the stop function is
not possible, or the stop function is interrupted and the engine
is switched on as soon as the “defrost” mode is selected. This
also applies if the difference between the set specified tem‐
perature and the measured actual temperature exceeds a
certain value in heating and cooling mode ⇒ Vehicle diagnostic
4.8.2 Test requirements

• Ambient temperature above 15 °C
• Radiator and condenser clean; clean if necessary
• Poly V-belt for compressor drive OK and correctly tensioned,
pulley actually driving air conditioner compressor (vehicles
without high-voltage system).
chamber cover
⇒ page 293
lation mode) not impeded by dirt or retrofitted components
• Vehicles without glove box cooling: Connection for glove box
cooling at air conditioning unit sealed off ⇒ page 319 .
• Vehicles with glove box cooling: Connection for glove box
cooling at air conditioning unit fitted as specified (currently not
available, introduction not yet finalised) ⇒ page 319 .

Note
On vehicles with high-voltage system, the engine does not nec‐

essarily run when the vehicle's drive system is active. If the engine
is too cold and the charge level of the hybrid battery unit - AX1-
is such that the engine does not start, try starting and running the
engine by changing the setting for the function “e-tron mode” in
the “Car”/“Car systems” menu of the Multi Media Interface (MMI)
e.g. to “Increase battery charge”, or by releasing the bonnet (with
vehicle's drive system ready - see display in “power meter” in dash
panel insert) ⇒ Owner's Manual and ⇒ Infotainment/MMI Oper‐
ating Manual .
• Event memory of operating unit ( air conditioning system con‐

trol unit - J301- / Climatronic control unit - J255- ) interrogated
and erased, basic setting performed and coding checked for -
J301- / -J255- ⇒ Vehicle diagnostic tester (“Guided Fault
Finding”).
• Adaption of -J301- / -J255- checked ⇒ Vehicle diagnostic test‐
er (“Guided Fault Finding”).
• All dash panel vents and any vents in rear centre console
open.
• Air outlet from rear footwell vents (beneath front seats) not
obstructed by floor mats or other objects; check.
• Front lid closed
♦ Ignition switched on and drive system active (READY; note
display in “power meter”); engine only starts or runs if e.g. hy‐
brid battery unit - AX1- is not sufficiently charged or bonnet is
released ⇒ Owner's Manual and ⇒ Infotainment/MMI Oper‐
ating Manual .
♦ With ignition switched on and temperature set to “warm” on air
conditioner operating unit ( Climatronic control unit - J255- -
“HI” on display), the flow of coolant through the heat exchanger
of the air conditioning unit is maintained by the coolant pump
for high-temperature circuit - V467-
coolant circuit”, page 343 and ⇒ Engine, mechanics; Rep. gr.
19 ; Coolant pump/thermostat assembly; Exploded view -
coolant pump .
DANGER!

♦ Open bonnet
tem
– Switch on ignition and activate vehicle's drive system (engine

does not have to start).
Vehicles without high-voltage system
– Start engine.
– Start engine; if necessary, change setting in operating unit ( -
J301- / -J255- ) to “heat”.
Vehicles with manually controlled air conditioner:
– Make the following settings on the operating unit ( air condi‐
tioning system control unit - J301- ):
-5- on
• Air recirculation mode on: Lamp in air recirculation but‐
ton -2- is on.

Vehicles with automatically controlled air conditioner (with or with‐

out high-voltage system):
– Make the following settings on the operating unit ( Climatronic
control unit - J255- ):
• “Auto” mode: Lamp in AUTO button -11- is on.
-8- on
Note
If the fresh air blower speed is changed manually, the lamp in the
AUTO button goes out.
All vehicles (continued):
Note
The maximum possible fresh air blower speed depends on sev‐

eral factors (electrical system voltage etc.).
Functions with engine running (vehicles without high-voltage sys‐

tem):
Functions with vehicle's drive system active (vehicles with high-
voltage system):
• Radiator fan(s) -V7- / -V177- running. Activation and speed
governed by pressure in refrigerant circuit and engine tem‐
perature.
Note
♦ Depending on the version of the operating unit -J301- / -J255- ,

the radiator fan(s) -V7- / -V177- is/are either switched on im‐
mediately or not switched on until a certain pressure is
reached in the refrigerant circuit (currently 9 bar). Activation of
the radiator fan(s) is displayed in the “Read measured values”
function ⇒ Vehicle diagnostic tester, “Guided Fault Finding”.
♦ Depending on the engine control unit, the specified and actual
speeds of radiator fans -V7- and -V177- may differ ⇒ Vehicle
• The fresh air blower runs at maximum speed.
Note
The maximum possible fresh air blower speed depends on sev‐

eral factors (electrical system voltage etc.).
• The air conditioner switches to air recirculation mode. Approx.

1 minute after starting the engine (i.e. activating the drive sys‐
tem), the air flow/fresh air flap is closed and the air recirculation
flap is opened, air is drawn in by the fresh air blower from the
passenger compartment beneath the dash panel/behind the
glove box.
If one of these requirements is not met:
– Interrogate event memory, perform final control diagnosis and
read out corresponding measured values ⇒ Vehicle diagnostic
Continued:
trolled air conditioner”, page 54
page 59
controlled air conditioner (with high-voltage system)”, page 64
4.8.3 Checking cooling output - vehicles with

page 49
Note

Procedure
• Requirements for checking cooling output met ⇒ page 50
– Measure ambient temperature: It must be over 15 °C.
– Start engine.

– Switch off air conditioner compressor on operating unit ( air

conditioning system control unit - J301- ): Lamp in AC or A/
C button -5- not on.
– “Read measured values” ⇒ Vehicle diagnostic tester (“Guided

Fault Finding”).
Checking
– Read out activation of air conditioner compressor regulating
valve -N280- .
• Activation of air conditioner compressor is switched off (via -
N280- ): Display is 0 A (amps) or 0 %.
– Read measured value of pressure sender for refrigerant circuit
-G805- .
• Pressure in refrigerant circuit is identical to or above value in
table below (depending on ambient temperature).
Ambient temperature in ° Pressure displayed (in bar)
C
15 3.0
20 4.0
25 5.0
30 6.0
35 7.0
Note
♦ On the absolute pressure scale, 0 bar corresponds to an ab‐

solute vacuum. Normal ambient pressure thus corresponds to
approx. 1 bar absolute and 0 bar gauge pressure. On the
scales of most pressure gauges, 0 bar gauge pressure corre‐
sponds to an absolute pressure of 1 bar (can be seen from -1
mark below 0).
♦ The pressure in the refrigerant circuit depends on the ambient
temperature. Due to the radiation of heat by components (e.g.
radiator), the pressure displayed when the engine is warm is
slightly higher than that given for the corresponding ambient
temperature.
If the displayed pressure in the refrigerant circuit is lower than that

indicated in the table:
– Check signal of -G805- ⇒ Vehicle diagnostic tester (“Guided
Fault Finding”).
If no fault is found on -G805- , there is not enough refrigerant in
the circuit.
– The necessary work may only be performed by appropriately
qualified personnel. If this is not possible on your premises,
the vehicle must be taken to a workshop equipped with the
necessary tools where this work can be performed by appro‐
priately qualified personnel ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; General information on air conditioning
systems , or ⇒ Air conditioner with refrigerant R1234yf - Gen‐
eral notes; Rep. gr. 00 ; Laws and regulations . Inform the
workshop of the problem detected.
If pressure displayed in refrigerant circuit is OK:

– Select the following settings on operating unit -J301- :
♦ Set rotary temperature control -1- to “cold” stop.
♦ Set rotary control -4- for air distribution to “Dash panel vents”.
♦ Air conditioner compressor on: Lamp in AC or A/C button
-5- on
♦ Air recirculation mode on: Lamp in air recirculation but‐
ton -2- is on.
♦ Set rotary control -3- for fresh air blower to maximum speed.
Fault Finding”).
– Check display in display zones:
• Current calculated by air conditioning system control unit -
J301- that flows via air conditioner compressor regulating
valve - N280- is displayed as greater than 0.3 A (30 %) with
air conditioner compressor switched on.
• Pressure indicated rises above value with air conditioner com‐
pressor switched off.
If there is no change in the pressure displayed and the activation
of the air conditioner compressor is OK:
– Check again whether the calculated current is actually flowing
via the air conditioner compressor regulating valve - N280-
and the air conditioner compressor is actually being driven.
If the current is actually flowing via -N280- and the air conditioner
compressor is being driven, there is a fault in the refrigerant cir‐
cuit. There may be problems with the control of the air conditioner
compressor.

Note
♦ -N280- is activated by -J301- so that the temperature of the air

downstream of the evaporator reaches the specified value
(approx. 2 to 6 ℃).
♦ After starting the vehicle, a value above 0.55 A (75 %) is dis‐
played for the activation of -N280- depending on the measured
temperature, engine speed and electrical system voltage. As
soon as the temperature measured by the evaporator output
temperature sender - G263- approaches the specified value,
activation is cancelled and the compressor output thus re‐
duced.
♦ Under certain operating conditions, residual moisture in the
refrigerant circuit may lead to the formation of ice at -N280-
and at the expansion valve. Such ice formation impedes the
control of the air conditioner compressor. The evaporator is
cooled down too much and ices up. An iced-up evaporator
may cause various problems ⇒ page 76 .
♦ If no current is displayed in the measured values for the acti‐
vation of the air conditioner compressor regulating valve -
N280- or if the current is too low, check the activation of -N280-
⇒ Vehicle diagnostic tester, “Guided Fault Finding”.
– Press Air recirculation button -2- on operating unit -

J301- .
• Lamp indicating “Air recirculation” mode in button lights up.
– Set engine speed to 2000 rpm (start of time measurement).
Fault Finding”).
– Compare measured value displayed for evaporator output

temperature sender - G263- to values in graph.
A - Air temperature measured by evaporator output temperature
sender - G263-
B - Ambient temperature
C - Permissible tolerance range
• Depending on the ambient temperature, the measured air
temperature should be within the stated tolerance range after
5 minutes.
If specified values are not attained:
– Compare measured value to measured value displayed for
evaporator output temperature sender - G263- .
If measured values only differ slightly:
– Perform Fault Finding measures to be taken if results do not
match specification ⇒ page 74 .
If measured value for evaporator output temperature sender -
G263- is higher than measured value determined:
– Check that -G263- is correctly installed ⇒ page 286 and per‐
form electrical check for this sender ⇒ Vehicle diagnostic
Note
The operation of the air conditioner can be detected e.g. from the
fact that the refrigerant pipe on the low-pressure side (thick pipe
from internal heat exchanger to air conditioner compressor) cools
down ⇒ page 133 .
If the measured value for the evaporator output temperature

sender - G263- and thus the air conditioner cooling output is OK:
– Compare measured values on thermometer and for evapora‐
tor output temperature sender - G263- .
• Measured values may not be lower nor (after 5 minutes) more
than 7° C higher than value for evaporator output temperature
sender - G263- .
If measured values determined are lower:
– Check that evaporator output temperature sender - G263- is
installed correctly and check its wiring for any contact resist‐
ance; renew sender if defective ⇒ Vehicle diagnostic tester
– Check activation and operation of temperature flap. To do so,
perform Fault Finding in the event of an increase in tempera‐
ture downstream of the evaporator ⇒ page 75 and ⇒ Vehicle
diagnostic tester, “Guided Fault Finding”.


automatically controlled air conditioner
(without high-voltage system)
page 49
Note

Procedure
♦ Requirements for checking cooling output met ⇒ page 50
– Open all dash panel vents and any vents in rear centre con‐
sole.
– Start engine.
– Switch off air conditioner compressor on operating unit ( Cli‐

matronic control unit - J255- ): Lamp in AC or A/C button -8-
not on.
Fault Finding”).
Checking
– Read out activation of air conditioner compressor regulating
valve -N280- .
• The activation of air conditioner compressor is deactivated (via
-N280- ): Display is 0 A (amps) or 0 %.
– Read measured value of pressure sender for refrigerant circuit
-G805- .
C
15 3.0
20 4.0
25 5.0
30 6.0
35 7.0
Note

mark below 0).
temperature.

– Check signal of -G805- ⇒ Vehicle diagnostic tester (“Guided
Fault Finding”).
If no fault is found on -G805- , there is not enough refrigerant in
the circuit.


– Select the following settings on operating unit -J255- :
-8- on
Fault Finding”).
• A current above 0.3 A (30%) is displayed (current flowing via
air conditioner compressor regulating valve - N280- ): Air con‐
ditioner compressor is switched on.
• Pressure indicated rises above value with air conditioner com‐
pressor switched off.
– Check again whether the air conditioner compressor is ac‐
tually being driven and the air conditioner compressor regu‐
lating valve - N280- is being activated.
If the current is actually flowing via the air conditioner compressor
regulating valve - N280- and the air conditioner compressor is
being driven, there is a fault in the refrigerant circuit. There may
be problems with the control of the air conditioner compressor.
Note
♦ The air conditioner compressor regulating valve - N280- is ac‐

tuated by -J255- so that the temperature of the air downstream
of the evaporator reaches the specified value (approx. 2 to 6
°C).
♦ After starting the vehicle, a value greater than 0.55 A is dis‐
played for the activation of the air conditioner compressor
regulating valve - N280- depending on the measured temper‐
ature, engine speed and voltage of the vehicle electrical sys‐
tem. As soon as the temperature measured by the evaporator
output temperature sender - G263- approaches the specified
value, the current is decreased and the air conditioner com‐
pressor output thus reduced.
refrigerant circuit may lead to the formation of ice at the air
conditioner compressor regulating valve - N280- and at the
expansion valve. Such ice formation impedes the control of
the air conditioner compressor. The evaporator is cooled down
too much and ices up. An iced-up evaporator may cause var‐
ious problems ⇒ page 76 .
♦ If no current is displayed in the measured values for the acti‐
vation of the air conditioner compressor regulating valve -
N280- or if the current is too low, check the activation of the
air conditioner compressor regulating valve - N280- ⇒ Vehicle

J255- .
– Set engine speed to 2000 rpm (start of time measurement).
Fault Finding”).


sender - G263-
5 minutes.
– Compare measured values for left vent temperature sender -
G150- and right vent temperature sender - G151- to measured
value displayed for evaporator output temperature sender -
Note
You can also use a thermometer to measure the temperature of

the air emerging from the dash panel vents (left and right).
If measured values for -G263- and -G150- / -G151- only differ

slightly:
G263- is higher than measured value for -G150- / -G151- :
Note
The operation of the air conditioner can be detected e.g. from the
fact that the refrigerant pipe on the low-pressure side (thick pipe)
cools down.
The cooling output test is completed if the measured value for the
evaporator output temperature sender - G263- (and thus the cool‐
ing output of the air conditioner) is OK and there are no problems.
If measured value for -G263- (and thus air conditioner cooling
output) is not OK:
– Perform Fault Finding if results do not match specification (re‐
quired cooling output is not attained) ⇒ page 74 .
output) is OK and there is a problem with excessively high or dif‐
fering air conditioner vent temperatures:
– Check actuation of temperature flaps in air conditioning unit
⇒ page 293 and ⇒ Vehicle diagnostic tester (“Guided Fault
Finding”).

(with high-voltage system)
page 49
Note


nents is necessary
voltage components”, page 19 and “General warning instructions
for work on the high-voltage system” ⇒ 4-cyl. direct injection en‐
gine (1.2, 1.4 ltr. 4-valve TFSI EA211; Rep. gr. 93 ; High-voltage
components .
DANGER!

♦ Open bonnet
tem

work, charge vehicle batteries e.g. with the battery charger
60A - VAS 5904- in battery standby mode ⇒ Electrical system;
General information; Rep. gr. 27 ; Battery; Charging battery .

Note
Owner's Manual .
Procedure
♦ Requirements for checking cooling output met ⇒ page 50
– Open all dash panel vents and any vents in rear centre con‐
sole.
Note

trol unit in dash panel insert - J285- via the “power meter”.
♦ Activating vehicle drive system (check "READY" display in
control unit in dash panel insert - J285- ) ⇒ Owner's Manual
♦ Move the selector lever to position “P” and activate the parking
brake before performing test and measurement work for which
the ignition must be switched on but where the vehicle's drive
system does not need to be active.
– Ignition is switched on and drive system is active (READY),

engine only starts or runs if e.g. hybrid battery unit - AX1- is
not sufficiently charged.
Note
On vehicles with a high-voltage system, it is not necessary for the

engine to be running when the cooling output test is performed
( electrical air conditioner compressor - V470- ).
– Switch off air conditioner compressor on operating unit ( Cli‐

matronic control unit - J255- ): Lamp in A/C button -8- off.
Fault Finding”).
Checking
♦ Read off activation of electrical air conditioner compressor -
V470- (compressor shut-off criteria and compressor speed).
♦ Read out measured value for pressure sender for refrigerant
circuit -G805- or refrigerant pressure and temperature sender
- G395- , depending on vehicle version.
Note
♦ Various measured values can be selected in the Guided Fault

Finding routine for the following test and displayed in a table
♦ The electrical air conditioner compressor - V470- is supplied
with electric power via a fuse fitted in the power and control
electronics for electric drive - JX1-
⇒ “9.8 Removing and installing fuse for electrical air condi‐
tioner compressor”, page 372 , ⇒ 4-cylinder direct injection
engine (1.2, 1.4 ltr. 4-valve TFSI EA 211); Rep. gr. 93 ; Power
and control electronics for electric drive and ⇒ Current flow
♦ The air conditioner compressor is deactivated, no compressor

speed is displayed.
♦ Pressure in refrigerant circuit is identical to or above value in
C
15 3.0
20 4.0
25 5.0
30 6.0
35 7.0

Note

mark below 0).
♦ Depending on the version of the air conditioner operating unit
( Climatronic control unit - J255- ), the measured values may
only be displayed as whole numbers. The display fluctuates
between two values if the measured pressure is between the
two.
♦ The displays for the activation of the air conditioner compres‐
sor differ. For a mechanically driven air conditioner compres‐
sor, the tester displays the specified and actual current for
activation of the air conditioner compressor regulating valve -
N280- . The specified speed of the electrical air conditioner
compressor - V470- calculated by -J255- and transmitted to
the control unit for air conditioner compressor - J842- and the
actual speed of -V470- determined by -J842- are displayed in
a measured value ⇒ Vehicle diagnostic tester (“Guided Fault
Finding” for air conditioner).
temperature.

– Check signal from -G805- or -G395- (depending on vehicle
version) ⇒ Vehicle diagnostic tester (“Guided Fault Finding”).
If no fault is found on -G805- or -G395- (depending on vehicle
version), there is not enough refrigerant in the circuit.

– Make the following settings on operating unit -J255- :
Fault Finding”).
• Activation of electrical air conditioner compressor - V470-
(compressor shut-off criteria and compressor speed). -V470-
is activated by -J842- when requested by -J255- so that the
speed is higher than 800 rpm.
• Check measured value of -G805- / -G395- (refrigerant pres‐
sure). Pressure indicated rises above value with air condition‐
er compressor switched off.
• Read off activation of refrigerant shut-off valve for heater and
air conditioning unit - N541- and refrigerant shut-off valve for
high-voltage battery heat exchanger - N542- . -N541- is not
activated; whether -N542- is activated depends on whether
the hybrid battery unit - AX1- needs to be cooled.

Note
♦ The specified speed for -V470- is calculated by the air condi‐

tioner operating unit ( Climatronic control unit - J255- ). The
request is transmitted via the data bus to the control unit for
air conditioner compressor - J842- ⇒ Vehicle diagnostic tester
♦ When driving, the air conditioner compressor operates over a
speed range of 800 to 8600 rpm.
♦ When the vehicle is stationary or only moving slowly (up to a
speed of approx. 45 km/h), the air conditioner compressor is
not activated at the maximum specified speed (of approx.
8500 rpm); the air conditioner compressor speed is limited to
approx. 5000 rpm.
♦ At an air conditioner compressor speed of 5000 rpm, with a
very high ambient temperature (in excess of 35 ℃) and a high
fresh air blower speed (unfavourable ambient conditions), the
output (delivery volume) of the air conditioner compressor is
at first not always sufficient to reduce the temperature of the
air downstream of the evaporator to the specified value. One
way of checking the control action of the air conditioner com‐
pressor under these conditions is to activate the fresh air
blower with only approx. 40 % of the maximum voltage and to
check the temperature at reduced fresh air blower speed
⇒ Vehicle diagnostic tester (“Guided Fault Finding” for air con‐
ditioner).
♦ If an insufficient speed or no speed at all is displayed as the
measured value (a speed of less than 4000 rpm although the
required temperature of the air downstream of the evaporator
has still not been reached), check the activation of the electri‐
cal air conditioner compressor - V470- by the control unit for
air conditioner compressor - J842- ⇒ Vehicle diagnostic tester
♦ -N541- and -N542- are open (de-energised).
♦ -N541- is activated e.g. when the air conditioner does not re‐
quest any cooling output, but the hybrid battery unit - AX1-
( power and control electronics for electric drive - JX1- ) needs
to be cooled.
♦ -N542- is activated e.g. when the air conditioner requests
cooling output and -AX1- and/or -JX1- do not have to be
cooled.
– In the “Read measured values” function, read out the pressure

in the refrigerant circuit measured by -G805- or -G395- . The
pressure displayed increases to above the value with the air
conditioner compressor switched off ⇒ Vehicle diagnostic test‐
er (“Guided Fault Finding”).
– Check activation and operation of -N541- (it must not be acti‐
vated) ⇒ Vehicle diagnostic tester (“Guided Fault Finding”).
– Check installation position of -N541- (arrow must point in flow

direction of refrigerant from condenser to expansion valve)
⇒ page 166 .
If the air conditioner compressor is being driven, but -N541- is not
being activated (although it is installed correctly), there is a fault
in the refrigerant circuit. There may be too little refrigerant in the
circuit, or -N541- may be blocked.
Note
♦ The electrical air conditioner compressor - V470- is activated

by the control unit for air conditioner compressor - J842- when
requested by the air conditioner operating unit ( Climatronic
control unit - J255- ) in such a way that the temperature of the
air downstream of the evaporator reaches the specified value
(approx. 2 to 6 ℃).
♦ After the engine is started, the air conditioner compressor is
activated at a speed greater than 3000 rpm depending on the
measured temperature, engine speed and electrical system
voltage. As soon as the temperature measured by the evap‐
orator output temperature sender - G263- approaches the
specified value, the activation is reduced and the compressor
output is decreased.
refrigerant circuit may lead to the formation of ice at the ex‐
pansion valve for the evaporator in the air conditioning unit.
This ice formation can impair the control function of the ex‐
pansion valve/air conditioner compressor. The evaporator is
insufficiently or excessively cooled and may ice up. An iced-
up evaporator may cause various problems ⇒ page 76 .

J255- .
Fault Finding”).


sender - G263-
5 minutes.
– Compare measured values for left vent temperature sender -
G150- and right vent temperature sender - G151- to measured
value displayed for evaporator output temperature sender -
Note
♦ You can also use a thermometer to measure the temperature

of the air emerging from the dash panel vents (left and right).
♦ The operation of the air conditioner can be detected e.g. from
the fact that the refrigerant pipe on the low-pressure side (thick
pipe) cools down.
♦ When the vehicle is stationary or only moving slowly (up to a
speed of approx. 45 km/h), the air conditioner compressor is
not activated at the maximum specified speed (of approx.
8500 rpm); the air conditioner compressor speed is limited to
approx. 5000 rpm.
♦ At an air conditioner compressor speed of 5000 rpm, with a
high ambient temperature (in excess of 30 ℃) and a high fresh
air blower speed (unfavourable ambient conditions), the out‐
put (delivery volume) of the air conditioner compressor is at
first not always sufficient to reduce the temperature of the air
downstream of the evaporator to the specified value. One way
of checking the control action of the air conditioner compressor
under these conditions is to activate the fresh air blower with
only approx. 40 % of the maximum voltage and to check the
temperature at reduced fresh air blower speed ⇒ Vehicle di‐
agnostic tester (“Guided Fault Finding” for air conditioner).
If measured values for -G263- and -G150- / -G151- only differ

slightly:
G263- is higher than measured value for -G150- / -G151- :
The cooling output test is completed if the measured value for the
evaporator output temperature sender - G263- (and thus the cool‐
ing output of the air conditioner) is OK and there are no problems.
output) is not OK:
– Perform Fault Finding if results do not match specification (re‐
quired cooling output is not attained) ⇒ page 74 .

output) is OK and there is a problem with excessively high or dif‐
fering air conditioner vent temperatures:
– Check actuation of temperature flaps in air conditioning unit
⇒ page 293 and ⇒ Vehicle diagnostic tester (“Guided Fault
Finding”).
If the measured value of the evaporator output temperature send‐
er - G263- (and thus the cooling output of the air conditioner) is
OK and there is a problem with a lack of cooling output for com‐
ponents of the high-voltage system:
– Check activation and operation of -N542- ; it must not be ac‐
tivated when cooling output is requested for cooling high-
voltage system components
⇒ “8.2 Incorporation of heat exchanger for high-voltage battery
into coolant circuit of high-voltage system”, page 347 and
– Check installation position of -N542- (arrow must point in flow
direction of refrigerant from condenser to heat exchanger for
high-voltage battery) ⇒ page 169 .
– Check connections between heat exchanger for high-voltage
battery ("chiller") and coolant circuit of high-voltage system
⇒ page 347 and ⇒ 4-cylinder direct injection engine (1.2, 1.4
ltr. 4-valve TFSI EA 211); Rep. gr. 19 ; Cooling system/cool‐
ant; Connection diagram - coolant hoses, cooling components
for high-voltage system .
– Check operation and activation of coolant pump for high-volt‐
age battery - V590- and coolant valve for high-voltage battery
- N688-
into coolant circuit of high-voltage system”, page 347 , ⇒ Ve‐
hicle diagnostic tester (“Guided Fault Finding” for hybrid bat‐
tery energy management system) and ⇒ 4-cylinder direct
injection engine (1.2, 1.4 ltr. 4-valve TFSI EA 211); Rep. gr.
hoses, cooling components for high-voltage system .
If the air conditioner compressor is being driven, but -N542- is not
being activated (although it is installed correctly) and there is no
fault in the coolant circuit of the high-voltage system, there is a
fault in the refrigerant circuit. The constriction (restrictor) in the
refrigerant circuit between -N542- and the heat exchanger for the
high-voltage battery, or -N542- , may be blocked ⇒ page 146 .

Note
♦ In air conditioner control mode -N542- is closed; it is activated

by the air conditioner operating unit ( Climatronic control unit
- J255- ). Only if there is a request for cooling output via the
heat exchanger for the high-voltage battery from the hybrid
battery unit - AX1- and/or the power and control electronics for
electric drive - JX1- does -J255- switch off the activation of -
N542- ; the refrigerant can then flow via the restrictor in the
refrigerant line into the heat exchanger for the high-voltage
battery and cool it. The hybrid battery unit - AX1- is only cooled
if the coolant pump for high-voltage battery - V590- is also ac‐
tivated correctly. In order for the power and control electronics
for electric drive - JX1- and the control unit for high-voltage
battery charging unit - J1050- to be cooled, the coolant valve
for high-voltage battery - N688- and the coolant circulation
pump before power and control electronics for electric drive -
V508- must also be activated correctly
into coolant circuit of high-voltage system”, page 347 , ⇒ Ve‐
♦ If the air conditioner operating unit ( Climatronic control unit -
J255- ) detects a fault in the connection between -J255- and -
N542- , it switches off the activation of the electrical air
conditioner compressor - V470- (depending on version of -
J255- ); cooling output is then stopped.
♦ Depending on the version of the air conditioner operating unit
( Climatronic control unit - J255- ), -N542- is not activated when
the final control diagnosis for the electrical air conditioner com‐
pressor - V470- is being performed so that the cooling output
for the heat exchanger for the high-voltage battery can be
checked during the diagnosis ⇒ Vehicle diagnostic tester
♦ The refrigerant shut-off valve for high-voltage battery heat ex‐
changer - N542- -A- is open (de-energised); this means that
the heat exchanger for the high-voltage battery is cooled as
long as -N542- is not activated in air conditioning mode. If, with
the ignition switched off, a different shut-off valve (with the
same electrical values as -N542- -A-) is connected, or if coil
-B- is removed from shut-off valve -D-, the cooling of the heat
exchanger for the high-voltage battery can be checked without
a fault being detected in the Climatronic control unit - J255-
⇒ “8.9 Removing and installing heat exchanger for high-volt‐
age battery”, page 352 . (Should it be necessary to unplug the
electrical connector for coil -B- in order to detach the coil, re‐
member to plug it in again.)
♦ Screws -C- must be removed to detach coil -B- (do not unplug
connector with ignition switched on; if it has been detached
plug it in again before switching on the ignition).
♦ If there is a complaint and the vehicle's cooling output is OK

and the heat exchanger for the high-voltage battery is cooled
correctly while -N542- is not being activated, check the acti‐
vation of -N542- as well as the connections between the heat
exchanger for the high-voltage battery and the low-tempera‐
ture coolant circuit; also check the activation and operation of
the corresponding components
into coolant circuit of high-voltage system”, page 347 ⇒ Ve‐
♦ If the vehicle's cooling output is OK and the heat exchanger
for the high-voltage battery is not being cooled while -N542- is
not being activated (or when coil -B- is detached), the cause
could also be a blocked restrictor in refrigerant line -E-
⇒ page 146 .
– If there is a fault in the refrigerant circuit, the necessary work

may only be performed by appropriately qualified personnel.
If this is not possible on your premises, the vehicle must be
taken to a workshop equipped with the necessary tools where
this work can be performed by appropriately qualified person‐
nel ⇒ Air conditioner with refrigerant R134a; Rep. gr. 87 ;
00 ; Laws and regulations . Inform the workshop of the problem
detected.
4.8.6 Fault Finding if results do not match

specifications
Required cooling output is not attained
trolled air conditioner”, page 54 ,
page 59 and
controlled air conditioner (with high-voltage system)”, page 64 .
Note

There may be various reasons for a readout not matching the

specification:
– Determine cause ⇒ Vehicle diagnostic tester (“Guided Fault
Finding”).
Possible reasons for deviation from specification:
♦ Radiator or air conditioner condenser dirty
♦ Components retrofitted at front end of vehicle
♦ Problem with activation or operation of radiator fans -V7- / -
V177-
♦ Faults in coolant circuit, coolant becomes too hot

♦ Problem with activation of air conditioner compressor regulat‐

ing valve -N280- by air conditioning system control unit -
J301- / Climatronic control unit - J255- (vehicles without high-
voltage system).
♦ Request(s) transmitted by other control units to air condition‐
ing system control unit - J301- / Climatronic control unit - J255-
for deactivation of -N280- (vehicles without high-voltage
system).
♦ Problem with operation of air conditioner compressor regulat‐
ing valve -N280- (vehicles without high-voltage system).
♦ Faults in refrigerant circuit or air conditioner compressor.
♦ Problem with activation or operation of battery regulation con‐
trol unit - J840- , electrical air conditioner compressor - V470- ,
control unit for air conditioner compressor - J842- or refrigerant
shut-off valve for heater and air conditioning unit - N541- (ve‐
hicles with high-voltage system).
If “Guided Fault Finding” reveals a fault in the refrigerant circuit:
– If there is a fault in the refrigerant circuit, the necessary work
may only be performed by appropriately qualified personnel.
If this is not possible on your premises, the vehicle must be
taken to a workshop equipped with the necessary tools where
this work can be performed by appropriately qualified person‐
nel ⇒ Air conditioner with refrigerant R134a; Rep. gr. 87 ;
00 ; Laws and regulations . Inform the workshop of the problem
detected.
4.8.7 Fault Finding if temperature increases

downstream of evaporator
The increase in temperature in the air conditioning unit is exces‐
sive
trolled air conditioner”, page 54 ,
page 59 and
controlled air conditioner (with high-voltage system)”, page 64 .
Note

There may be various reasons for a readout not matching the

specification due to an increase in temperature downstream of
the evaporator:
– Determine cause ⇒ Vehicle diagnostic tester (“Guided Fault
Finding”).
Possible reasons for deviation from specification:
♦ Temperature flaps in air conditioning unit do not reach end
stops properly (faulty activation).
♦ One or more measured values for temperature sensors not
OK.
♦ Warm air flowing past temperature flaps set to “cold” stop.
Note
This fault can be determined as follows: Clamp off the two coolant
hoses from the engine to the heat exchanger of the air condition‐
ing unit e.g. using hose clamps up to 40 mm - 3093- and repeat
the cooling output test. If the measured values are then OK, this
is an indication of a fault in the area of the temperature flaps.
4.8.8 Fault finding if ice forms at evaporator

♦ The air conditioner compressor regulating valve - N280- is ac‐
tivated by the operating unit -J301- / -J255- so that the tem‐
perature of the air downstream of the evaporator reaches the
specified value (approx. 2 to 6 ℃).
♦ After starting the vehicle, a value above 0.55 A (75 %) may be
displayed in the “Read measured values” function for the op‐
erating unit -J301- / -J255- for the activation of the air condi‐
tioner compressor regulating valve - N280- depending on the
measured temperature, engine speed and voltage of the ve‐
hicle electrical system ⇒ Vehicle diagnostic tester, “Guided
Fault Finding” function. As soon as the temperature measured
by the evaporator output temperature sender - G263- ap‐
proaches the specified value, the activation is reduced and the
compressor output is decreased.
♦ Under extreme ambient conditions ice could form at the evap‐
orator if certain settings are selected on the air conditioner,
e.g. air outflow direction set to dash panel vents with these
vents closed, maximum cooling output with minimum fresh air
blower speed selected. When these settings are selected, air
no longer flows through the evaporator, which means that the
temperature measured by the evaporator output temperature
sender - G263- is higher than the actual temperature at the
evaporator. However, the air conditioner control uses the
measured value of -G263- as the basis for the actual evapo‐
rator temperature and continues to activate -N280- ; as a
consequence, the evaporator cools down too much.
refrigerant circuit may lead to the formation of ice at the com‐
pressor regulating valve and expansion valve. Such ice for‐
mation impedes the control of the air conditioner compressor.
The evaporator is cooled down too much and ices up. An iced-
up evaporator may cause the following problems
⇒ page 77 .
Vehicles with high-voltage system
♦ The electrical air conditioner compressor - V470- is activated
via the control unit for air conditioning compressor - J842- by
the air conditioner operating unit ( Climatronic control unit -
J255- ) in such a way that the temperature of the air down‐
stream of the evaporator reaches the specified value (approx.
2 to 6 ℃).
♦ After the ignition is switched on, a value greater than 3000 rpm
is displayed for the air conditioner compressor speed depend‐
ing on the road speed, the measured temperature and the

voltage of the vehicle's electrical system. As soon as the tem‐

perature measured by the evaporator output temperature
sender - G263- approaches the specified value, the activation
is reduced and the compressor output is decreased.
♦ Under extreme ambient conditions ice could form at the evap‐
orator if certain settings are selected on the air conditioner,
e.g. air outflow direction set to dash panel vents with these
vents closed, maximum cooling output with minimum fresh air
blower speed selected. When these settings are selected, air
no longer flows through the evaporator, which means that the
temperature measured by the evaporator output temperature
sender - G263- is higher than the actual temperature at the
evaporator. The air conditioner control system however as‐
sumes that the measured value of -G263- corresponds to the
actual evaporator temperature and continues to activate the
electrical air conditioner compressor - V470- at increased
speed, with the result that the evaporator is excessively
cooled.
♦ If the air conditioner is switched off and there is a request for
cooling output via the heat exchanger for the high-voltage bat‐
tery from the battery regulation control unit - J840- (for the
hybrid battery unit - AX1- ) or from the power and control elec‐
tronics for electric drive - JX1- , the evaporator also might ice
up under unfavourable conditions if the operation of the re‐
frigerant shut-off valve for heater and air conditioning unit -
N541- is not OK. The air conditioner operating unit -J255-
activates -V470- and -N541- . If -N541- does not close, the
evaporator will cool down so much that the condensate water
on the evaporator fins will freeze because the evaporator tem‐
perature will not be controlled. Check operation of -N541-
⇒ Vehicle diagnostic tester (“Guided Fault Finding” for air
conditioner).
refrigerant circuit may lead to the formation of ice at the ex‐
pansion valve. Such ice formation impedes the control of the
air conditioner compressor. The evaporator is cooled down too
much and ices up. An iced-up evaporator may cause the fol‐
lowing problems ⇒ page 77 .
Possible customer complaint (all vehicles, with or without high-
voltage system):
♦ The air conditioner fails repeatedly or sporadically (no cooling/
heating output) after extended driving; after the vehicle has
been stopped or the air conditioner has been switched off, the
air conditioner functions properly again (after a short wait).
♦ The windows mist up on the inside after long journeys; initially
the windows are not de-misted even after pressing the “de‐
frost” button e.g. on vehicles with an automatic air conditioner;
after the ignition is switched off and waiting a short while, the
air conditioner functions properly again.
Remedy:
– Check measured value for evaporator output temperature
Finding”).
If measured value for sender is too high under usage conditions
described by customer (e.g. above 10 °C depending on ambient
temperature) although air conditioner is functioning properly.
– Check evaporator output temperature sender - G263- . The
evaporator may ice up as a result of an incorrect measured
value.
If the measured value for the sender is too low under the usage
conditions described by the customer (at ambient temperature
above 0 °C, colder than 0 °C for lengthy period):
– Check the refrigerant line between the connection on the right

longitudinal member (from the internal heat exchanger/from
the evaporator) and the air conditioner compressor (thick pipe,
low-pressure side) with the engine running. If this line is se‐
verely iced up when the problem occurs (thin layer of ice is
permissible), this indicates that evaporator temperature is too
low.
– There is a fault in the refrigerant circuit. There may be prob‐
lems with the control of the air conditioner compressor.
– Checking pressures in refrigerant circuit ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ; General information on air
conditioning systems (Air conditioner with refrigerant R134a;
General information on air conditioning systems), or ⇒ Air
87 ; Working with the air conditioner service station; Checking
pressures .
Note
The necessary work may only be performed by appropriately

qualified personnel. If this is not possible on your premises, the
vehicle must be taken to a workshop equipped with the necessary
tools where this work can be performed by appropriately qualified
personnel ⇒ Air conditioner with refrigerant R134a; Rep. gr. 87 ;
General information on air conditioning systems . Inform the work‐
shop of the faults found, or refer to ⇒ Air conditioner with refrig‐
erant R1234yf - General notes; Rep. gr. 00 ; Laws and
regulations .
4.9 Discharging refrigerant circuit

Refrigerant must not be allowed to escape into the environment;
it should be extracted from the refrigerant circuit with an air con‐
ditioner service station. The extracted refrigerant must then either
be re-processed on site or returned to the manufacturer for proper
disposal. Different or additional regulations may apply in other
countries. For this reason, the vehicle must be taken to a work‐
shop which is equipped with the necessary tools and at which the
work can be performed by appropriately qualified personnel ⇒ Air
conditioner with refrigerant R134a; Rep. gr. 87 ; Refrigerant cir‐
cuit (Working with the air conditioner service station), or ⇒ Air
conditioner with refrigerant R1234yf - General notes; Rep. gr. 00 ;
Laws and regulations .
Refrigerant must not be allowed to escape into the environment;
it should be extracted from the refrigerant circuit with an air con‐
ditioner service station. The extracted refrigerant must then either
be re-processed on site or returned to the manufacturer for proper
disposal. Different or additional regulations may apply in other
countries. For this reason, the vehicle must be taken to a work‐
shop equipped with the necessary tools where this work can be
performed by appropriately qualified personnel ⇒ Air conditioner
with refrigerant R134a; Rep. gr. 87 ; General information on air
conditioning systems , or ⇒ Air conditioner with refrigerant
R1234yf - General notes; Rep. gr. 00 ; Laws and regulations .
Reason:
If refrigerant R134a or R1234yf escapes into the earth’s atmos‐
phere, it contributes towards 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 R134a and R1234yf do not affect the earth's ozone
layer (R134a and R1234yf do not have any chlorine atoms).
Depletion of the ozone layer in the upper atmosphere is 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 approx. 4;
the GWP of R134a is approx. 1400 (GWP of carbon dioxide =
1) ⇒ Air conditioners with refrigerant R1234yf - General infor‐
mation; Rep. gr. 00 ; Laws and regulations .
After discharging air conditioner, unplug electrical connector from

air conditioner compressor regulating valve - N280- (vehicles
without high-voltage system) or from pressure sender for refrig‐
erant circuit - G805- (or -G395- depending on vehicle version).
Reason:
♦ The air conditioner compressor ( air conditioner compressor
regulating valve - N280- ) is then no longer activated.
♦ The mechanically driven air conditioner compressor then
merely idles with the engine. The mechanically driven air con‐
ditioner compressor is designed so that, when running at idle,
lubrication of the components of the air conditioner compres‐
sor is guaranteed via an internal oil circuit (provided there is
enough refrigerant oil in the air conditioner compressor).
4.10 Working on refrigerant circuit

nents is necessary
voltage components”, page 19 and “General warning instructions
for work on the high-voltage system” ⇒ 4-cyl. direct injection en‐
gine (1.2, 1.4 ltr. 4-valve TFSI EA211); Rep. gr. 93 ; High-voltage
components .
DANGER!

♦ Open bonnet
tem

tem .
Note
Owner's Manual .

All vehicles
WARNING
Risk of injury due to pressure build-up in the air conditioner

(exposure to heat).
♦ Exposure to heat generates considerable pressure in the
air conditioning system, which could cause it to burst.
♦ Welding, brazing and soldering work must not be per‐
formed on components of air conditioning system when
charged. This also applies to welding and soldering work
on the vehicle if there is a danger of air conditioner com‐
ponents becoming hot.
♦ Renew damaged or leaking components of the air condi‐
tioner.
Caution
The ingress of moisture will lead to the air conditioner mal‐

functioning.
♦ When servicing the air conditioner, re-seal all open com‐
ponents and pipe connections immediately.
♦ If the air conditioner has been open for a certain amount
of time, check components for corrosion and renew if nec‐
essary.
4.11 Paintwork repairs on vehicles with air

conditioning system
When performing paintwork repairs, object temperatures of 80 °
C must not be exceeded in drying booths or their preheating
zones.
Reason:
Exposure to heat generates considerable pressure in the system,
which could cause it to burst.
4.12 Refrigerant circuit seals

♦ O-rings should always only be used once and must then be
renewed.
♦ Coat O-rings with refrigerant oil before fitting.
♦ Make sure O-rings are seated correctly on pipe or in groove.
♦ Ensure absolute cleanliness when working (even the slightest
contamination, e.g. a single hair, could cause leakage).
Note
♦ Only install O-rings which are resistant to refrigerant R134a

and/or R1234yf and the corresponding refrigerant oils. These
O-rings may be colour-coded to prevent mix-ups (e.g. “red”,
“purple” or “violet”) ⇒ Electronic parts catalogue .
♦ Dimensions -a- and -b- differ depending on where the O-ring
is fitted ⇒ Electronic parts catalogue .
♦ In addition to the coloured O-rings, black O-rings are also used
at the factory for certain connections.
4.13 Notes on control motors

⇒ “4.13.1 Notes on control motors”, page 82
⇒ “4.13.2 Preparing adapter cable for activation of control mo‐
tors”, page 83
4.13.1 Notes on control motors
Caution
Heater and air conditioner malfunctions can occur.

♦ The heater/air conditioner will not function properly if con‐
trol motors and/or the corresponding connectors are in‐
terchanged.
♦ The connectors of the control motors are identical. If these
are connected incorrectly, the corresponding flaps can no
longer be properly matched and/or activated.
♦ The actuator socket in the control motor may not have a
stop. It rotates permanently if the control motor is activa‐
ted. A control motor should therefore not be activated after
it has been detached (or only if necessary for installation).
♦ There are various identical connectors on the heater/air con‐

ditioning unit. To avoid the risk of interchanging them, mark
the connectors before unplugging them.
♦ Different control motors are fitted on the heater/air condition‐
ing unit; these motors have different electrical values and part
numbers ⇒ Electronic parts catalogue . The control motors
must be marked before they are removed to avoid the risk of
interchanging them.
♦ After installing a control motor, perform the basic setting of the
air conditioner ⇒ Vehicle diagnostic tester, “Guided Fault Find‐
ing” function.
♦ The activation of the electrical components of the air condi‐
tioner can be checked via the “Final control diagnosis” and
“Basic setting” functions (e.g. to check for interchanged com‐
ponents) ⇒ Vehicle diagnostic tester (“Guided Fault Finding”).
♦ After installing a new control motor, perform the basic setting
and check the activation by the operating unit ( heater control
unit - J65- , air conditioning system control unit - J301- , Cli‐
matronic control unit - J255- ) and the operation of the control
motor ⇒ Vehicle diagnostic tester, “Guided Fault Finding” func‐
tion.

Proceed as follows if actuator socket -F- of a control motor -A- (or

a fitted connecting element) is positioned so that control motor
cannot be installed:
– If it is possible to switch on the ignition, connect the relevant
control motor -A- to the vehicle wiring harness -C-, then switch
on the ignition and select a setting on -J65- / -J301- or -J255-
in which the control motor is moved to the desired position (e.g.
to centre position). Wait until the control motor has reached
the required position and then switch off the ignition.
– If it is not possible to switch on the ignition, you can use e.g.
an adapter cable ⇒ page 83 (or a test lead from the adapter
set - V.A.G 1594/C- ) to connect contacts “5” and “6” of the
control motor removed earlier to a 12 V battery via a 5 A fuse.
Then turn the control motor until the actuator socket -F- of the
control motor -A- (or the installed connecting element) reaches
a position in which no pre-tension is required for attaching it
or in which it can be joined in the specified position. The di‐
rection of rotation of the control motor can be reversed by
interchanging positive and negative.
Note
For example, the lug of an adjustment unit -E- and the actuator
socket -F- of a control motor -A- are only to be joined in the po‐
sition in which no force is required to do so. If the lug -E- can only
be inserted with force, check the shaft of the motor (it may be 180°
out of position).
4.13.2 Preparing adapter cable for activation of

control motors
Procedure
– Connect one cable each (with a cross section of 0.25 mm2) to
contacts “5” and “6” of connector -A- ( flat contact housing with
auxiliary contact lock - 6Q0 972 706- ) ⇒ Electronic parts
catalogue .
– Connect other end of each cable to a commercially available
banana plug -B-.
4.14 Notes on dust and pollen filter

⇒ “4.14.1 Dust and pollen filter with activated charcoal filter in‐
sert”, page 83
4.14.1 Dust and pollen filter with activated char‐

coal filter insert
The dust and pollen filter with activated charcoal filter insert is only
fitted on vehicles with air quality sensor - G238- .
Note
♦ Different filters are available for this vehicle depending on the

equipment version.
♦ A dust and pollen filter without activated charcoal filter insert
is fitted at the factory on vehicles without air conditioner and
vehicles with a manually controlled air conditioner (both with‐
out air quality sensor - G238- ). These vehicles may also be
retro-fitted with a dust and pollen filter with activated charcoal
filter insert ⇒ Electronic parts catalogue .
♦ A dust and pollen filter with activated charcoal filter insert is
fitted at the factory on vehicles with automatically controlled
air conditioner (with air quality sensor - G238- ) ⇒ Electronic
parts catalogue .
♦ From model year 2017 onwards, Audi A3 vehicles are gradu‐
ally fitted with a dust and pollen filter with bioactive substances
(from the start of production onwards on Audi Q2 vehicles).
These bioactive substances reduce the amount of allergens
in the air flowing through the filter. These filters can be retro‐
fitted in all vehicles ⇒ Electronic parts catalogue .
The filter with activated charcoal acts as a dust and pollen filter.
However, it can also filter gaseous pollutants such as ozone,
benzene and nitrogen dioxide out of the air. The main function of
the activated charcoal layer in the dust and pollen filter is to keep
peak concentrations away from the passenger compartment.
However, the activated charcoal also absorbs certain gaseous
impurities in the air passing through. The activated charcoal layer
in the dust and pollen filter has different effects on the various
pollutants in the air:
♦ Certain pollutants are firmly bound in the activated charcoal
layer.
♦ Other pollutants are converted into harmless compounds, as
in a catalytic converter.
♦ For the rest of the pollutants the activated charcoal functions
like a capacitor. When the pollution increases, the activated
charcoal initially absorbs pollutants until a certain level of sat‐
uration has been reached. If the pollutant level drops, the
activated charcoal layer continuously emits the absorbed par‐
ticles again.
As the activated charcoal layer permanently binds some of the
particles in the air, we recommend renewing the dust and pollen
filter earlier than specified under the following operating condi‐
tions:
♦ If the vehicle is driven in areas with a high level of air pollution
♦ If the vehicle is driven with the “automatic air recirculation”
function deactivated
Note
♦ The activated charcoal layer in the dust and pollen filter be‐
comes saturated after a certain time.
♦ A saturated filter can no longer absorb pollutants; they will then
pass through unfiltered.

4.15 Notes on high-voltage heater (PTC) -

Z115- (and high-voltage heater (PTC)
control unit - J848- )
nents is necessary (Safety precautions when working in the vi‐
cinity of high-voltage system components
voltage components”, page 19 and ⇒ 4-cyl. direct injection engine
(1.2, 1.4 ltr. 4-valve TFSI EA211); Rep. gr. 93 ; High-voltage
components ).
♦ The high-voltage heater (PTC) - Z115- -1- has a nominal pow‐

er of approx. 5000 W (watts). The nominal power is only
produced at low coolant temperatures.
♦ The power delivered to the coolant flowing through the heater
-Z115- depends greatly on the temperature of the coolant. If
there is not enough coolant flowing through the heater -Z115- ,
the coolant will heat up more; however due to the small amount
of coolant less energy is generated.
Components involved in activation of supplementary heater:
♦ Heat energy is delivered to the coolant via the high-voltage
heater (PTC) - Z115- -1- before it enters the heat exchanger
(in the air conditioning unit)
coolant circuit”, page 343 and ⇒ Vehicle diagnostic tester
(“Guided Fault Finding”). For this to happen, there must be a
request from the operating unit ( Climatronic control unit -
J255- ).
♦ If the air conditioner control unit -J255- determines that heat
output mode is necessary, various control units are interroga‐
ted by -J255- via the data bus, e.g. the battery regulation
control unit - J840- (fitted in the hybrid battery unit - AX1- ) and
the control unit for high-voltage battery charging unit - J1050- .
If no conditions preventing the activation of -Z115- are trans‐
mitted by these control units, -J255- will activate -Z115- . For
further information, refer to
⇒ “2.8 Auxiliary air conditioner - vehicles with high-voltage
system only”, page 16 , ⇒ Vehicle diagnostic tester (“Guided
Fault Finding”) and ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
♦ So that the coolant heated up by -Z115- is conveyed through
the air conditioner heat exchanger when the engine is running,
in electric mode (with the engine stopped) and when the “Aux‐
iliary air conditioner” function is active (with the ignition switch‐
ed off), the coolant pump for high-temperature circuit - V467- ,
the coolant changeover valve 2 - N633- and the coolant valve
for gearbox - N488- must also be activated (by the corre‐
sponding engine control unit). To ensure that the coolant flows
in the right direction, the non-return valves fitted in the coolant
circuit must also be installed correctly and they must operate
correctly. For further information, refer to
system only”, page 16 ,
hoses , ⇒ Vehicle diagnostic tester (“Guided Fault Finding”)
locations.
♦ On vehicles with high-voltage system and an auxiliary heater
fitted as an optional extra, the auxiliary heater or the high-volt‐
age heater (PTC) - Z115- is activated by the air conditioner
operating unit -J255- depending on various factors. For more
information, refer to
system only”, page 16 and ⇒ Auxiliary/supplementary heater;
Rep. gr. 00 ; General notes (Notes on auxiliary heater oper‐
ation - vehicles with high-voltage system).
♦ The air conditioner operating unit -J255- and the high-voltage
heater (PTC) control unit - Z115- fitted in the high-voltage
heater (PTC) - J848- exchange the data for switching -Z115-
on and off via a data line (LIN bus) ⇒ Vehicle diagnostic tester
(“Guided Fault Finding”) and ⇒ Current flow diagrams, Elec‐
trical fault finding and Fitting locations.

Criteria for activation of high-voltage heater (PTC) - Z115-

The operating unit -J255- transmits a request for the activation of
the supplementary heater to the high-voltage heater (PTC) con‐
trol unit - J848- fitted in -Z115- . If the conditions stored in -J255-
are met and no fault is detected by -J848- , it will activate -Z115- .
If any of the conditions for activating -Z115- stored in -J255- are
not met, no request is transmitted or activation is switched off.
The cut-in criteria must be met in the operating unit -J255- , and/
or no shut-off criterion may be active. For a list of the cut-in criteria,
refer to ⇒ Vehicle diagnostic tester (“Guided Fault Finding” for air
conditioner).
Shut-off criteria for activation of supplementary heater
The operating unit -J255- deactivates the request for activation of
-Z115- if one of the cut-in criteria is no longer met or a fault is
detected by -J848- .
4.16 Notes on high-voltage components and potential equalisation lines

A potential equalisation measurement must be performed on the
high-voltage components affected after installation of high-volt‐
age components or potential equalisation lines.
– Connect vehicle diagnostic tester .
– Select and start ODIS-Service mode.
– Select Special functions tab.
– Select the following:
♦ High-voltage
♦ Potential equalisation measurement on high-voltage
components
♦ 8C - Potential equalisation measurement hybrid

battery unit AX1
5 Technical data
⇒ “5.1 Refrigerant capacities”, page 88
⇒ “5.2 Approved refrigerant oils and refrigerant oil capacities”,
page 90
⇒ “5.3 Oil distribution”, page 96
5.1 Refrigerant capacities

⇒ “5.1.1 Capacities for refrigerant R134a”, page 88
⇒ “5.1.2 Capacities for refrigerant R1234yf”, page 89
5.1.1 Capacities for refrigerant R134a

Refrigerant R134a/refrigerant oil capacities ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ; Capacities for refrigerant R134a/
refrigerant oil and approved refrigerant oils
– Discharging, evacuating and charging refrigerant circuit ⇒ Air
conditioner with refrigerant R134a; Rep. gr. 87 ; Refrigerant
circuit (Air conditioner with refrigerant R134a; Refrigerant cir‐
cuit; Working with the air conditioner service station).
– Start up air conditioner after charging refrigerant circuit
⇒ page 199 .
Note
♦ The versions of the compressor and condenser may differ de‐

pending on the production period and engine ⇒ Electronic
parts catalogue .
♦ The refrigerant and refrigerant oil capacities depend on the
versions of the air conditioner compressor and condenser ⇒
Air conditioner with refrigerant R134a; Rep. gr. 87 ; Capacities
for refrigerant R134a/refrigerant oil and approved refrigerant
oils .
♦ Always charge the refrigerant circuit as far as the upper toler‐
ance limit (some refrigerant remains in filler hoses).
♦ For further information, refer to ⇒ page 3 and ⇒ Air conditioner
with refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit (Air
conditioner with refrigerant R134a; Refrigerant circuit; Work‐
ing with the air conditioner service station).

5.1.2 Capacities for refrigerant R1234yf
Note
♦ The capacities for the Audi A3 (8V_ or 85_ for China) apply to
all versions (Saloon, Sportback, Cabriolet, etc.)
♦ When charging the high-pressure side of refrigerant circuits,
always fill to the upper tolerance limit (some liquid refrigerant
will remain in the filler hoses).
♦ Unless otherwise stated, the capacities specified for refriger‐
ant R1234yf also apply to the S and RS versions of this vehicle
model.
♦ When charging a vehicle's refrigerant circuit, the air condition‐
er service station must be on the same level as the vehicle
(maximum difference 50 cm). Depending on how the air con‐
ditioner service station is designed, having too great a height
difference can cause the amount of refrigerant shown to differ
from the actual amount poured in. The accuracy of the air
conditioner service station may change.
♦ The capacities for refrigerant R1234yf and the corresponding
refrigerant oil are now listed in this manual rather than in the
Workshop Manual for all models
⇒ “5.2.3 Refrigerant oil capacities for refrigerant R1234yf”,
page 94 , and ⇒ Air conditioners with refrigerant R1234yf -
General information; Rep. gr. 00 ; Technical data .
♦ Note different capacities for refrigerant R1234yf in vehicles
without rear air conditioning unit (with one evaporator) and
vehicles with high-voltage system (with two evaporators).
♦ For additional notes on evacuating and charging the refriger‐
ant circuit, refer to ⇒ Air conditioner with refrigerant R1234yf
- General notes; Rep. gr. 87 ; Working with the air conditioner
service station .
– Discharge, evacuate and charge refrigerant circuit ⇒ Air con‐

ditioners with refrigerant R1234yf - General information; Rep.
gr. 87 ; Working with the air conditioner service station .
⇒ page 199 .
Capacity for refrigerant R1234yf
Vehicle Production Capacity in Differing characteristics
model period grams of this refrigerant circuit
Audi From 460 +/- 15 • None
Q2 06.16 on‐
Audi A3 wards
A3 e- From 450 +/- 15 • Electrically driven air
tron 06.16 on‐ conditioner compres‐
wards sor
• With second evapo‐
rator in heat exchang‐
er for high-voltage
battery ("chiller")
5. Technical data 89
Vehicle Production Capacity in Differing characteristics

model period grams of this refrigerant circuit
Audi From 520 +/- 15 • Different type of con‐
RS 3 06.16 on‐ denser fitted ⇒ Elec‐
• With wards tronic parts cata‐
5- logue .
cyl.
en‐
gine
5.2 Approved refrigerant oils and refrigerant

oil capacities
⇒ “5.2.1 Approved refrigerant oils and refrigerant oil capacities for
refrigerant R134a”, page 90
⇒ “5.2.2 Approved refrigerant oils for refrigerant R1234yf”,
page 91
page 94
5.2.1 Approved refrigerant oils and refrigerant

oil capacities for refrigerant R134a
The special refrigerant oil to be used exclusively for refrigerant
circuits with refrigerant R134a is not always available on the re‐
frigerant oil market ⇒ Electronic parts catalogue .
For refrigerant R134a and refrigerant oil capacities, refer to ⇒ Air
conditioner with refrigerant R134a; Rep. gr. 87 ; Capacities for
refrigerant R134a/refrigerant oil and approved refrigerant oils .
– Discharge, evacuate and charge refrigerant circuit ⇒ Air con‐
ditioner with refrigerant R134a; Rep. gr. 87 ; Refrigerant
circuit .
– Starting up air conditioner after charging refrigerant circuit
⇒ page 199 , and ⇒ Air conditioner with refrigerant R134a;
Rep. gr. 87 ; General information on air conditioning systems
(Air conditioner with refrigerant R134a, General information on
air conditioning systems). (before using air conditioner after it
has been re-charged).

Caution
Charging the refrigerant circuit with the wrong refrigerant oil will
cause malfunctions of the air conditioner.
♦ The refrigerant circuit must only be charged with approved
refrigerant oils ⇒ Electronic parts catalogue . The correct
refrigerant oil depends on the manufacturer and version
of the air conditioner compressor installed ⇒ Air condi‐
tioner with refrigerant R134a; Rep. gr. 87 ; Capacities for
refrigerant R134a/refrigerant oil and approved refrigerant
oils .
Charging the refrigerant circuit with the wrong quantity of re‐
frigerant oil will cause malfunctions of the air conditioner.
♦ Too much refrigerant oil in the refrigerant circuit results in
higher pressures and a reduction in the cooling output of
the system.
♦ Too little refrigerant oil in the refrigerant circuit may result
in failure of the air conditioner compressor due to lubrica‐
tion problems.
Risk of corrosion in refrigerant circuit.
♦ Refrigerant oil absorbs moisture. Never use refrigerant oil
from containers which have been open for a lengthy period
⇒ Air conditioner with refrigerant R134a; Rep. gr. 87 ;
General information on air conditioning systems .
Important information:
As refrigerant oil is extremely hygroscopic, open containers must
be closed and re-sealed immediately after use to prevent mois‐
ture from entering.
Note
♦ A use-by date for the refrigerant oil is stated on the bottle in

which the refrigerant oil is supplied.
♦ This date is not relevant if the bottle is sealed air-tight.
♦ If the bottle is sealed air-tight, the refrigerant oil can also be
used after the date stated on the bottle.
5.2.2 Approved refrigerant oils for refrigerant

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

water); open containers should therefore be closed immedi‐
ately so that they are air-tight.
♦ PAG oil becomes unusable if it is stored in open containers for
a long period of time.
Caution
Charging the refrigerant circuit with the wrong refrigerant oil will
cause malfunctions of the air conditioner.
♦ The refrigerant circuit must only be charged with approved
refrigerant oils ⇒ Electronic parts catalogue . The correct
refrigerant oil depends on the make and type of the air
conditioner compressor fitted.
Charging the refrigerant circuit with the wrong quantity of re‐
frigerant oil will cause malfunctions of the air conditioner.
♦ Too much refrigerant oil in the refrigerant circuit results in
higher pressures and a reduction in the cooling output of
the system.
♦ Too little refrigerant oil in the refrigerant circuit may result
in failure of the air conditioner compressor due to lubrica‐
tion problems.
Risk of corrosion in refrigerant circuit.
♦ Refrigerant oil absorbs moisture. Never use refrigerant oil
from containers which have been open for a long period
of time ⇒ Air conditioners with refrigerant R1234yf - Gen‐
eral information; Rep. gr. 00 ; Repair instructions; Refrig‐
erant and refrigerant oil .
Important information:
As refrigerant oil is extremely hygroscopic, open containers must
be closed and re-sealed immediately after use to prevent mois‐
ture from entering.
Note
♦ A use-by date for the refrigerant oil is stated on the bottle in

which the refrigerant oil is supplied.
♦ This date is not relevant if the bottle is sealed air-tight.
♦ If the bottle is sealed air-tight, the refrigerant oil can also be
used after the date stated on the bottle.
♦ The refrigerant oils used with refrigerant R134a are not ap‐
propriate for use with refrigerant R1234yf ⇒ Electronic parts
catalogue .
♦ The special refrigerant oil to be used exclusively for refrigerant
circuits with refrigerant R1234yf is not always available on the
refrigerant oil market ⇒ Electronic parts catalogue .
♦ Refrigerant oils intended specifically for a particular air condi‐
tioner compressor can therefore be obtained from the replace‐
ment parts range ⇒ Electronic parts catalogue .
♦ If a defective air conditioner compressor is replaced by a com‐
pressor from a different manufacturer, it is important to check
whether the refrigerant oil already in the refrigerant circuit
(from the removed compressor) is also approved for the new
compressor. If a different refrigerant oil is approved for the new
air conditioner compressor than for the removed compressor,
the refrigerant circuit must be cleaned (flushed) ⇒ Air condi‐
tioners with refrigerant R1234yf - General information; Rep.
gr. 87 ; Refrigerant circuit; Renewing components .

♦ Using other refrigerant oils may cause the system to fail, as it

cannot be guaranteed that they will mix and circulate with re‐
frigerant R1234yf to lubricate the air conditioner compressor.
♦ There are different refrigerant oils for “Denso”, “Delphi/Mahle”,
“Visteon” and “Sanden” air conditioner compressors ⇒ Elec‐
tronic parts catalogue .
♦ The refrigerant oil (part no. G 055 535 M2, external designa‐
tion ND 12) for use in refrigerant circuits with “Denso” air
conditioner compressors is the same for mechanical and elec‐
tric air conditioner compressors ⇒ Electronic parts catalogue .
♦ For refrigerant circuits with mechanically or electrically driven
“Sanden”, “Delphi/Mahle” or “Visteon” air conditioner com‐
pressors, use refrigerant oil with part no. G 052 535 M2
(external designation SP A2) ⇒ Electronic parts catalogue .
Note
♦ To ensure that air conditioner service stations do not always

need to be cleaned before starting work on a different type of
vehicle (due to the different refrigerant oils used depending on
the manufacturer of the air conditioner compressor), specified
small quantities (up to max. 10 %) of the total quantity of re‐
frigerant oil in the corresponding refrigerant circuit are permit‐
ted to meet a different specification from that of the air
conditioner compressor installed. On Audi vehicles, this
means that it is permitted to use max. 10 % refrigerant oil of
the type SP A2 on vehicles with a “Denso” air conditioner
compressor (with ND 12 refrigerant oil) or max. 10 % refriger‐
ant oil of the type ND 12 on vehicles with a “Sanden”, “Delphi/
Mahle” or “Visteon” air conditioner compressor (with SP A2
refrigerant oil). However, other refrigerant oils not listed here
must not be used (different properties due to different viscos‐
ity, different/missing additives etc.).
♦ Instead of using an air conditioner service station, refrigerant
oil extracted when emptying the refrigerant circuit can be add‐
ed via an open connection or, when valve -3- is removed, via
a service connection -1- or -2- using a commercially available
disposable syringe before evacuating the refrigerant circuit ⇒
Air conditioners with refrigerant R1234yf - General informa‐
tion; Rep. gr. 87 ; Working with the air conditioner service
station . This may be practical e.g. if the refrigerant oil specified
for the refrigerant circuit is normally only rarely used. Always
use fresh refrigerant oil ⇒ Electronic parts catalogue . Service
connection -1- or -2- may be in a different location in the ve‐
hicle ⇒ “2.1 System overview - refrigerant circuit”, page 133 .

page 94
5.2.3 Refrigerant oil capacities for refrigerant

R1234yf
Note
♦ The capacities for the Audi A3 (8V_ or 85_ for China) apply to
all versions (Saloon, Sportback, Cabriolet, etc.)
♦ The compressor version may differ depending on the produc‐
tion period and engine ⇒ Electronic parts catalogue .
♦ There may be different refrigerant oil capacities for the refrig‐
erant circuit depending on the type of air conditioner compres‐
sor ⇒ Electronic parts catalogue .
♦ There are different refrigerant oils for “Denso”, “Delphi/Mahle”,
“Visteon” and “Sanden” air conditioner compressors
⇒ “5.2.2 Approved refrigerant oils for refrigerant R1234yf”,
page 91 , and ⇒ Electronic parts catalogue .
♦ For further notes on refrigerant oil, refer to ⇒ Air conditioner
with refrigerant R1234yf - General notes; Rep. gr. 00 ; Repair
instructions; Refrigerant and refrigerant oil .
♦ ⇒ “5.2.2 Approved refrigerant oils for refrigerant R1234yf”,

page 91
♦ Layout and characteristics of refrigerant circuit
⇒ “2.1 System overview - refrigerant circuit”, page 133
Ve‐ Produc‐ Total quantity Quantity of re‐ Differing char‐
hicle tion pe‐ of oil in refrig‐ frigerant oil in acteristics of
mod riod erant circuit in replacement this refrigerant
el cm3 compressor in circuit
cm3
Audi From 110 +/- 10 110 +/- 10 • “Denso” air
Q2 06.16 conditioner
Audi on‐ compres‐
A3 wards sor
75 +/- 10 75 +/- 10 • “Sanden”

air condi‐
tioner com‐
pressor
110 +/- 10 110 +/- 10 • “Delphi/

Mahle” air
conditioner
compres‐
sor

Ve‐ Produc‐ Total quantity Quantity of re‐ Differing char‐

hicle tion pe‐ of oil in refrig‐ frigerant oil in acteristics of
mod riod erant circuit in replacement this refrigerant
el cm3 compressor in circuit
cm3
Audi From 120 +/- 10 120 +/- 10 • Electrically
A3 06.16 driven air
e- on‐ conditioner
tron wards compres‐
sor
• With sec‐
ond evapo‐
rator in
high-volt‐
age battery
heat ex‐
changer
• Different
type of re‐
frigerant oil
Audi From 110 +/- 10 110 +/- 10 • “Sanden”

RS 06.2016 air condi‐
3 to tioner com‐
• With
07.2016 pressor
5- with dou‐
cyl. ble-belt pul‐
en‐ ley and dif‐
gine ferent type
(PR of condens‐
no. er fitted ⇒
TB9) Electronic
parts cata‐
logue .
Audi From 110 +/- 10 110 +/- 10 • “Denso” air

RS 02.2017 conditioner
3 on‐ compres‐
• Withwards sor
5-
cyl.
en‐
gine
(PR
no.
TM1)
Note
♦ The replacement compressor contains the full quantity of oil

intended for the refrigerant circuit. If the air conditioner com‐
pressor is renewed, the quantity of oil in the compressor must
therefore be adjusted accordingly ⇒ Air conditioners with re‐
frigerant R1234yf - General information; Rep. gr. 87 ; Refrig‐
erant circuit; Renewing components .
♦ Different air conditioner compressors are fitted depending on
the production period and engine ⇒ Electronic parts cata‐
logue .
♦ These air conditioner compressors are available as replace‐
ment parts with different refrigerant oil capacities, and atten‐
tion must therefore be paid to the oil quantity in the air
conditioner compressor as well as the exact part number ⇒
Electronic parts catalogue
♦ The different oil quantities in the air conditioner compressor
may result from the design of the air conditioner compressor
(with or without oil separator at high-pressure connection) or,
in the case of identical air conditioner compressors, from the
design of the refrigerant circuit; pay attention to these quanti‐
ties. Too much oil in the circuit results in higher pressures and
a reduced cooling output of the system. Too little oil may lead
to lubrication problems in the air conditioner compressor.
♦ The air conditioner compressor may have been fitted at the
factory with a type plate indicating the part number and the
quantity of refrigerant oil in the air conditioner compressor.
5.3 Oil distribution

♦ During operation of the air conditioner, the refrigerant oil that
was in the air conditioner compressor before it was activated
for the first time is distributed throughout the refrigerant circuit.
♦ The extent to which the refrigerant oil is distributed throughout
the refrigerant circuit differs depending on the last air condi‐
tioner operating status before it was switched off, the ambient
temperatures etc. Therefore it is not possible to give generally
applicable information on the distribution of the refrigerant oil
in the refrigerant circuit. Therefore observe the notes on re‐
newing components of the refrigerant circuit ⇒ Air conditioner
with refrigerant R134a; Rep. gr. 87 ; Renewing components
of refrigerant circuit (Air conditioner with refrigerant R134a;
Renewing components of refrigerant circuit) or ⇒ Air condi‐
tioner with refrigerant R1234yf - General notes; Rep. gr. 87 ;
Refrigerant circuit; Renewing components .

80 – Heating
1 Overview of fitting locations - heater
⇒ “1.1 Overview of fitting locations - components not located in
passenger compartment”, page 97
⇒ “1.2 Overview of fitting locations - components in passenger
compartment (front)”, page 99
1.1 Overview of fitting locations - compo‐

nents not located in passenger compart‐
ment
Continued coolant circulation pump, coolant shut-off valve, heat‐
ed rear window ⇒ page 97
Plenum chamber water drain, forced ventilation vents for pas‐
senger compartment ⇒ page 98
Continued coolant circulation pump, coolant shut-off valve, heat‐

ed rear window
1 - Ambient temperature sen‐

sor - G17-
❑ Checking ⇒ Vehicle di‐
agnostic tester (“Guided
Fault Finding”) and
⇒ Current flow dia‐
grams, Electrical fault
finding and Fitting loca‐
tions
Note
The measured value of the ambient

temperature sensor - G17- is evalu‐
ated by the onboard supply control
unit - J519- .
❑ Removing and installing
⇒ “9.2 Removing and in‐
stalling ambient temper‐
ature sensor G17 ”,
page 362
2 - Continued coolant circula‐
tion pump - V51- / auxiliary
pump for heating - V488-
❑ Different designations
depending on engine
version: -V51- or -V488-
❑ Shown on 1.4 ltr. TFSI
engine as an example
❑ May be installed in cool‐
ant circuit (depending
on engine version) ⇒
Engine, mechanics;
Rep. gr. 19 ; Cooling
system/coolant; Con‐
nection diagram - cool‐
ant hoses and ⇒ Current
flow diagrams, Electri‐
cal fault finding and Fitting locations
1. Overview of fitting locations - heater 97

❑ Activated by engine control unit when requested by operating unit ( heater control unit - J65- )
❑ Also supports engine coolant pump to improve flow of coolant through heat exchanger at certain engine
speeds to enhance heating output
❑ Removing and installing ⇒ Engine, mechanics; Rep. gr. 19 ; Cooling system/coolant; Connection dia‐
gram - coolant hoses .
3 - Fresh air intake
❑ Removing and installing ⇒ “6.7 Removing and installing fresh air intake”, page 329
4 - Heated rear window - Z1-
❑ Notes on operation of heated rear window ⇒ page 12
❑ Checking activation and operation of seat heating ⇒ Vehicle diagnostic tester (“Guided Fault Finding”)
and ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
5 - Coolant shut-off valve - N82-
❑ Shown on 1.8 ltr. TFSI engine as an example
❑ Installed in coolant circuit depending on engine version ⇒ Engine, mechanics; Rep. gr. 19 ; Cooling
system/coolant; Overview of fitting locations - cooling system and ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations
❑ Activated by engine control unit following release by operating unit ( heater control unit - J65- )
❑ Depending on setting on operating unit ( heater control unit - J65- ), blocks flow of coolant through heat
exchanger when engine is cold e.g. to accelerate warm-up of engine
❑ Removing and installing ⇒ Engine, mechanics; Rep. gr. 19 ; Cooling system/coolant; Overview of fitting
locations - cooling system

senger compartment
98 Rep. gr.80 - Heating

1 - Plenum chamber water

drain (left-side)
❑ Checking and cleaning
⇒ “6.10 Checking ple‐
num chamber water
drain”, page 333
drain (right-side)
num chamber water
drain”, page 333
3 - Forced ventilation vent in
passenger compartment
(right-side)
❑ Checking
⇒ “6.8 Checking forced
ventilation vents in pas‐
senger compartment”,
page 329
stalling forced ventila‐
tion vents in passenger
compartment”,
page 332
passenger compartment (left-
side)
❑ Checking
page 329
tion vents in passenger compartment”, page 332

nents in passenger compartment (front)
Passenger compartment (front left) ⇒ page 99
Passenger compartment (front right) ⇒ page 100
Passenger compartment (front left)

1 - Footwell vent (left-side)

❑ Exploded view
⇒ “6.1 Exploded view -
routing of air flow and air
distribution in passen‐
ger compartment”, page
319
2 - Dash panel vent (left-side)
❑ With sealing plug in‐
stead of vent tempera‐
ture sender on vehicles
without automatic air
conditioner
❑ A loose or missing seal‐
ing plug will cause flow
noise
❑ Exploded view
319
3 - Side dash panel vent (left-
side)
❑ Exploded view
319
4 - Dash panel vent (centre
left)
❑ Exploded view
319
5 - Front seat (left-side)
❑ Equipment version with seat heating
❑ Different versions ⇒ Electronic parts catalogue
❑ Notes on operation of seat heating ⇒ page 10
❑ Servicing seat heating ⇒ General body repairs, interior; Rep. gr. 74 ; Covers and padding on front seats
6 - Operating unit ( heater control unit - J65- )
❑ Checking ⇒ Vehicle diagnostic tester (“Guided Fault Finding”) and ⇒ Current flow diagrams, Electrical
⇒ “7.2 Removing and installing operating and display unit J65 / J301 / J255 ”, page 340
Passenger compartment (front right)

1 - Plug
❑ In underbody (instead of
condensation drain on
vehicles with air condi‐
tioner)
2 - Front seat (right-side)
❑ Equipment version with
seat heating
❑ Different versions ⇒
Electronic parts cata‐
logue
❑ Notes on operation of
seat heating ⇒ page 10
❑ Checking activation and
operation of seat heat‐
ing ⇒ Vehicle diagnostic
tester (“Guided Fault
Finding”) and ⇒ Current
cal fault finding and Fit‐
ting locations
❑ Servicing seat heating
⇒ General body repairs,
interior; Rep. gr. 74 ;
Covers and padding on
front seats
3 - Dash panel vent (centre
right)
❑ Exploded view
319
4 - Windscreen dash panel
vent
❑ Exploded view
⇒ “6.1 Exploded view - routing of air flow and air distribution in passenger compartment”, page 319
5 - Side dash panel vent (right-side)
❑ Exploded view
6 - Dash panel vent (right-side)
❑ With sealing plug instead of vent temperature sender on vehicles without automatic air conditioner
❑ A loose or missing sealing plug will cause flow noise
❑ Exploded view
7 - Footwell vent (right-side)
❑ Exploded view
8 - Heater
❑ Exploded view ⇒ “2.1 Exploded view - heater unit”, page 102

2 Heater
⇒ “2.1 Exploded view - heater unit”, page 102
⇒ “2.2 Removing and installing fresh air blower V2 ”, page 107
⇒ “2.3 Removing and installing fresh air blower control unit J126
”, page 107
⇒ “2.4 Removing and installing auxiliary air heater element Z35 ”,
page 107
⇒ “2.5 Removing and installing temperature flap control motor
V68 with potentiometer G92 ”, page 108
⇒ “2.6 Removing and installing air recirculation flap control motor
V113 ”, page 108
⇒ “2.7 Removing and installing air distribution flap control motor
⇒ “2.8 Removing and installing dust and pollen filter”, page 108
⇒ “2.9 Removing and installing heat exchanger”, page 109
⇒ “2.10 Removing and installing heater unit”, page 109
⇒ “2.11 Dismantling and assembling heater unit”, page 109
2.1 Exploded view - heater unit
Note
♦ The heater unit is available in different versions and from dif‐

ferent manufacturers. The individual components of the vari‐
ous heaters are similar but not identical; the combination of
components by different manufacturers is therefore not per‐
missible ⇒ Electronic parts catalogue .
♦ The following illustrations show a Valeo heater; distinguishing
features compared to heaters from other manufacturers
⇒ “1.1 Identification of heater and air conditioning unit”,
page 1 .
Heater, flap control ⇒ page 102

Heater unit, heat exchanger, auxiliary air heater element
⇒ page 104
Heater, flap control

1 - Operating lever
❑ For actuating defroster
flap and air distribution
flap
2 - Air distribution flap control
motor - V428-
❑ With potentiometer for
air distribution flap con‐
trol motor - G645-
tions
⇒ page 253
3 - Bolt
❑ 2x
❑ Tightening torque
⇒ page 262
4 - Bolt
❑ 3x
⇒ page 262
5 - Bolt
❑ 2x
⇒ page 262
6 - Temperature flap control
motor - V68-
temperature flap control motor - G92-
❑ Removing and installing ⇒ page 238
7 - Operating lever
❑ For actuation of warm air flap
8 - Heater
❑ Different versions ⇒ page 1
❑ It is not permissible to combine components from different manufacturers
⇒ “1.1 Identification of heater and air conditioning unit”, page 1
❑ The following illustrations show a Valeo heater.
❑ The design is largely identical to that of the heater/air conditioning unit.
❑ Not fitted: expansion valve, condensation drain, evaporator etc.
❑ A honeycomb element is installed instead of the evaporator.
❑ There is no opening for the expansion valve in the seal for the plenum chamber back wall, or it is closed
off by a foam pad.
❑ Exploded view ⇒ page 291
9 - Actuator for defroster and air distribution flap
2. Heater 103
Heater unit, heat exchanger, auxiliary air heater element
1 - Bolt
⇒ page 262
2 - Coolant pipe for heat ex‐
changer
logue
❑ Coolant supply from en‐
gine
⇒ page 310
3 - Clip
❑ Can also be replaced by
a clamp in the course of
service work
changer
logue
❑ Coolant return to engine
⇒ page 310
5 - O-ring
logue
❑ Renew
6 - Cover
❑ For heat exchanger
7 - Bolt
❑ Tightening torque ⇒ page 262
8 - Foam spacer
❑ For seal/insulation
❑ Vehicles without air conditioner: no opening for expansion valve ⇒ Electronic parts catalogue
❑ Note installation position
9 - Bracket
❑ For coolant pipes
10 - Foam
❑ For insulation
11 - Heater
❑ The opening for the supplementary heater is sealed on vehicles without auxiliary air heater element -
Z35-
❑ Dismantling and assembling ⇒ page 291
12 - Heat exchanger

13 - Auxiliary air heater element - Z35-

❑ Checking activation ⇒ page 8
14 - Bolt
❑ 2x
15 - Electrical wire
❑ For auxiliary air heater element - Z35-
❑ Detaching and attaching ⇒ “5.17 Removing and installing auxiliary air heater element Z35 ”, page 298
16 - Earth wire
❑ For supplementary heater
17 - Bolt
❑ 3x
18 - Clamp
19 - O-ring
❑ Renewing ⇒ “5.18 Removing and installing heat exchanger”, page 299
Air intake duct, dust and pollen filter, fresh air blower, flap control
2. Heater 105
1 - Bolt/clip
❑ 2x
❑ Tightening torque for
bolt ⇒ page 269
Note
♦ Different versions; renew clip

version if necessary ⇒ Electron‐
ic parts catalogue .
♦ Use e.g. pliers or a screwdriver
to prise out version with clip.
2 - Cover
3 - Housing (top section)
4 - Bolt
❑ 2x
⇒ page 262
5 - Air intake duct
❑ Do not dismantle
❑ With fresh air and air re‐
circulation flap
logue
⇒ page 328
6 - Not installed
Only installed on vehicles with
automatic air conditioner
⇒ “5.2 Exploded view - attach‐
ments for heater and air condi‐
tioning unit and air intake box”, page 269
7 - Not installed
Only installed on vehicles with automatic air conditioner
⇒ “5.2 Exploded view - attachments for heater and air conditioning unit and air intake box”, page 269
8 - Air recirculation flap control motor - V113-

❑ Without potentiometer with limit switches at end stops ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations
9 - Bolt
❑ 2x
10 - Dust and pollen filter

Note
Not fitted with an activated charcoal

filter insert at the factory on vehicles
without air conditioner and vehicles
with manually controlled air condi‐
tioner ⇒ page 83
❑ Change interval ⇒ Maintenance tables
11 - Cover
❑ For dust and pollen filter
12 - Fresh air blower - V2-
13 - Fresh air blower control unit - J126-
14 - Bolt
❑ 2x
2.2 Removing and installing fresh air blower

- V2-
The removal and installation procedures are the same as for ve‐
hicles with air conditioner ⇒ page 296 .
Note
Checking ⇒ Vehicle diagnostic tester (“Guided Fault Finding”) and

tions

control unit - J126-
Note

tions
2.4 Removing and installing auxiliary air

heater element - Z35-
2. Heater 107
Note

tions
2.5 Removing and installing temperature

flap control motor - V68- with potentiom‐
eter -G92-
Note

tions
2.6 Removing and installing air recirculation

flap control motor - V113-
Note

tions
2.7 Removing and installing air distribution

flap control motor - V428- with potenti‐
ometer -G645-
Note

tions
2.8 Removing and installing dust and pollen

filter
Note
Different filters are available depending on equipment

⇒ page 83 and ⇒ Electronic parts catalogue .

2.9 Removing and installing heat exchanger

2.10 Removing and installing heater unit
Note
The design of the heater is largely identical to that of the heater/

air conditioning unit. The expansion valve, condensation drain,
evaporator etc. are not fitted.
The removal and installation procedures are the same as for the
air conditioning unit ⇒ page 287 .
2.11 Dismantling and assembling heater unit

The dismantling and assembly procedures for the heater unit are
the same as for the heater/air conditioning unit of the manually
controlled air conditioner ⇒ page 291 .
Note
The design of the heater is largely identical to that of the heater/

air conditioning unit. The expansion valve, condensation drain,
evaporator etc. are not fitted; a honeycomb element is fitted in the
heater unit instead of the evaporator. There is no opening for the
expansion valve in the seal for the plenum chamber back wall, or
it is closed off by a foam pad.
2. Heater 109
3 Air duct
⇒ “3.1 Exploded view - routing of air flow and air distribution in
⇒ “3.2 Removing and installing vents (front)”, page 110
⇒ “3.3 Removing and installing fresh air intake”, page 110
⇒ “3.4 Checking forced ventilation vents in passenger compart‐
ment”, page 110
⇒ “3.5 Removing and installing forced ventilation vents in pas‐
senger compartment”, page 110
⇒ “3.6 Checking plenum chamber water drain”, page 110
3.1 Exploded view - routing of air flow and

air distribution in passenger compart‐
ment
The exploded view of the routing of air flow and the air distribution
in the passenger compartment is the same as for vehicles with a
manually controlled air conditioner ⇒ page 319 .
3.2 Removing and installing vents (front)

hicles with an air conditioner; removing and installing
⇒ “6.2.3 Removing and installing dash panel vents”, page 324
and ⇒ General body repairs, interior; Rep. gr. 70 ; Dash panel;
Exploded view - dash panel .
3.3 Removing and installing fresh air intake

3.4 Checking forced ventilation vents in

3.5 Removing and installing forced ventila‐

tion vents in passenger compartment
3.6 Checking plenum chamber water drain

Checking is the same as for a vehicle with air conditioner
⇒ page 333 .

4 Operating and display unit

⇒ “4.1.1 Overview of fitting locations - operating and display unit
J65 ”, page 111
⇒ “4.2.1 Removing and installing operating and display unit J65
”, page 112
4.1 Overview of fitting locations - operating

and display unit
J65 ”, page 111
4.1.1 Overview of fitting locations - operating

and display unit -J65-
Heater control unit - J65-
A - Operating unit ( heater con‐

trol unit - J65- ) for vehicles
without seat heating
1 - Rotary temperature control
2 - Button for air recirculation
mode
❑ If LED lights up, “air re‐
circulation mode” is se‐
lected
❑ “Air recirculation mode”
is cancelled when air
distribution is set to “de‐
frost” function (air to
windscreen)
3 - Rotary control for fresh air
blower - V2-
4 - Heated rear window button
❑ If LED lights up, “Rear
window heating on” is
selected
❑ Rear window heating
can be permanently
switched on by pressing
and holding button
⇒ page 13
5 - Rotary control for setting air
distribution
❑ Different versions (with
different symbols) ⇒
4. Operating and display unit 111

logue
B - Operating unit ( heater control unit - J65- ) for vehicles with seat heating
1 - Button for air recirculation mode
❑ If LED lights up, “air recirculation mode” is selected
❑ “Air recirculation mode” is cancelled when air distribution is set to “defrost” function (air to windscreen)
3 - Button for left seat heating
❑ LEDs indicate selected setting
❑ Selected setting can be reduced by one level after a pre-set time has elapsed ⇒ page 11
4 - Button for right seat heating
❑ Selected setting can be reduced by one level after a pre-set time has elapsed ⇒ page 11
5 - Rotary control for setting air distribution
❑ Different versions (with different symbols) ⇒ Electronic parts catalogue
❑ If LED lights up, “Rear window heating on” is selected
❑ Rear window heating can be permanently switched on by pressing and holding button ⇒ page 13
7 - Rotary control for fresh air blower - V2-
4.2 Removing and installing operating and

display unit
⇒ “4.2.1 Removing and installing operating and display unit J65
”, page 112
4.2.1 Removing and installing operating and

display unit -J65-
hicles with air conditioner
⇒ “7.2 Removing and installing operating and display unit J65 /
J301 / J255 ”, page 340 .
Note

tions

5 Further control components

⇒ “5.1 Removing and installing ambient temperature sensor G17
”, page 113
⇒ “5.2 Removing and installing continued coolant circulation
pump V51 / auxiliary pump for heating V488 ”, page 113
⇒ “5.3 Removing and installing coolant shut-off valve N82 ”, page
113
5.1 Removing and installing ambient tem‐

perature sensor - G17-
hicles with air conditioner
”, page 362 .
Note

tions
5.2 Removing and installing continued cool‐

ant circulation pump - V51- / auxiliary
pump for heating - V488-
Note
♦ Different designations depending on engine version ( -V51- or

-V488- ).
♦ -V51- / -V488- is installed in the coolant circuit (depending on
engine version) ⇒ Engine, mechanics; Rep. gr. 19 ; Cooling
system/coolant; Connection diagram - coolant hoses and
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations.
Removing and installing ⇒ Engine, mechanics; Rep. gr. 19 ;

Coolant pump/thermostat assembly; Exploded view - electric
coolant pump
5.3 Removing and installing coolant shut-off

valve - N82-
Note
Depending on the engine version, the coolant shut-off valve -

N82- is installed in the coolant circuit ⇒ Engine, mechanics; Rep.
gr. 19 ; Cooling system/coolant; Connection diagram - coolant
hoses and ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.

Cooling system/coolant; Connection diagram - coolant hoses .
5. Further control components 113

87 – Air conditioning system

1 Overview of fitting locations - air con‐
ditioner
⇒ “1.1 Overview of fitting locations - components not located in
⇒ “1.2 Overview of fitting locations - components in passenger
compartment (front)”, page 127

nents not located in passenger compart‐
ment
Continued coolant circulation pump, coolant shut-off valve, air
quality sensor, heated rear window ⇒ page 114
Mechanically driven air conditioner compressor, condenser, serv‐
ice connections, expansion valve, condensation drain
⇒ page 116
senger compartment ⇒ page 119
Additional components (and components fitted differently on A3
e-tron) on vehicles with high-voltage system (A3 e-tron)
⇒ page 120
Continued coolant circulation pump, coolant shut-off valve, air

quality sensor, heated rear window
114 Rep. gr.87 - Air conditioning system

1 - Ambient temperature sen‐

sor - G17-
tions
Note
Measured value of -G17- is evalu‐

ated by -J519- .
stalling ambient temper‐
ature sensor G17 ”,
page 362
2 - Continued coolant circula‐
tion pump - V51-
❑ Shown on 1.4 ltr. TFSI
engine as an example
❑ May be installed in cool‐
ant circuit (depending
on engine version) ⇒
Engine, mechanics;
Rep. gr. 19 ; Cooling
system/coolant; Con‐
nection diagram - cool‐
ant hoses and ⇒ Current
ting locations
❑ Activated by engine
control unit when re‐
quested by operating
unit ( air conditioning
system control unit - J301- / Climatronic control unit - J255- )
❑ Also supports engine coolant pump to improve flow of coolant through heat exchanger at certain engine
speeds to enhance heating output
❑ Removing and installing ⇒ Engine, mechanics; Rep. gr. 19 ; Coolant pump/thermostat assembly; Ex‐
ploded view - electric coolant pump
3 - Fresh air intake
Note
Depending on the vehicle version, a

dust filter may be installed instead of
the intake grille (introduction not yet
finalised).
4 - Air quality sensor - G238- with humidity sender in fresh air intake duct - G657-
❑ Only installed on vehicles with automatically controlled air conditioner
5 - Heated rear window - Z1-
❑ Notes on operation of heated rear window ⇒ page 12
1. Overview of fitting locations - air conditioner 115

❑ Checking activation and operation of heated rear window ⇒ Vehicle diagnostic tester (“Guided Fault
Finding”) and ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
6 - Coolant shut-off valve - N82-
❑ Shown on 1.8 ltr. TFSI engine as an example
❑ May be installed in coolant circuit (depending on engine version) ⇒ Engine, mechanics; Rep. gr. 19 ;
Cooling system/coolant; Connection diagram - coolant hoses and ⇒ Current flow diagrams, Electrical
❑ Activated by engine control unit when enabled by operating unit ( air conditioning system control unit -
J301- / Climatronic control unit - J255- )
❑ Depending on setting on operating unit ( air conditioning system control unit - J301- / Climatronic control
unit - J255- ), e.g. with air conditioner switched off, blocks flow of coolant through heat exchanger when
engine is cold to accelerate warm-up of engine
❑ Removing and installing ⇒ Engine, mechanics; Rep. gr. 19 ; Cooling system/coolant; Connection dia‐
gram - coolant hoses .
Tightening torque for nuts at fresh air intake
Note
First tighten nuts on left and right -arrows- slightly and then tighten
centre nut -arrow- before tightening all three nuts to the final tor‐
que in the same sequence.
– Tighten nuts -arrows- to 3 Nm.
Tightening torque for nuts at drip rail

– Tighten nuts -arrows- to 3 Nm.
Mechanically driven air conditioner compressor, condenser, serv‐

ice connections, expansion valve, condensation drain

1 - Condenser
❑ With integrated receiver
❑ Exploded view
condenser, air condi‐
tioner compressor, re‐
frigerant lines and ex‐
pansion valve”,
page 146
2 - Desiccant cartridge
❑ Exploded view
pansion valve”,
page 146
3 - Air conditioner compressor
regulating valve - N280-
tions
❑ Not on vehicles with
high-voltage system
Note
♦ Certain malfunctions of -N280-

(e.g. sticking valve or open cir‐
cuit in coil) can lead to problems
with air conditioner compressor
(no cooling output from air con‐
ditioner, evaporator icing up
etc.). If -N280- (and not air con‐
ditioner compressor itself) is
cause of problem, air conditioner
compressor can be serviced by
renewing -N280- ⇒ Air condi‐
tioner with refrigerant R134a;
Rep. gr. 87 ; Renewing compo‐
nents of refrigerant circuit , or ⇒
Air conditioners with refrigerant
R1234yf - General information;
Rep. gr. 87 ; Refrigerant circuit;
Renewing components .
♦ -N280- is not available as a re‐
placement part for all air condi‐
tioner compressors. If -N280-
cannot be obtained separately
for a particular air conditioner
compressor (different versions
available), the entire air condi‐
tioner compressor must be re‐
newed if problems occur ⇒
Electronic parts catalogue .

❑ Mechanically driven; not on vehicles with high-voltage system
❑ For correct version refer to ⇒ Electronic parts catalogue

❑ Exploded view ⇒ “3.1 Exploded view - drive unit for air conditioner compressor”, page 204
❑ Different versions depending on refrigerant (R134a or R1234yf) ⇒ Electronic parts catalogue
Note
Vehicles with a 5-cylinder engine

(Audi RS 3) have 1 or 2 poly V-belts
on the air conditioner compressor
(depending on the engine type). The
air conditioner compressor is there‐
fore provided with a single or dou‐
ble-belt pulley ⇒ 5-cylinder direct
injection engine (2.5 ltr. 4-valve
TFSI); Rep. gr. 13 ; Cylinder block
(pulley end); Removing and instal‐
ling poly V-belts .
5 - Service connection (high-pressure side)

❑ For measuring, discharging and charging
Caution
Danger from escaping
pressurised refrigerant if
valve in refrigerant line is
defective.
Danger of frostbite on
skin and other parts of
the body.
Always
♦ discharge refrig‐
erant circuit before re‐
moving component; con‐
nection has no valve ⇒
Air conditioner with refrig‐
erant R134a; Rep. gr.
87 ; General information
on air conditioning sys‐
tems , or ⇒ Air condition‐
er with refrigerant
R1234yf - General notes;
Rep. gr. 87 ; Refrigerant
circuit; General descrip‐
tion of refrigerant circuit
components .
❑ Different versions depending on refrigerant (R134a or R1234yf)

⇒ “2.14 Differences in service connections depending on refrigerant (R134a or R1234yf)”, page 194 and
⇒ Electronic parts catalogue
❑ Exploded view
⇒ “2.2 Exploded view - condenser, air conditioner compressor, refrigerant lines and expansion valve”,
page 146
6 - Pressure sender for refrigerant circuit - G805-
❑ Exploded view
page 146
⇒ “2.3 Removing and installing pressure sender for refrigerant circuit G805 ”, page 160
Note
Not always fitted on vehicles with

high-voltage system ⇒ page 120

7 - Service connection (low-pressure side)

❑ For measuring and discharging
Caution
defective.
the body.
Always
er with refrigerant
components .

❑ Exploded view
page 146
8 - Condensation drain
❑ Checking ⇒ “5.20 Checking condensation drain hose”, page 313
❑ Removing and installing ⇒ “5.21 Removing and installing condensation drain hose”, page 316
9 - Expansion valve
❑ Exploded view
page 146

senger compartment


drain (left-side)
num chamber water
drain”, page 333
drain (right-side)
num chamber water
drain”, page 333
(right-side)
❑ Checking
page 329
tion vents in passenger
compartment”,
page 332
passenger compartment (left-
side)
❑ Checking
page 329
tion vents in passenger compartment”, page 332
Additional components (and components fitted differently on A3

e-tron) on vehicles with high-voltage system (A3 e-tron)

1 - High-voltage heater (PTC)

- Z115- (with high-voltage
heater (PTC) control unit -
J848- )
❑ For all work on - Z115-
(and on vehicles with
high-voltage system),
note additional warn‐
ings for working on such
vehicles ⇒ page 19 and
⇒ 4-cylinder direct in‐
jection engine (1.2, 1.4
ltr. 4-valve TFSI EA
211); Rep. gr. 00 ; Safe‐
ty precautions; Safety
precautions when work‐
ing on vehicles with
high-voltage system .
tions
⇒ page 356
❑ Incorporation of - Z115-
into coolant circuit to air
conditioner heat ex‐
changer ⇒ page 343
2 - Coolant changeover valve
2 - N633-
⇒ page 351 and ⇒ En‐
gine, mechanics; Rep.
gr. 19 ; Coolant pump/
thermostat assembly
❑ Checking activation and operation of -N633- ⇒ Vehicle diagnostic tester (“Guided Fault Finding” for en‐
gine), ⇒ Rep. gr. 19 ; Coolant pump/thermostat assembly and ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations
❑ Checking connections between -N633- and engine coolant circuit
⇒ “8.1 Incorporation of high-voltage heater (PTC) Z115 into coolant circuit”, page 343 and ⇒ Engine,
mechanics; Rep. gr. 19 ; Coolant pump/thermostat assembly
Note
♦ -N633- is activated by the corre‐

sponding engine control unit
(e.g. by engine control unit -
J623- ) if heat output is reques‐
ted from the air conditioner and
the vehicle is in electric drive
mode or the “Auxiliary air condi‐
tioner” function is active
⇒ “2.8 Auxiliary air conditioner -
vehicles with high-voltage sys‐
tem only”, page 16 , ⇒ Current
flow diagrams, Electrical fault
finding and Fitting locations and
⇒ Vehicle diagnostic tester

♦ Check correct installation posi‐

tion and operation if there is a
problem with insufficient heat
output from the air conditioner
with engine stopped and/or run‐
ning, regardless of whether -
Z115- is activated ⇒ Current flow
diagrams, Electrical fault finding
and Fitting locations and ⇒ Vehi‐
cle diagnostic tester (“Guided
Fault Finding”).
♦ So that the coolant heated up by
-Z115- is conveyed through the
air conditioner heat exchanger,
the coolant pump for high-tem‐
perature circuit - V467- and the
coolant valve for gearbox -
N488- must also be activated (by
the corresponding engine con‐
trol unit). To ensure that the cool‐
ant flows in the right direction,
the non-return valves fitted in the
coolant circuit must also be in‐
stalled correctly and they must
operate correctly. For further in‐
formation, refer to
⇒ “8.1 Incorporation of high-volt‐
age heater (PTC) Z115 into cool‐
ant circuit”, page 343 ,
⇒ “2.8 Auxiliary air conditioner -
vehicles with high-voltage sys‐
tem only”, page 16 , ⇒ Engine,
mechanics; Rep. gr. 19 ; Cooling
system/coolant; Connection dia‐
gram - coolant hoses , ⇒ Vehicle
diagnostic tester (“Guided Fault
Finding”) and ⇒ Current flow di‐
agrams, Electrical fault finding
3 - Coolant changeover valve 1 - N632-

❑ Removing and installing ⇒ page 351 and ⇒ 4-cylinder direct injection engine (1.2, 1.4 ltr. 4-valve TFSI
EA 211); Rep. gr. 19 ; Coolant pump/thermostat assembly; Removing and installing coolant valves
❑ Checking activation and operation of -N632- ⇒ Vehicle diagnostic tester (“Guided Fault Finding” for en‐
gine), ⇒ Engine, mechanics; Rep. gr. 19 ; Coolant pump/thermostat assembly and ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations
❑ Checking connections between -N632- and coolant circuit of high-voltage system ⇒ 4-cylinder direct
injection engine (1.2, 1.4 ltr. 4-valve TFSI EA 211); Rep. gr. 19 ; Cooling system/coolant; Connection
diagram - coolant hoses, cooling components for high-voltage system .

Note
-N632- is activated by the corre‐

sponding engine control unit (e.g.
engine control unit - J623- ) if the
power and control electronics for
electric drive - JX1- or the control
unit for high-voltage battery charg‐
ing unit - J1050- need to be cooled.
⇒ Vehicle diagnostic tester (“Guided
Fault Finding”), ⇒ Current flow dia‐
grams, Electrical fault finding and
Fitting locations and ⇒ 4-cylinder
direct injection engine (1.2, 1.4 ltr. 4-
valve TFSI EA 211); Rep. gr. 19 ;
Cooling system/coolant; Connec‐
tion diagram - coolant hoses, cool‐
ing components for high-voltage
system .
4 - Refrigerant shut-off valve for high-voltage battery heat exchanger - N542-

❑ Further information
⇒ “2.1.2 System overview - refrigerant circuit, vehicles with high-voltage system”, page 138
5 - Refrigerant line with restrictor
❑ A restrictor (constriction) is fitted in this refrigerant line ⇒ page 146 .
❑ Before removing component, refrigerant shut-off valve for high-voltage battery heat exchanger - N542-
must be detached ⇒ page 169 , and refrigerant line must be disconnected from high-voltage battery heat
exchanger ⇒ page 352 .
Note
♦ Diameter of restrictor hole is ap‐

prox. 0.7 mm. Depending on the
version of the refrigerant line, the
restrictor is either only inserted
or fixed in position in the refrig‐
erant line. If it is inserted, there
may be a strainer for separating
float elements, which may block
off the restrictor hole.
♦ When the refrigerant shut-off
valve for high-voltage battery
heat exchanger - N542- is open,
the restrictor restricts the flow of
coolant to the high-voltage bat‐
tery heat exchanger (and thus its
cooling output).
6 - High-voltage battery heat exchanger

7 - Refrigerant shut-off valve for heater and air conditioner unit - N541-
❑ Checking
⇒ “4.8.5 Checking cooling output - vehicles with automatically controlled air conditioner (with high-voltage

system)”, page 64 , ⇒ Vehicle diagnostic tester (“Guided Fault Finding”) and ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations
8 - Coolant valve for high-voltage battery - N688-
EA 211); Rep. gr. 19 ; Coolant pump/thermostat assembly; Removing and installing coolant valves
❑ Checking connections between heat exchanger for high-voltage battery ("chiller"), coolant pump for high-
voltage battery - V590- and -N688- in coolant circuit of high-voltage system
⇒ “8.2 Incorporation of heat exchanger for high-voltage battery into coolant circuit of high-voltage sys‐
tem”, page 347 and ⇒ 4-cylinder direct injection engine (1.2, 1.4 ltr. 4-valve TFSI EA 211); Rep. gr. 19 ;
Cooling system/coolant; Connection diagram - coolant hoses, cooling components for high-voltage sys‐
tem .
❑ Checking operation and activation of -V590- and -N688- ⇒ Vehicle diagnostic tester (“Guided Fault Find‐
ing” for hybrid battery energy management system) and ⇒ 4-cylinder direct injection engine (1.2, 1.4 ltr.
4-valve TFSI EA 211); Rep. gr. 19 ; Cooling system/coolant; Connection diagram - coolant hoses, cooling
components for high-voltage system .
1 - Refrigerant pressure and

temperature sender - G395-
tions
❑ Only installed on certain
versions (e.g. on vehi‐
cles for North America)
⇒ Electronic parts cata‐
logue
❑ Exploded view - electri‐
cally driven air condi‐
frigerant lines, high-
voltage battery heat
exchanger (vehicles
with high-voltage sys‐
tem) ⇒ page 153
⇒ “2.1.2 System over‐
view - refrigerant circuit,
vehicles with high-volt‐
age system”, page 138
2 - Electrically driven air condi‐
tioner compressor
❑ With control unit for air
conditioning compres‐
sor - J842- and electrical
air conditioner compres‐
sor - V470-
❑ For all work on -V470-
(and on vehicles with
high-voltage system),
note additional warn‐
ings for working on such vehicles ⇒ page 19 and ⇒ 4-cylinder direct injection engine (1.2, 1.4 ltr. 4-valve
TFSI EA 211); Rep. gr. 00 ; Safety precautions; Safety precautions when working on vehicles with high-
voltage system .


⇒ “3.5.2 Removing and installing electrically driven air conditioner compressor”, page 232
❑ ⇒ “3.1.3 Exploded view - drive unit for electrically driven air conditioner compressor”, page 210
❑ Different versions (e.g. for vehicles for Europe or for North America) ⇒ Electronic parts catalogue and
Note
The electrical air conditioner com‐

pressor - V470- is supplied with
electric power via a fuse fitted in the
electric drive - JX1-
⇒ “9.8 Removing and installing fuse
for electrical air conditioner com‐
pressor”, page 372 , ⇒ 4-cylinder
direct injection engine (1.2, 1.4 ltr. 4-
Power and control electronics for
electric drive and ⇒ Current flow di‐
agrams, Electrical fault finding and
Fitting locations.
3 - Coolant pump for high-temperature circuit - V467-

❑ Removing and installing ⇒ Engine, mechanics; Rep. gr. 19 ; Coolant pump/thermostat assembly
❑ Check connections between -V467- and engine coolant circuit ⇒ Engine, mechanics; Rep. gr. 19 ;
Cooling system/coolant .
❑ Check operation and activation of -V467- and coolant changeover valve 2 - N633- ⇒ Vehicle diagnostic
tester (“Guided Fault Finding”) and ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
❑ For further information, refer to ⇒ Item 2 (page 121) .
Caution
defective.
the body.
Always
er with refrigerant
components .


Caution
defective.
the body.
Always
er with refrigerant
components .

❑ Only installed on certain versions (e.g. not installed on vehicles for North America) ⇒ Electronic parts
catalogue and ⇒ Vehicle diagnostic tester (“Guided Fault Finding”).
7 - Power and control electronics for electric drive - JX1-
❑ With fuse protection for electrical air conditioner compressor - V470- ⇒ 4-cylinder direct injection engine
(1.2, 1.4 ltr. 4-valve TFSI EA 211); Rep. gr. 93 ; Power and control electronics for electric drive and
⇒ Current flow diagrams, Electrical fault finding and Fitting locations
EA 211); Rep. gr. 93 ; Power and control electronics for electric drive .
❑ Checking ⇒ Vehicle diagnostic tester (“Guided Fault Finding” for air conditioner and battery regulation)
Note
The electrical air conditioner com‐

pressor - V470- is supplied with
electric power via a fuse fitted in the
electric drive - JX1- .


nents in passenger compartment (front)
Passenger compartment (front left) ⇒ page 127
Passenger compartment (front right) ⇒ page 129
Passenger compartment (front left)
1 - Footwell vent (left-side)

❑ Exploded view
319
❑ Exploded view
319
3 - Side dash panel vent (left-
side)
❑ Sealing plug instead of
vent temperature send‐
er on vehicles with heat‐
er or manually control‐
led air conditioner
ing plug or an incorrectly
installed vent tempera‐
ture sender will cause
flow noise
❑ Exploded view
319
4 - Left vent temperature send‐
er - G150-
❑ Only installed on vehi‐
cles with automatically
controlled air condition‐
er
❑ An incorrectly installed vent temperature sender will cause flow noise
⇒ “5.8 Removing and installing vent temperature sender G150 / G151 ”, page 286
5 - Dash panel vent (centre left)
❑ Exploded view
6 - Air conditioner operating unit
♦ Air conditioning system control unit - J301- (manually controlled air conditioner)

♦ Climatronic control unit - J255- (automatically controlled air conditioner)

⇒ “7.2 Removing and installing operating and display unit J65 / J301 / J255 ”, page 340
Note
♦ On vehicles with air conditioning

system control unit - J301- , no
humidity sender - G355- is instal‐
led. The permissible stop time is
calculated using characteristic
curves which are influenced by
the measured outside tempera‐
ture, the function “air recircula‐
tion mode” and the status of the
windscreen wipers. In order for -
J301- to allow the stop function,
the time calculated must be
greater than approx. 20 sec‐
onds. To prevent the front and
door windows from misting up,
the stop time may be reduced at
low outside temperatures when
the air recirculation mode is ac‐
tive or if it is raining. If the time
calculated for the stop function is
less than approx. 20 seconds,
this will be prevented.
♦ For the A3 Cabriolet, neck heat‐
ing is available as optional equip‐
ment. Vehicles with neck heating
are equipped with an additional
vent in the seat and with addi‐
tional buttons for switching the
neck heating on and off in the air
conditioner operating unit ( Cli‐
matronic control unit - J255- ).
⇒ “2.7 Neck heating”, page 14 .
♦ Different versions of -J255- for
vehicles with or without high-
voltage system. Vehicles with
high-voltage system: different
versions e.g. for vehicles for Eu‐
rope or for North America
7 - Infrared sensor
❑ For determining temperature in passenger compartment
❑ With automatically controlled air conditioner only; integrated into operating unit -J255-
❑ A contaminated infrared sensor will cause problems with air conditioner control ⇒ Vehicle diagnostic
8 - Heater and air conditioning unit (left-side)
❑ Exploded view ⇒ “5.1 Exploded view - heater and air conditioning unit”, page 262
❑ Removing and installing ⇒ “5.9 Removing and installing heater and air conditioning unit”, page 287
❑ Dismantling and assembling
⇒ “5.11 Dismantling and assembling heater and air conditioning unit”, page 291
9 - Condensation drain
❑ Checking ⇒ “5.20 Checking condensation drain hose”, page 313
❑ Removing and installing ⇒ “5.21 Removing and installing condensation drain hose”, page 316

10 - Footwell vent temperature sender - G192-

⇒ “5.16 Removing and installing footwell vent temperature sender G192 ”, page 297
Note
Right-hand drive vehicles: installed

in duct for footwell vent (right-side)
11 - Front seat (left-side)

❑ Equipment version with seat heating
Note
For the A3 Cabriolet, neck heating is

available as optional equipment.
Vehicles with neck heating are
equipped with an additional vent in
the seat and with additional buttons
for switching the neck heating on
and off in the air conditioner operat‐
ing unit ( Climatronic control unit -
J255- ). For further information, refer
to ⇒ “2.7 Neck heating”, page 14 .
Passenger compartment (front right)

1 - Heater and air conditioning

unit (right-side)
❑ Exploded view
heater and air condition‐
ing unit”, page 262
stalling heater and air
conditioning unit”,
page 287
❑ Dismantling and assem‐
bling
⇒ “5.11 Dismantling and
assembling heater and
air conditioning unit”,
page 291
2 - Evaporator output temper‐
ature sender - G263-
tions
stalling evaporator out‐
put temperature sender
G263 ”, page 286
3 - Front seat (right-side)
❑ Equipment version with
seat heating
logue
Note
For the A3 Cabriolet, neck heating is

available as optional equipment.
Vehicles with neck heating are
equipped with an additional vent in
the seat and with additional buttons
for switching the neck heating on
and off in the air conditioner operat‐
ing unit ( Climatronic control unit -
J255- ). For further information, refer
to ⇒ “2.7 Neck heating”, page 14 .
4 - Dash panel vent (centre right)

❑ Exploded view
5 - Humidity sender - G355-

❑ Removing and installing ⇒ “9.7 Removing and installing sensors G355 / G397 / G107 ”, page 372
❑ On Audi Q2 vehicles with automatic air conditioner, sunlight penetration photosensor - G107- is combined
as one unit with humidity sender - G355- and rain and light sensor - G397- ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations
Note
♦ On vehicles with air conditioning

system control unit - J301- , no
humidity sender - G355- (no sun‐
light penetration photosensor) is
installed. The permissible stop
time is calculated using charac‐
teristic curves which are influ‐
enced by the measured outside
temperature, the “air recircula‐
tion mode” function and the sta‐
tus of the windscreen wipers. In
order for -J301- to allow the stop
function, the time calculated
must be greater than approx. 20
seconds. To prevent the front
and door windows from misting
up, the stop time may be reduced
at low outside temperatures
when the air recirculation mode
is active or if it is raining. If the
time calculated for the stop func‐
tion is less than approx. 20 sec‐
onds, this will be prevented.
♦ The humidity sender - G355- is
integrated in the rain and light
sensor - G397- and cannot be
renewed separately in the event
of a fault. Renewing rain and light
sensor - G397- (with humidity
sender - G355- ) ⇒ General body
repairs, exterior; Rep. gr. 64 ;
Windscreen; Exploded view -
windscreen or ⇒ Electrical sys‐
tem; Rep. gr. 92 ; Windscreen
wiper system .
♦ The removal procedure for -
G397- (with -G355- ) is descri‐
bed in different assembly groups
depending on the vehicle.
6 - Sunlight penetration photosensor - G107-

❑ Only installed on Audi A3 vehicles with automatic air conditioner
⇒ “9.1 Removing and installing sunlight penetration photosensor G107 ”, page 361
❑ On Audi Q2 vehicles with automatic air conditioner, sunlight penetration photosensor - G107- is combined
as one unit with humidity sender - G355- and rain and light sensor - G397- .
❑ Removing and installing - Audi Q2
⇒ “9.7 Removing and installing sensors G355 / G397 / G107 ”, page 372
7 - Windscreen dash panel vent
❑ Exploded view

8 - Side dash panel vent (right-side)

❑ Exploded view
9 - Right vent temperature sender - G151-
⇒ “5.8 Removing and installing vent temperature sender G150 / G151 ”, page 286
❑ An incorrectly installed vent temperature sender will cause flow noise
❑ Sealing plug instead of vent temperature sender on vehicles with heater or manually controlled air con‐
ditioner
❑ A loose or missing sealing plug or an incorrectly installed vent temperature sender will cause flow noise
❑ Exploded view
11 - Footwell vent (right-side)
❑ Exploded view

2 Refrigerant circuit
⇒ “2.2 Exploded view - condenser, air conditioner compressor,
refrigerant lines and expansion valve”, page 146
⇒ “2.3 Removing and installing pressure sender for refrigerant
circuit G805 ”, page 160
⇒ “2.4 Removing and installing refrigerant pressure and temper‐
ature sender G395 ”, page 161
⇒ “2.5 Checking cut-in signal for air conditioner compressor reg‐
ulating valve N280 ”, page 163
⇒ “2.6 Removing and installing refrigerant shut-off valve for heater
and air conditioner unit N541 ”, page 166
⇒ “2.7 Removing and installing refrigerant shut-off valve for high-
voltage battery heat exchanger N542 ”, page 169
⇒ “2.8 Additional weight at refrigerant line”, page 171
⇒ “2.9 Removing and installing expansion valve”, page 171
⇒ “2.10 Detaching and attaching refrigerant lines at condenser”,
page 173
⇒ “2.11 Removing and installing condenser”, page 177
⇒ “2.12 Removing and installing desiccant cartridge”, page 181
⇒ “2.13 Removing and installing refrigerant lines with internal heat
exchanger”, page 189
⇒ “2.15 Removing and installing service connections (low and
high-pressure sides)”, page 197
⇒ “2.16 Starting up air conditioner after charging refrigerant cir‐
cuit”, page 199
⇒ “8.9 Removing and installing heat exchanger for high-voltage
battery”, page 352
2.1 System overview - refrigerant circuit

⇒ “2.1.1 System overview - refrigerant circuit, vehicles without
high-voltage system”, page 133
⇒ “2.1.2 System overview - refrigerant circuit, vehicles with high-
⇒ “2.1.3 Refrigerant line with restrictor”, page 146
2.1.1 System overview - refrigerant circuit, vehicles without high-voltage system

HD = High-pressure side
ND = Low-pressure side
2. Refrigerant circuit 133


regulating valve - N280-
❑ Checking activation and
operation ⇒ page 163 ,
⇒ Vehicle diagnostic
tester (“Guided Fault
Finding”) and ⇒ Current
ting locations
Note


Note
♦ Depending on the design of the

refrigerant line and the produc‐
tion period, the refrigerant line on
the low-pressure side may be
provided with an additional
weight (vibration damper, reso‐
nator for reducing noise at refrig‐
erant line) ⇒ page 171 . Make
sure that this component is not in
contact with other components
and cannot come into contact
during operation (noise) ⇒ Elec‐

♦ Vehicles with a 5-cylinder engine

(Audi RS 3) have 1 or 2 poly V-
belts on the air conditioner com‐
pressor (depending on the en‐
gine type). The air conditioner
compressor is therefore provi‐
ded with a single or double-belt
pulley ⇒ 5-cylinder direct injec‐
tion engine (2.5 ltr. 4-valve
TFSI); Rep. gr. 13 ; Cylinder
block (pulley end); Removing
and installing poly V-belts .
3 - High-pressure safety valve
Caution
valve is defective.
the body.
Always
nection has no valve.
4 - Cap
❑ With seal
❑ Always screw on
Caution
defective.
the body.
Always
er with refrigerant
components .


6 - Connection in refrigerant line (low-pressure side)

❑ From internal heat exchanger to air conditioner compressor
❑ From expansion valve to internal heat exchanger
8 - Expansion valve
9 - Evaporator
10 - Connection in refrigerant line (high-pressure side)
❑ From internal heat exchanger to expansion valve
11 - Refrigerant line with internal heat exchanger
❑ In the internal heat exchanger, the hot liquid refrigerant flowing through the high-pressure side gives off
energy to the cold refrigerant vapour flowing through the low-pressure side, thus enhancing the efficiency
of the air conditioner.
❑ From condenser to internal heat exchanger
14 - Connection with valve
15 - Condenser

Caution
defective.
the body.
Always
er with refrigerant
components .

18 - Cap
❑ With seal
❑ Always screw on

2.1.2 System overview - refrigerant circuit, vehicles with high-voltage system

HD = High-pressure side
ND = Low-pressure side

tioner compressor
❑ Exploded view
⇒ “3.1.3 Exploded view
- drive unit for electrical‐
ly driven air conditioner
compressor”, page 210
sor - V470-
⇒ “3.5.2 Removing and
installing electrically
driven air conditioner
❑ ⇒ “3.1.3 Exploded view
- drive unit for electrical‐
ly driven air conditioner
❑ ⇒ “3.5.2 Removing and
❑ Different versions (e.g.
for vehicles for Europe
or for North America) ⇒
logue
❑ Different versions de‐
pending on refrigerant
(R134a or R1234yf) ⇒
logue
Note
♦ On vehicles with -G805- or -

G395- , there are also different
versions of the electrical air con‐
ditioner compressor - V470-
(with control unit for air condi‐
tioner compressor - J842- ) and
of the air conditioner operating
unit ( Climatronic control unit -
J255- ) in addition to the pres‐
sure sender ⇒ Vehicle diagnostic
tester (“Guided Fault Finding”)
and ⇒ Electronic parts cata‐
logue .

♦ On vehicles with a high-voltage

system, -V470- is activated (via -
J842- ) by the air conditioner op‐
erating unit ( Climatronic control
unit - J255- ) via the LIN bus
(“Guided Fault Finding”) and
⇒ Current flow diagrams, Electri‐
cal fault finding and Fitting loca‐
tions.
♦ The electrical air conditioner
compressor - V470- is supplied
with electric power via a fuse fit‐
ted in the power and control elec‐
tronics for electric drive - JX1-
⇒ “9.8 Removing and installing
fuse for electrical air conditioner
compressor”, page 372 , ⇒ 4-
cylinder direct injection engine
(1.2, 1.4 ltr. 4-valve TFSI EA
211); Rep. gr. 93 ; Power and
control electronics for electric
drive and ⇒ Current flow dia‐
grams, Electrical fault finding
♦ The compressor version may dif‐
fer depending on the production
period and engine ⇒ Electronic
parts catalogue .
♦ The air conditioner compressors
are available as replacement
parts with different oil capacities;
please observe the oil quantity in
the compressor and the exact
part number ⇒ Electronic parts
catalogue and
⇒ “5.2 Approved refrigerant oils
and refrigerant oil capacities”,
page 90 , ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ;
Capacities for refrigerant R134a/
refrigerant oil and approved re‐
frigerant oils , or ⇒ Air condition‐
er with refrigerant R1234yf -
General notes; Rep. gr. 00 ;
Technical data .

♦ There may be different refriger‐

ant oil capacities for the refriger‐
ant circuit depending on the type
of air conditioner compressor.
The reason for the different oil
quantities in the air conditioner
compressor for an otherwise
identical refrigerant circuit is the
design of the actual compressor;
please note the different oil
quantities. Too much oil in the
refrigerant circuit results in high‐
er pressures and a reduction in
the cooling output of the air con‐
ditioner. Lubrication problems
may occur in the air conditioner
compressor if there is insufficient
oil
⇒ “5.2 Approved refrigerant oils
and refrigerant oil capacities”,
page 90 , ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ;
Capacities for refrigerant R134a/
refrigerant oil and approved re‐
frigerant oils , or ⇒ Air condition‐
er with refrigerant R1234yf -
General notes; Rep. gr. 00 ;
Technical data .
♦ When fitting refrigerant lines and
the corresponding retainers,
make sure there is adequate
clearance from other compo‐
nents (such as belts and engine
pulleys).
2 - Cap
❑ With seal
❑ Always screw on

Caution
defective.
the body.
Always
er with refrigerant
components .

❑ Outlet in refrigerant line to high-voltage battery heat exchanger
❑ Between refrigerant lines from expansion valve and to air conditioner compressor
❑ At expansion valve
7 - Expansion valve
8 - Evaporator
❑ At expansion valve
10 - Refrigerant line
❑ From expansion valve to refrigerant shut-off valve for heater and air conditioner unit - N541-
⇒ “2.13 Removing and installing refrigerant lines with internal heat exchanger”, page 189 and
⇒ “2.9 Removing and installing expansion valve”, page 171
❑ Checking ⇒ “4.8 Checking cooling output”, page 49 , ⇒ Vehicle diagnostic tester (“Guided Fault Finding”)
❑ From condenser to expansion valve (via refrigerant shut-off valve for heater and air conditioner unit -
N541- )


catalogue
Note

logue .
♦ Depending on the version of the
refrigerant line, -G805- may also
be fitted on vehicles with refrig‐
erant pressure and temperature
sender - G395- so that the con‐
nection is effectively closed with
a valve. On these vehicles, -
G805- is not connected to the
vehicle electrical system.
14 - Connection with valve

❑ Only fitted on vehicles with -G805-
15 - Cap
❑ With seal
❑ Always screw on

Caution
defective.
the body.
Always
er with refrigerant
components .

17 - Refrigerant line with restrictor
must be detached ⇒ page 169 , and refrigerant line must be disconnected from high-voltage battery heat
exchanger ⇒ page 352 .
Note

cooling output).

❑ From condenser to expansion valve (via a refrigerant line and - N541- ) to high-voltage battery heat
exchanger (via - N542- )

Note
Checking operation
⇒ “4.8.5 Checking cooling output -
vehicles with automatically control‐
led air conditioner (with high-voltage
system)”, page 64
21 - Condenser
23 - Connection without valve
❑ Only fitted on vehicles with -G395-
Caution
-G395- is removed with
refrigerant circuit not
completely empty
the body.
Always
moving -G395- ; connec‐
tion has no valve ⇒ Air
conditioner with refriger‐
ant R134a; Rep. gr. 87 ;
General information on
air conditioning systems ,
or ⇒ Air conditioner with
refrigerant R1234yf -
General notes; Rep. gr.
87 ; Refrigerant circuit;
General description of re‐
frigerant circuit compo‐
nents .
24 - Refrigerant pressure and temperature sender - G395-

❑ Only installed on certain versions (e.g. on vehicles for North America) ⇒ Electronic parts catalogue
❑ Exploded view - electrically driven air conditioner compressor, refrigerant lines, high-voltage battery heat
exchanger (vehicles with high-voltage system) ⇒ page 153

Note
On vehicles with -G395- , different

versions of the electrical air condi‐
tioner compressor - V470- (with con‐
trol unit for air conditioner compres‐
sor - J842- ) and of the air
conditioner operating unit ( Clima‐
tronic control unit - J255- ) are fitted
in addition to the pressure sender
⇒ Vehicle diagnostic tester (“Guided
Fault Finding”) and ⇒ Electronic
parts catalogue .
Caution
completely empty
the body.
Always
nents .
25 - High-pressure safety valve
Caution
valve is defective.
the body.
Always
nection has no valve.

2.1.3 Refrigerant line with restrictor
Note
♦ The illustration shows a refrigerant line -A- with a permanently

installed restrictor -B- (without strainer).
♦ Before removing the refrigerant line, the refrigerant shut-off
valve for high-voltage battery heat exchanger - N542- must be
detached ⇒ page 169 , and the refrigerant line must be dis‐
connected from the high-voltage battery heat exchanger
⇒ page 352 .
♦ The diameter of the restrictor hole -B- is approx. 0.7 mm. De‐
pending on the version of the refrigerant line, the restrictor is
either only inserted or fixed in position in the refrigerant line. If
it is inserted, there may be a strainer for separating float ele‐
ments, which may block off the restrictor hole.
♦ Prior to installation, check the restrictor hole -B- for dirt, and
clean or renew the component as necessary.
♦ Different versions ⇒ Electronic parts catalogue
2.2 Exploded view - condenser, air condi‐

tioner compressor, refrigerant lines and
expansion valve
♦ Condenser, receiver ⇒ page 146
♦ Mechanically driven air conditioner compressor, refrigerant
lines, expansion valve (vehicles without high-voltage system)
⇒ page 149
♦ Electrically driven air conditioner compressor, refrigerant
lines, high-voltage battery heat exchanger (vehicles with high-
voltage system) ⇒ page 153
Condenser, receiver

1 - Condenser
logue
⇒ “2.11 Removing and
installing condenser”,
page 177
2 - O-ring
❑ Renew; for correct ver‐
sion refer to ⇒ Electron‐
ic parts catalogue
❑ Before installing, lubri‐
cate with refrigerant oil
⇒ “4.12 Refrigerant cir‐
cuit seals”, page 81
❑ From connection point
on right longitudinal
member (to internal
heat exchanger)
Note
♦ There are different versions of

the refrigerant lines from the con‐
denser to the internal heat ex‐
changer and to the air condition‐
er compressor depending on the
vehicle model. On vehicles with
a 2.5 ltr. TFSI engine (Audi
RS 3), an additional connection
is fitted in these refrigerant lines
⇒ Electronic parts catalogue .
The refrigerant lines must be dis‐
connected at these connections
if necessary. The tightening tor‐
ques for the bolts on the connec‐
tions are the same as those for
the bolts on the refrigerant lines
at the internal heat exchanger
and at the condenser.
♦ On vehicles with a 2.5 ltr. TFSI
engine (Audi RS 3), the refriger‐
ant lines from the condenser can
only be detached if the condens‐
er has been removed. The refrig‐
erant lines must be detached at
their connections where neces‐
sary.
4 - Bolt
❑ 8 Nm
5 - Bolt
❑ 8 Nm
❑ From air conditioner compressor

Note
♦ There are different versions of

the refrigerant lines from the con‐
denser to the internal heat ex‐
changer and to the air condition‐
er compressor depending on the
vehicle model. On vehicles with
a 2.5 ltr. TFSI engine (Audi
RS 3), an additional connection
is fitted in these refrigerant lines
The refrigerant lines must be dis‐
connected at these connections
if necessary. The tightening tor‐
ques for the bolts on the connec‐
tions are the same as those for
the bolts on the refrigerant lines
at the internal heat exchanger
and at the condenser.
♦ On vehicles with a 2.5 ltr. TFSI
engine (Audi RS 3), the refriger‐
ant lines from the condenser can
only be detached if the condens‐
er has been removed. The refrig‐
erant lines must be detached at
their connections where neces‐
sary.
7 - O-ring
❑ Renew; for correct version refer to ⇒ Electronic parts catalogue
❑ Before installing, lubricate with refrigerant oil ⇒ “4.12 Refrigerant circuit seals”, page 81
8 - Bracket
❑ For refrigerant lines
9 - Cap
10 - Circlip
11 - Cap
❑ Renew if damaged
❑ 2 Nm
12 - O-rings
❑ Removing and installing:
♦ Denso condenser ⇒ “2.12.1 Removing and installing desiccant cartridge - Denso condenser”, page 181
♦ Modine condenser ⇒ “2.12.2 Removing and installing desiccant cartridge - Modine condenser”, page 183
♦ Showa/Keihin condenser
⇒ “2.12.3 Removing and installing desiccant cartridge - Showa/Keihin condenser”, page 187
14 - Strainer
⇒ “2.12.2 Removing and installing desiccant cartridge - Modine condenser”, page 183

15 - Receiver
❑ Integrated in condenser on this version
Mechanically driven air conditioner compressor, refrigerant lines,

expansion valve (vehicles without high-voltage system)
1 - Mechanically driven air con‐

ditioner compressor
(R134a or R1234yf) ⇒
logue
❑ Exploded view
drive unit for air condi‐
tioner compressor”,
page 204
❑ Not installed on vehicles
tem ⇒ page 153 (further
components on vehicles
tem)
Note
Vehicles with a 5-cylinder engine

(Audi RS 3) have 1 or 2 poly V-belts
on the air conditioner compressor
(depending on the engine type). The
air conditioner compressor is there‐
fore provided with a single or dou‐
ble-belt pulley ⇒ 5-cylinder direct
injection engine (2.5 ltr. 4-valve
TFSI); Rep. gr. 13 ; Cylinder block
(pulley end); Removing and instal‐
ling poly V-belts .
2 - Seal
logue
❑ Lubricate O-ring with re‐
frigerant oil before in‐
stalling ⇒ “4.12 Refrigerant circuit seals”, page 81 .
❑ Renew

3 - Oil drain plug
Caution
defective.
the body.
Always
er with refrigerant
components .

❑ Tightening torque:
♦ Denso air conditioner compressor: 30 Nm
♦ Sanden air conditioner compressor: 10 Nm
♦ Not installed on vehicles with high-voltage system ⇒ page 153 (further components on vehicles with high-
voltage system)
4 - O-ring
❑ To condenser
6 - Bolt
❑ 22 Nm
❑ To connection point on right longitudinal member (from internal heat exchanger)
❑ Additional weight at refrigerant line ⇒ “2.8 Additional weight at refrigerant line”, page 171
Note
Depending on the design of the re‐

frigerant line and the production pe‐
riod, this refrigerant line may be
provided with an additional weight
(vibration damper, resonator for re‐
ducing noise at refrigerant line).
Make sure that this component is
not in contact with other compo‐
nents and cannot come into contact
during operation (noise) ⇒ Electron‐
8 - Bolt
❑ 22 Nm

Caution
defective.
the body.
Always
er with refrigerant
components .

⇒ “2.15 Removing and installing service connections (low and high-pressure sides)”, page 197
❑ 5 Nm
⇒ “2.3 Removing and installing pressure sender for refrigerant circuit G805 ”, page 160
Note
Not always installed on vehicles with

high-voltage system ⇒ page 153
(further components on vehicles
with high-voltage system)

Caution
defective.
the body.
Always
er with refrigerant
components .

⇒ “2.15 Removing and installing service connections (low and high-pressure sides)”, page 197
12 - Refrigerant line (high-pressure side)
❑ To refrigerant line with internal heat exchanger
13 - Refrigerant line (low-pressure side)
❑ To refrigerant line with internal heat exchanger
14 - O-ring
❑ From condenser and air conditioner compressor
⇒ “2.13 Removing and installing refrigerant lines with internal heat exchanger”, page 189
16 - Nut
❑ 8 Nm
17 - Nut
❑ 8 Nm
18 - O-ring
❑ Before installing, lubricate with refrigerant oil ⇒ page 81
❑ To expansion valve
⇒ “2.13 Removing and installing refrigerant lines with internal heat exchanger”, page 189
20 - O-ring


21 - Expansion valve
❑ Removing and installing ⇒ “2.9 Removing and installing expansion valve”, page 171
22 - Bolt
❑ 2x
❑ 10 Nm
23 - O-ring
24 - Bolt
❑ 8 Nm
25 - O-ring
Electrically driven air conditioner compressor, refrigerant lines,

high-voltage battery heat exchanger (vehicles with high-voltage
system)

tioner compressor
❑ Exploded view
⇒ page 210
sor - V470-
⇒ page 232
❑ Different versions (e.g.
for vehicles for Europe
or for North America) ⇒
logue
(R134a or R1234yf) ⇒
logue
❑ Further notes on electri‐
cally driven air condi‐
tioner compressors
⇒ page 138
2 - O-ring
ic parts catalogue
⇒ page 81
3 - Refrigerant line (low-pres‐
sure side)
❑ From connection point

on right longitudinal
member (to air conditioner compressor)
❑ With outlet to high-voltage battery heat exchanger
❑ Additional weight at refrigerant line ⇒ page 171
Note
Depending on the design of the re‐

frigerant line and the production pe‐
riod, this refrigerant line may be
provided with an additional weight
(vibration damper, resonator for re‐
ducing noise at refrigerant line).
Make sure that this component is
not in contact with other compo‐
nents and cannot come into contact
during operation (noise) ⇒ Electron‐
4 - Bolt
❑ 22 Nm
5 - Refrigerant pressure and temperature sender - G395-
❑ 8 Nm
❑ Only installed on certain versions (e.g. on vehicles for North America) ⇒ Electronic parts catalogue
Note
On vehicles with -G395- , different

versions of the electrical air condi‐
tioner compressor - V470- (with con‐
trol unit for air conditioner compres‐
sor - J842- ) and of the air
conditioner operating unit ( Clima‐
tronic control unit - J255- ) are also
fitted in addition to the pressure
sender ⇒ Vehicle diagnostic tester
(“Guided Fault Finding”) and ⇒

Caution
completely empty
the body.
Always
nents .
6 - Bolt
❑ 22 Nm
❑ To condenser
❑ Different versions (with or without connection for refrigerant pressure and temperature sender - G395- )
8 - Outlet from refrigerant line (high-pressure side)
❑ To high-voltage battery heat exchanger
Caution
defective.
the body.
Always
er with refrigerant
components .


10 - Outlet from refrigerant line (low-pressure side)
11 - Connection for pressure sender for refrigerant circuit - G805-
catalogue
Caution
defective.
the body.
Always
er with refrigerant
components .

❑ 5 Nm
catalogue
Note

logue .

♦ Depending on the version of the

refrigerant line, -G805- may also
be fitted on vehicles with refrig‐
erant pressure and temperature
sender - G395- so that the con‐
nection is effectively closed with
a valve. On these vehicles, -
G805- is not connected to the
vehicle electrical system.
14 - Outlet from refrigerant line (high-pressure side)

❑ From condenser to connection point on right longitudinal member
❑ With outlet to high-voltage battery heat exchanger
❑ Different versions (with or without connection for pressure sender for refrigerant circuit - G805- ) ⇒
16 - O-ring
❑ From expansion valve to connection point on right longitudinal member
❑ From refrigerant shut-off valve for heater and air conditioner unit - N541- to expansion valve
❑ From connection point on right longitudinal member to -N541-
⇒ “2.6 Removing and installing refrigerant shut-off valve for heater and air conditioner unit N541 ”, page
166 and ⇒ “2.13 Removing and installing refrigerant lines with internal heat exchanger”, page 189
19 - O-ring
❑ From connection point on right longitudinal member to refrigerant shut-off valve for heater and air con‐
ditioner unit - N541-
22 - Nut
❑ 8 Nm
23 - O-ring

1 - Refrigerant line (low-pres‐

sure side)
❑ From expansion valve
to connection point on
right longitudinal mem‐
ber
⇒ page 189
2 - O-ring
ic parts catalogue
⇒ page 81
3 - Expansion valve
logue
(R134a or R1234yf) ⇒
logue
⇒ page 171
4 - Bolt
❑ 2x
❑ 10 Nm
5 - O-ring
ic parts catalogue
cate with refrigerant oil ⇒ page 81
6 - Bolt
❑ 8 Nm
❑ From refrigerant shut-off valve for heater and air conditioner unit - N541- ⇒ Item 20 (page 157) to ex‐
pansion valve
❑ Refrigerant line from connection point on right longitudinal member to -N541- ⇒ Item 21 (page 157)
⇒ “2.6 Removing and installing refrigerant shut-off valve for heater and air conditioner unit N541 ”, page
166 and ⇒ “2.13 Removing and installing refrigerant lines with internal heat exchanger”, page 189
9 - O-ring
10 - Refrigerant line (high-pressure side) with restrictor
❑ From - N542- to high-voltage battery heat exchanger

must be detached
⇒ “2.7 Removing and installing refrigerant shut-off valve for high-voltage battery heat exchanger N542
”, page 169 , and refrigerant line must be disconnected from high-voltage battery heat exchanger
⇒ “8.9 Removing and installing heat exchanger for high-voltage battery”, page 352 .
Note
♦ Before removing component, re‐

frigerant shut-off valve for high-
voltage battery heat exchanger -
N542- must be detached
⇒ page 169 , and refrigerant line
must be disconnected from high-
voltage battery heat exchanger
⇒ page 352 .
cooling output).
11 - Bolt
❑ 8 Nm
❑ Refrigerant line to - N542- from outlet in refrigerant line, high-pressure side (from condenser to connection
point on right longitudinal member) ⇒ Item 14 (page 157)
14 - O-ring
❑ Refrigerant line from high-voltage battery heat exchanger to outlet in refrigerant line, low-pressure side
(from connection point on right longitudinal member to air conditioner compressor)
⇒ Item 10 (page 156)

2.3 Removing and installing pressure send‐

er for refrigerant circuit - G805-
WARNING
Danger from escaping pressurised refrigerant if the refrigerant

line is damaged.
Danger of frostbite on skin and other parts of the body.
♦ Carefully unfasten pressure sensor -1-, paying attention
to joint between switch connection -3- and refrigerant line
-4-.
♦ Should the joint between the switch connection -3- and the
refrigerant line -4- become deformed when unfastening
the pressure sensor -1- (e.g. because of a gummed-up O-
ring), use suitable pliers to counterhold the switch con‐
nection -3- while unfastening the pressure sensor -1-.
Danger from escaping pressurised refrigerant if valve in refrig‐
erant line is defective.
♦ If refrigerant emerges from the switch connection for more
than 1 second when unfastening the pressure sensor
-1-, tighten the pressure sensor -1- again immediately.
♦ Discharge refrigerant circuit before removing ⇒ Air con‐
ditioner with refrigerant R134a; Rep. gr. 87 ; Refrigerant
circuit (Air conditioner with refrigerant R134a; Refrigerant
circuit; Working with the air conditioner service station), or
Rep. gr. 87 ; Working with the air conditioner service sta‐
tion .
♦ If defective, renew valve in switch connection of refrigerant
line ⇒ Air conditioner with refrigerant R134a; Rep. gr. 87 ;
General information on air conditioning systems (Air con‐
ditioner with refrigerant R134a; General information on air
conditioning systems), or ⇒ Air conditioner with refrigerant
R1234yf - General notes; Rep. gr. 87 ; Refrigerant circuit;
General description of refrigerant circuit components .
WARNING
Danger from escaping pressurised refrigerant.

• Extract the refrigerant and then immediately open up the
• Extract the refrigerant again if more than 10 minutes have
passed since the initial extraction and the refrigerant cir‐
cuit has not been opened up. Renewed evaporation leads
to the build-up of pressure in the refrigerant circuit.
Note
Not always fitted on vehicles with high-voltage system


Removing
– Unplug electrical connector -2-.
– Loosen and remove pressure sender -1-.
Installing
Installation is carried out in reverse order; note the following:
• Tightening torque
Note
Renew O-ring ⇒ page 81 . For correct version refer to ⇒ Electronic

parts catalogue .
– As a final step, interrogate event memory and erase any en‐

tries displayed ⇒ Vehicle diagnostic tester (“Guided Fault Find‐
ing”).
2.4 Removing and installing refrigerant

pressure and temperature sender -
G395-
Note
Only installed on certain vehicles with a high-voltage system

Note
Specific tools are required for discharging the refrigerant circuit;

such work may only be performed by appropriately qualified per‐
sonnel ⇒ Air conditioner with refrigerant R134a; Rep. gr. 87 ;
Refrigerant circuit (Air conditioner with refrigerant R134a; Refrig‐
erant circuit; Working with the air conditioner service station), and
⇒ Air conditioner with refrigerant R1234yf - General notes; Rep.
gr. 00 ; Laws and regulations .
Removing
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit (Air conditioner with
refrigerant R134a; Refrigerant circuit; Working with the air
conditioner service station), or ⇒ Air conditioner with refriger‐
ant R1234yf - General notes; Rep. gr. 87 ; Working with the
air conditioner service station .
– Remove bumper cover (front) ⇒ General body repairs, exte‐
rior; Rep. gr. 63 ; Bumper (front) ; Exploded view - bumper
(front).


– Check refrigerant line and connection -4- for dirt; clean if nec‐
essary.
Note
♦ Should it not be possible to unplug the electrical connector

-2- or unfasten the sender -1- due to the confined installation
space, detach the refrigerant line from the condenser
⇒ page 173 .
♦ Refrigerant circuit must be empty when removing refrigerant
pressure and temperature sender - G395- -1-; there is no valve
at connection -4-.
WARNING

– Loosen and remove sender -1-.

– Seal off open connection -4- with a clean plug from engine
bung set - VAS 6122- .
Installing
• Check connection -4- for dirt or damage; clean or renew if
necessary.
refrigerant lines and expansion valve”, page 146 (electrically
driven air conditioner compressor, refrigerant lines, high-volt‐
age battery heat exchanger)
Note
♦ Renew O-ring -3- ⇒ page 81 . For correct version refer to ⇒

♦ At the start of production, -G395- is only available in combi‐
nation with the refrigerant line. In this case, renew refrigerant
line as well if renewing -G395- ⇒ Electronic parts catalogue .
– Evacuate and charge refrigerant circuit ⇒ Air conditioner with

refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit (Working
with the air conditioner service station), or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station .
⇒ page 199 .


ing”).
2.5 Checking cut-in signal for air conditioner

compressor regulating valve - N280-
Note
♦ The following sequence describes the procedure for testing air

conditioner compressors without air conditioning system mag‐
netic clutch - N25- . Perform the check in the same manner on
vehicles with a different type of compressor or a compressor
from a different manufacturer.
♦ The difference on air conditioner compressors with -N25- is
that a 3-pin connector may be installed ⇒ Current flow dia‐
♦ Certain malfunctions of -N280- (e.g. sticking valve or open cir‐
cuit in coil) can lead to problems with air conditioner compres‐
sor (no cooling output from air conditioner, evaporator icing up
etc.). If -N280- (and not air conditioner compressor itself) is
cause of problem, air conditioner compressor can be serviced
by renewing -N280- ⇒ Air conditioner with refrigerant R134a;
Rep. gr. 87 ; Renewing components of refrigerant circuit , or
⇒ Air conditioners with refrigerant R1234yf - General infor‐
mation; Rep. gr. 87 ; Refrigerant circuit; Renewing compo‐
nents .
♦ -N280- is not available as a replacement part for all air condi‐
tioner compressors. If -N280- cannot be obtained separately
for a particular air conditioner compressor (different versions
available), the entire air conditioner compressor must be re‐
newed if problems occur ⇒ Electronic parts catalogue .
♦ On air conditioner compressors with -N25- , you may have to
discard plug contacts from connector housing on -N280- be‐
fore renewing -N280- ⇒ Air conditioner with refrigerant R134a;
Rep. gr. 87 ; Renewing components of refrigerant circuit , or
Rep. gr. 87 ; Refrigerant circuit; Renewing components .

♦ Test instrument adapter/DSO (2-pin) - VAS 5256- , test instru‐
ment adapter/DSO (3-pin) - VAS 5257- or auxiliary measuring
set - V.A.G 1594C-
♦ Probe - VAS 5051/8-

Test sequence
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Removing and installing noise
insulation .
– Use an adapter cable to re-establish connection between con‐
nector -2- and air conditioner compressor regulating valve -
N280- -1-.
Note
♦ Different adapter cables must be used, depending on the ver‐

sion of the air conditioner compressor (with or without air
conditioning system magnetic clutch - N25- ). For example,
test instrument adapter/DSO (2-pin) - VAS 5256- must be
used for an air conditioner compressor without -N25- , and test
instrument adapter/DSO (3-pin) - VAS 5257- must be used for
an air conditioner compressor with -N25- . If no suitable adapt‐
er is available, you can establish the connection between
connector -1- and connector -2- with components from the
auxiliary measuring set - V.A.G 1594 C- .
♦ Alternatively, you can use an improvised adapter cable for this
test. For this you will need e.g. one 2-pin connector each
(-A- and -B-; part numbers 1J0 973 702 and 1J0 973 802 and
the corresponding plug contacts), two commercially available
sockets for banana plugs -C- and two cables (cross-section =
0.5 mm2) for an air conditioner compressor without -N25- .
♦ Activation of the air conditioner compressor regulating valve -
N280- and the current flowing via the air conditioner compres‐
sor regulating valve - N280- as measured by the operating unit
( Climatronic control unit - J255- or air conditioning system
control unit - J301- ) are displayed in the measured values of
the operating unit. “Read measured values” ⇒ Vehicle diag‐
♦ On an air conditioner compressor with a different connector
(e.g. a 3-pin connector on an air conditioner compressor with
-N25- ), pay attention to the pin assignment when connecting
the test cables ⇒ Current flow diagrams, Electrical fault finding

– Connect probe - VAS 5051/8- to adapter cables.

• Test lead (signal wire) to contact “2” of connector -2-
• Test lead (screen, earth) to contact “1” of connector -2-.
– Set “Test Instruments” mode on vehicle diagnostic tester:
DSO (digital storage oscilloscope).
– Select setting 5V/div = 0.5 ms/div (5 V DC and 0.5 milliseconds
per unit).
– Start engine.
– Set temperature for driver side and front passenger side to
“Lo” on air conditioner operating unit. Use Auto and A/C but‐
tons to activate and deactivate air conditioner compressor
regulating valve - N280- .
– Set rotary temperature control to coldest position on operating
unit. Use A/C button to activate and deactivate air conditioner
compressor regulating valve - N280- .
Depending on the setting on the operating unit, the oscilloscope
display will show:

• In “OFF” mode (lamp in A/C button off), no square-wave sig‐

nal ( air conditioner compressor regulating valve - N280- is not
activated).
• In “AUTO” mode (automatic air conditioner only) with A/C but‐
ton pressed (lamp in A/C button on), square-wave signal with
pulse width -A- between 75% and 100% ( air conditioner com‐
pressor regulating valve - N280- is activated).
Note
♦ The illustration shows a signal with a duty cycle of approx.

80 %.
♦ The pulse width -A- depends on the required cooling output,
the electrical system voltage etc.; over the width of area -A-,
the current is controlled via the air conditioner compressor
regulating valve - N280- by the operating unit ( Climatronic
control unit - J255- / air conditioning system control unit -
J301- ).
♦ The signal distance -B- is always 2 milliseconds (correspond‐
ing to a frequency of 500 Hertz).
♦ The duty cycle is derived from the ratio of pulse width -A- to
signal distance -B-.
– The setting on the operating unit and the measured ambient

influences govern the pulse width of the square-wave signal
(duty cycle between 30 % and 100 %; the air conditioner com‐
pressor regulating valve - N280- is activated so that the com‐
pressor output required to obtain the specified temperatures
is achieved).
Note
♦ For example, in “Auto” mode (automatically controlled air con‐

ditioner) with “Lo” temperature setting and the A/C button
pressed (lamp in A/C button lights up), the air conditioner
compressor regulating valve - N280- is activated so that the
maximum permissible current of approx. 0.65 A flows via the
air conditioner compressor regulating valve - N280- (maximum
compressor output).
♦ In control mode, the activation time is governed by the required
cooling output and the voltage of the vehicle's electrical sys‐
tem, for example; however, it is always long enough to achieve
a mean current of 0.3 A.

shut-off valve for heater and air condi‐
tioner unit - N541-
Removing
R134a; Rep. gr. 87 ; Refrigerant circuit (Working with the air
conditioner service station), or ⇒ Air conditioners with refrig‐
erant R1234yf - General information; Rep. gr. 87 ; Working
with the air conditioner service station .

– Unfasten bracket -A- (for coolant valve for high-voltage battery

- N688- ) from plenum chamber partition panel.
– Unfasten heat shield -B- from plenum chamber partition panel
in vicinity of refrigerant shut-off valve for heater and air condi‐
tioner unit - N541- -D- and refrigerant line -F- (to connection
point on right longitudinal member) and carefully bend it back.
– Remove speed nuts -1 and 3-.

– Fold heat shield -2- as far forwards as possible (and neces‐
sary) -arrow-.
– Unplug electrical connector -C- from refrigerant shut-off valve

for heater and air conditioner unit - N541- -D-.
WARNING

– Counterhold refrigerant shut-off valve for heater and air con‐

ditioner unit - N541- -D- and loosen union nuts -E-.
– Unfasten refrigerant line -F- (to connection point on right lon‐
gitudinal member) from bracket on plenum chamber partition
panel.

– Remove refrigerant shut-off valve for heater and air condition‐

er unit - N541- -D-.
Installing
Install in reverse order of removal; note the following.
Note
♦ Observe fitting instructions for O-rings -B- ⇒ page 81 .

– Renew O-rings -B-; for correct version refer to ⇒ Electronic

parts catalogue .
– Screw in union nuts -E- by hand until they make contact.

– Secure refrigerant line -F- (to connection point on right longi‐
tudinal member) in bracket on plenum chamber partition pan‐
el.
– Counterhold refrigerant shut-off valve for heater and air con‐
ditioner unit - N541- -D- and loosen union nuts -E-; make sure
refrigerant lines are routed without tension.
♦ Tightening torque for union nuts -E-: 16.5 Nm
Note
♦ When tightening the union nuts, make sure not to strain the
refrigerant lines.

– Interrogate event memory of operating unit ( Climatronic con‐
trol unit - J255- ) and erase any entries displayed ⇒ Vehicle
⇒ page 199 .
Note
Observe notes on starting up air conditioner after charging ⇒ Air

conditioner with refrigerant R134a; Rep. gr. 87 ; General infor‐
mation on air conditioning systems (Air conditioner with refriger‐
ant R134a; General information on air conditioning systems), or
gr. 87 ; Working with the air conditioner service station; Starting
up air conditioner after charging refrigerant circuit . (before using
air conditioner after it has been re-charged).


shut-off valve for high-voltage battery
heat exchanger - N542-
Removing
– Unplug electrical connector -A- from -N542- -B-.
WARNING

– Counterhold refrigerant shut-off valve for high-voltage battery

heat exchanger - N542- -B- and loosen union nuts -C-.
– Detach refrigerant line -D- from high-voltage battery heat ex‐
changer. ⇒ page 352
– Remove refrigerant shut-off valve for high-voltage battery heat

exchanger - N542- -D-.
Installing
Note
♦ Observe fitting instructions for O-rings -B- ⇒ page 81 .

– Renew O-rings -B-; for correct version refer to ⇒ Electronic

parts catalogue .

– Check restrictor in refrigerant line -D- (to high-voltage battery

heat exchanger) for dirt ⇒ page 146 .
– Screw in union nuts -C- by hand until they make contact.
– Connect refrigerant line -D- to high-voltage battery heat ex‐
changer ⇒ page 352 .
– Counterhold -N542- -B- and tighten union nuts -C-; make sure
refrigerant lines are routed without tension.
♦ Tightening torque for union nuts -C-: 16.5 Nm
Note
♦ When tightening the union nuts, make sure not to strain the
refrigerant lines.

⇒ page 199 .
Note


2.8 Additional weight at refrigerant line
Note
♦ Depending on the vehicle version, the refrigerant line version

and the production period, the refrigerant line -A- may be pro‐
vided with an additional weight -B- (vibration damper, resona‐
tor for reducing noise) ⇒ Electronic parts catalogue .
♦ Make sure that this additional weight -B- is seated firmly on
the refrigerant line, is not in contact with other components and
cannot make contact during operation (noise).
♦ The additional weight -B- must not crush the refrigerant line
-A-.
♦ Tightening torque for bolts -D-: 10 Nm

♦ Dimension -C-: 30 mm
2.9 Removing and installing expansion

valve
Note
♦ Specific tools are required for discharging the refrigerant cir‐

cuit; such work may only be performed by appropriately quali‐
fied personnel ⇒ Air conditioner with refrigerant R134a; Rep.
gr. 87 ; Refrigerant circuit (Air conditioner with refrigerant
R134a; Refrigerant circuit; Working with the air conditioner
service station), or ⇒ Air conditioner with refrigerant R1234yf
service station .
♦ Different versions depending on refrigerant (R134a or
R1234yf) ⇒ Electronic parts catalogue

♦ Engine bung set - VAS 6122-
Removing
– Remove refrigerant lines with internal heat exchanger
⇒ “2.13 Removing and installing refrigerant lines with internal
heat exchanger”, page 189 .
– Remove bolts -1, 3-.
– Pull expansion valve -4- out of heat insulation -2-.
– Seal open lines and connections with clean plugs from engine

Installing
Note
♦ There are different versions of the expansion valve (identical

housing, but different characteristic curve). For correct version
refer to ⇒ Electronic parts catalogue .
♦ Check refrigerant pipes to evaporator for dirt and damage.
♦ Lubricate O-rings with refrigerant oil before installing
⇒ page 81 .
♦ Make sure O-rings are seated correctly on connecting pipes
of evaporator.
– Renew O-rings; for correct version, refer to ⇒ Electronic parts

catalogue .
– Insert O-rings -1 and 4- at connecting pipes -2 and 3- to evap‐
orator.
– Check that securing element -4- (retainer for securing expan‐

sion valve to evaporator pipes) is in correct position: It must
not be pressed too far into foam body -5-; otherwise bolts may
no longer seize.
– Fit expansion valve -4- on refrigerant lines leading to evapo‐

rator.
– Tighten bolts -1 and 3-.
Note
If the heat insulation -2- is not installed or is not installed properly,

the output of the air conditioner may be reduced (change in set
characteristic curve due to heat radiation).
Perform remaining installation steps in reverse sequence; ob‐

serve the following:
– Install refrigerant lines with internal heat exchanger
Tightening torques:
♦ ⇒ “2.2 Exploded view - condenser, air conditioner compressor,

2.10 Detaching and attaching refrigerant

lines at condenser
⇒ “2.10.1 Detaching and attaching refrigerant lines at condenser
- A3”, page 173
⇒ “2.10.2 Detaching and attaching refrigerant lines at condenser
- Q2, Q2 China”, page 175
2.10.1 Detaching and attaching refrigerant

lines at condenser - A3
Note


Removing
rior; Rep. gr. 63 ; Bumper (front); Removing and installing
bumper cover .
– Release retaining tab -1- -arrow- and detach cover.
Note
Design of cover -2- varies depending on model, or cover is not

fitted.

Note
♦ There are different versions of the refrigerant lines from the

condenser to the internal heat exchanger and to the air con‐
ditioner compressor depending on the vehicle model ⇒ Elec‐
tronic parts catalogue . On vehicles with a 2.5 ltr. TFSI engine
(Audi RS 3), an additional connection -2, 4- is fitted in these
refrigerant lines -1, 3-. The refrigerant lines must be discon‐
nected from these connections -2, 4- where necessary. The
tightening torques for the bolts on the connections -2, 4- are
the same as those for the bolts on the refrigerant lines at the
internal heat exchanger and at the condenser.
♦ On vehicles with a 2.5 ltr. TFSI engine (Audi RS 3), the refrig‐
erant line at the condenser -1, 3- can only be detached if the
condenser has been removed. The refrigerant lines must be
detached at the connections -2, 4- where necessary.
WARNING

– Remove bolts -2 and 3- and detach refrigerant lines

-1 and 4-.
Note
♦ This illustration shows a refrigerant line without a connection

for refrigerant pressure and temperature sender - G395- . -
G395- is installed on certain vehicles with a high-voltage sys‐
tem
⇒ “2.4 Removing and installing refrigerant pressure and tem‐
perature sender G395 ”, page 161 .
♦ Vehicles with -G395- : Unplug connector to sender
⇒ “2.4 Removing and installing refrigerant pressure and tem‐
perature sender G395 ”, page 161 .

Installing
catalogue .
– If fitted, check that dowel pin -4- is not damaged and is seated
correctly.
– Check guide ring -2- at refrigerant line connection for damage.
– Insert O-ring -3- in groove -arrow- in connection for refrigerant
line -1-.
Note

⇒ page 81 .
♦ Make sure O-rings are seated correctly in groove of corre‐
sponding refrigerant line.
♦ Routing and attaching refrigerant lines ⇒ page 26

⇒ page 199 .
ing”).

lines at condenser - Q2, Q2 China
Note


Removing

– If possible, remove air intake grille (right-side) ⇒ General body

repairs, exterior; Rep. gr. 63 ; Bumper (front); Exploded view
- bumper cover .
– If it is not possible to remove air intake grille, remove bumper
cover (front) ⇒ General body repairs, exterior; Rep. gr. 63 ;
Bumper (front); Removing and installing bumper cover .
– Release cover -1- and detach it in direction of -arrow-.
WARNING


-1 and 4-.

Installing
catalogue .
correctly.
line -1-.
Note

⇒ page 81 .

⇒ page 199 .
ing”).
2.11 Removing and installing condenser

⇒ “2.11.1 Removing and installing condenser - A3, Q2”,
page 177
⇒ “2.11.2 Removing and installing condenser - Q2 China”,
page 179
2.11.1 Removing and installing condenser -

A3, Q2
Removing
bumper cover .
– Separate refrigerant lines from condenser ⇒ page 173 .
– Remove radiator air ducts ⇒ General body repairs, exterior;
Rep. gr. 50 ; Lock carrier .
Further steps depending on engine and vehicle version:
– Remove air cleaner housing (e.g. on vehicles with 1.8 ltr./2.0
ltr. TFSI engine or 1.6 ltr./2.0 ltr. TDI engine) ⇒ Engine, me‐
chanics; Rep. gr. 23 ; Air cleaner; Removing and installing air
cleaner housing (vehicles with diesel engine) or ⇒ Rep. gr.

24 ; Air cleaner; Removing and installing air cleaner housing

(vehicles with petrol engine).
– Remove radiator cowl (e.g. on vehicles with 1.8 ltr./2.0 ltr. TFSI
engine, 1.6 ltr./2.0 ltr. TDI engine or 2.5 ltr. TFSI engine) ⇒
Engine, mechanics; Rep. gr. 19 ; Radiator/radiator fans; Ex‐
ploded view - radiator cowl and radiator fan .
– Vehicles with 1.4 ltr./2.5 ltr. TFSI engine and 1.6 ltr./2.0 ltr. TDI
engine: Remove radiator ⇒ Engine, mechanics; Rep. gr. 19 ;
Radiator/radiator fans; Removing and installing radiator .
– Vehicles with 1.2 ltr. TFSI engine and large water radiator for
charge air cooling circuit: Remove radiator ⇒ Engine, me‐
chanics; Rep. gr. 19 ; Radiator/radiator fans; Exploded view
- radiator cowl and radiator fan .
– Vehicles with 1.2 ltr. TFSI engine and small charge air cooler:
Unfasten radiator and tilt as far as possible towards engine ⇒
Note
Vehicles with a 1.2 ltr. TFSI engine have different water radiators
for charge air cooling circuit (large and small versions) ⇒ Engine,
mechanics; Rep. gr. 19 ; Radiator/radiator fans; Exploded view -
radiator cowl and radiator fan .
– Vehicles with 1.8 ltr./2.0 ltr. TFSI engine: Remove water radi‐
ator for charge air cooling circuit ⇒ Engine, mechanics; Rep.
gr. 19 ; Radiator/radiator fans; Exploded view - radiator cowl
and radiator fan .
Note
Depending on the version of the water radiator for charge air

cooling circuit, the radiator may also have to be removed in order
to remove the water radiator ⇒ Engine, mechanics; Rep. gr. 19 ;
Radiator/radiator fans; Exploded view - radiator cowl and radiator
fan .
– Vehicles with 1.8 ltr./2.0 ltr. TFSI engine with radiator installed:
Unfasten radiator and tilt as far as possible towards engine ⇒


– Release sealing lip -1- at bottom of water radiator for charge
air cooling circuit -item 2- -arrow A- and disengage at top
-arrow B-.
– Have a 2nd mechanic release retaining clips -1- in direction of

-arrow A- and lift condenser -3- out of mountings on water ra‐
diator for charge air cooling circuit -item 2- -arrows B-.
Installing
Note
Installing radiators and condensers ⇒ page 26

⇒ page 199 .
ing”).
2.11.2 Removing and installing condenser - Q2

China
Removing
bumper cover .
– Separate refrigerant lines from condenser ⇒ page 175 .
– Remove radiator air ducts ⇒ General body repairs, exterior;
Rep. gr. 50 ; Lock carrier .
– Detach radiator and tilt it as far as possible towards engine ⇒
Engine, mechanics; Rep. gr. 19 ; Radiator/radiator fans (Ex‐
ploded view - radiator cowl and radiator fans).

– Release sealing lip -1- at bottom of water radiator for charge

air cooling circuit -item 2- -arrow A- and disengage at top
-arrow B-.
– Have a 2nd mechanic release retaining clips -1- in direction of

-arrow A- and lift condenser -3- out of mountings on water ra‐
diator for charge air cooling circuit -item 2- -arrows B-.
Installing
Note
Installing radiators and condensers ⇒ page 26

⇒ page 199 .
ing”).

2.12 Removing and installing desiccant car‐

tridge
⇒ “2.12.1 Removing and installing desiccant cartridge - Denso
condenser”, page 181
⇒ “2.12.2 Removing and installing desiccant cartridge - Modine
condenser”, page 183
⇒ “2.12.3 Removing and installing desiccant cartridge - Showa/
Keihin condenser”, page 187
2.12.1 Removing and installing desiccant car‐

tridge - Denso condenser
Note

erant circuit; Working with the air conditioner service station), or

♦ Commercially available gripper tool
Removing
Perform steps for removing condenser until plug of desiccant car‐
tridge is accessible; do NOT unfasten refrigerant lines at con‐
denser ⇒ “2.11 Removing and installing condenser”, page 177 .

– Check pressure in refrigerant circuit via pressure gauge of air

conditioner service station ⇒ Air conditioner with refrigerant
WARNING

– Unscrew plug -A-.

– Lift dryer mount -C- with desiccant cartridge -D- out of con‐
denser.
– Using e.g. a gripper tool, pull filter element -E- upwards out of
condenser.
– Seal open receiver with plug -A- to prevent ingress of dirt and
moisture.
Installing
Note
The plug, O-ring and desiccant cartridge must always be renewed

after the receiver has been opened ⇒ Electronic parts catalogue .
– Check threads and sealing surfaces of receiver at condenser

for contamination or damage via opening.
Note
♦ Keep bag with air-tight seal containing desiccant cartridge

closed as long as possible. Only open bag immediately before
inserting desiccant cartridge in condenser. After opening bag,
desiccant cartridge soon becomes saturated with moisture
from ambient air and becomes unusable.
♦ Lubricate O-ring of plug slightly with refrigerant oil before fitting
⇒ page 81 .

– Insert filter element -E- in correct position in receiver of con‐

denser.
– Take desiccant cartridge -D- out of its bag and insert it in dryer
mount -C-.
– Insert dryer mount together with desiccant cartridge in receiver
of condenser.
– Fit and screw in plug -A-.
⇒ page 199 .
ing”).
Tightening torques:
♦ Tightening torque

tridge - Modine condenser
Note


♦ Socket T70 - T10128- for condenser version 2
Removing
Condenser version 1:
– Detach safety sticker (if applicable).
– Unscrew cap -1-.


WARNING

– Press cap -1- in slightly.

– Detach circlip -arrow- and pull cap out of condenser -2- using
an M12 bolt.
– Prepare a length of welding wire (∅ 2 mm) with the following

dimensions:
• Dimension -a- = 380 mm
• Dimension -b- = max. 7 mm
• Dimension -c- = max. 6 mm
– To prevent damaging the condenser, it is important to hook

the welding wire into the strainer as shown in the illustration.
– Using welding wire -1-, carefully pull filter element (strainer)
-2- out of receiver.

– Seal open receiver with cap -1- to prevent ingress of dirt and
moisture.
Condenser version 2:
– Unscrew protective cap -1- with socket T70 - T10128- .

WARNING

– Press cap -1- in slightly.

– Detach circlip -arrow- and pull cap out of condenser -2- using
an M12 bolt.

– Using long-nose pliers, pull dryer unit -1- out of condenser

-2-.
– Seal open receiver with cap to prevent ingress of dirt and
moisture.
Installing
Note


for contamination or damage via opening.
Version 1:
– Insert filter element (with strainer) -2- in correct position in re‐
ceiver of condenser.
• Make sure filter element is pressed in as far as possible (over
studs near bottom).
Note
Keep bag with air-tight seal containing desiccant cartridge closed

as long as possible. Only open bag immediately before inserting
desiccant cartridge in condenser. After opening bag, desiccant
cartridge soon becomes saturated with moisture from ambient air
and becomes unusable.
– Take desiccant cartridge out of its bag and insert it in receiver

of condenser.
Version 2:
– Take dryer unit -1- out of its bag and insert it in condenser
-2-.
All versions (continued):

– Insert cap -1- and press it downwards until circlip -arrow- can
engage in the groove.
Note
Moisten O-ring of cap slightly with refrigerant oil before fitting

⇒ page 81 .

– Version 1: Press on protective cap.

– Version 2: Screw in protective cap using socket T70 -
T10128- .
– Attach safety sticker (if applicable).
– All components removed have been re-installed.
⇒ page 199 .
ing”).
Tightening torques:

tridge - Showa/Keihin condenser
Note


♦ Commercially available gripper tool
Removing
Note
Depending on the version, either the entire receiver or just the

desiccant cartridge has to be renewed for the Showa/Keihin con‐
denser (different versions ⇒ Electronic parts catalogue ).


WARNING

– Unscrew plug -A-.

– Lift desiccant cartridge -E- out of receiver of condenser.
– Using e.g. a commercially available gripper tool, pull filter el‐
ement -F- upwards out of receiver of condenser.
– Seal open receiver with plug -A- to prevent ingress of dirt and
moisture.
Installing
Install in reverse order of removal; note the following:
Note


for dirt or damage via opening.
Note
♦ Keep bag with air-tight seal containing desiccant cartridge

closed as long as possible. Only open bag immediately before
inserting desiccant cartridge in receiver of condenser. After
opening bag, desiccant cartridge soon becomes saturated
with moisture from ambient air and becomes unusable.
♦ Lubricate O-ring of plug slightly with refrigerant oil before fitting
⇒ page 81 .

– Lubricate filter element -F- in area of sealing surface -J- lightly

with refrigerant oil before fitting
⇒ “4.12 Refrigerant circuit seals”, page 81 .
– Using a suitable tool -K-, insert filter element -F- as far as it will
go in correct position in mounting on receiver, taking care not
to damage webs -H-.
– Assemble plug -A- with O-rings -B- and -C- and support ring
-D-.
– Take desiccant cartridge -E- out of its bag and insert it in re‐
ceiver.
– Fit and screw in plug -A-.
– All components removed have been re-installed.
⇒ page 199 .
ing”).
Tightening torques:
2.13 Removing and installing refrigerant lines

with internal heat exchanger
Note
♦ The following describes the removal and installation proce‐

dures for the refrigerant line (going to the expansion valve) at
the connection point on the right longitudinal member. This
refrigerant line is designed to act as an internal heat exchanger
on vehicles without high-voltage system.
♦ On vehicles with a high-voltage system, a refrigerant line with‐
out an internal heat exchanger but with a refrigerant shut-off
valve for heater and air conditioner unit - N541- is installed.
The removal and installation procedures for the different ver‐
sions are basically the same. The only additional step required
on vehicles with a high-voltage system is to unplug a connec‐
tor to refrigerant shut-off valve for heater and air conditioner
unit - N541-
⇒ “2.6 Removing and installing refrigerant shut-off valve for
heater and air conditioner unit N541 ”, page 166 .

Note


Removing
Vehicles with 1.8 ltr/2.0 ltr. TFSI engine:
– Release hose clips -1, 2- and remove air pipe.
Vehicles with 2.0 ltr. TDI engine:

– Press release tabs at crankcase breather hose -1- and detach
hose from cylinder head cover.
– Move vacuum hoses clear at air pipe -arrows-.
– Release hose clip -3-.
– Unscrew bolt -2-, swivel air pipe with connection to the rear
and detach from turbocharger.

– Unfasten bracket -A- (for coolant valve for high-voltage battery

- N688- ) from plenum chamber partition panel.
– Unfasten heat shield -B- from plenum chamber partition panel
in vicinity of refrigerant shut-off valve for heater and air condi‐
tioner unit - N541- -D- and refrigerant line -F- (to connection
point on right longitudinal member) and carefully bend it back.

– Release fastener -arrow- (if fitted), pull off cover -1- towards
left and detach.
– Unclip wiring duct.
– Remove speed nuts -1 and 3-.

– Fold heat shield -2- as far forwards as possible -arrow-.

WARNING

– Remove bolt -7-.

– Detach refrigerant line -6- with internal heat exchanger from
expansion valve.
– Unscrew nuts -1, 3- and detach refrigerant lines -2, 4-.
– Take refrigerant line -5- with internal heat exchanger out to‐
wards right side.
Installing
catalogue .
– Clean connections on expansion valve -2- and on internal heat
exchanger -4- and check for damage.
– Thoroughly clean connection area of refrigerant lines and
check for damage.
Note

⇒ page 90 .
– Insert O-rings -1 and 3- in grooves at connection of internal

heat exchanger.
– Insert internal heat exchanger at expansion valve.
– Tighten bolt -5-.

– Clean connections on refrigerant lines and check for damage.

correctly.
Note

⇒ page 90 .

line -1-.
– Insert refrigerant lines in corresponding connections.
– Tighten bolts.
Note
Routing and attaching refrigerant lines ⇒ page 26

⇒ page 199 .
ing”).
Tightening torques:
♦ ⇒ Engine, mechanics; Rep. gr. 21 ; Turbocharger; Exploded
view - turbocharger

2.14 Differences in service connections de‐

pending on refrigerant (R134a or
R1234yf)
Note
♦ Only use valves and connections which are resistant to the

corresponding refrigerant (R134a and/or R1234yf) and related
refrigerant oils ⇒ Electronic parts catalogue .
♦ The service connections for the refrigerant circuits are de‐
signed such that only the specified service couplings for the
specified refrigerant (R134a or R1234yf) can be connected.
♦ These illustrations show service connections in which a
Schrader valve (needle valve or push pin) is installed. How‐
ever, depending on the vehicle version or the type of refriger‐
ant etc., service connections with a primary sealing valve (ball
valve) may also be installed (different technology).
♦ Arrangement in vehicle and in refrigerant circuit
⇒ “1.1 Overview of fitting locations - components not located
in passenger compartment”, page 114 and
♦ There are different connections (outer diameter) for high and
low-pressure sides.
♦ Discharge refrigerant circuit before removing valves or valve
cores ⇒ Air conditioner with refrigerant R134a; Rep. gr. 87 ;
Refrigerant circuit , or ⇒ Air conditioner with refrigerant
R1234yf - General notes; Rep. gr. 87 ; Working with the air
conditioner service station .
♦ Removing and installing valve from service connection (low
and high-pressure sides) ⇒ page 197 .
♦ Always screw on sealing caps with seal.

Service connections (refrigerant R134a and R1234yf)
WARNING
Before removing valves -B, E-, connect the air conditioner

service station and extract refrigerant. Refrigerant circuit must
be empty; danger of injury ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioner
with refrigerant R1234yf - General notes; Rep. gr. 87 ; Working
♦ Cap for service connection (high-pressure side) -A- with seal

-G-
♦ Valve core on high-pressure side (version: Schrader valve or
needle valve) -B-
♦ Service connection (high-pressure side) -C-
♦ Cap for service connection (high-pressure side) -D- with seal
-G-
♦ Valve core on low-pressure side (version: Schrader valve or
needle valve) -E-
♦ Service connection (low-pressure side) -F-

Note
♦ Service connections -C, F- for refrigerant R134a and R1234yf

are available in different versions (depending on manufactur‐
er), with different sealing caps -A, D- and valves -B, E-. Ensure
correct assignment ⇒ Electronic parts catalogue .
♦ Sealing caps -A, D- for the service connections on the R134a
refrigerant circuit are currently black. The sealing caps for the
service connections on the R1234yf refrigerant circuit are cur‐
rently grey. The refrigerant type (e.g. “R1234yf”) may also be
printed on the sealing caps.
♦ After connecting, carefully screw the handwheel of the service
coupling into the quick-release coupling adapter only to the
extent required to reliably open the valve -B, E- in the service
connection (observe the pressure gauge; do not open the
valve -B, E- too far).
♦ The service connections -C, F- for R134a and R134yf refrig‐
erant circuits are designed such that only the service couplings
specified for the corresponding refrigerant can be connected
(different dimensions ⇒ page 196 ).
♦ Service connections -C, F-, for example, are soldered into a
refrigerant line and therefore cannot be renewed separately.
♦ To remove and install the valves -B, E- (with the refrigerant
circuit drained), make use of an adapter from the socket -
T10364- for example ⇒ page 197 .
♦ Take care when tightening the valves -B, E- (low torque)
⇒ page 197 .
♦ There are different versions of these valves; therefore tight‐
ening torques may vary. Tightening torque for valve core -C-
with a VG5 thread (5.2 x 0.7 mm tyre valve): 0.4 Nm +- 0.1 Nm;
tightening torque for valve core with an M6 x 0.75 mm thread:
0.9 mm +- 0.1 Nm; tightening torque for valve core with M8 x
1.0 mm thread: 2.0 Nm +- 0.2 Nm.
♦ There are different versions of valve caps -A, D-; therefore
tightening torques vary. Tightening torque for valve cap with
M8 x 1 mm or M10 x 1 mm thread: 0.4 Nm +- 0.1 Nm.
Dimensions of service connections

♦ Valve core -A- (different versions) ⇒ Air conditioner with re‐

frigerant R134a; Rep. gr. 87 ; General information on air
conditioning systems , and ⇒ Air conditioners with refrigerant
R1234yf - General information; Rep. gr. 87 ; Refrigerant cir‐
cuit; General description of refrigerant circuit components .
♦ Service connection -B- (different versions on high-pressure
and low-pressure side depending on refrigerant)
Dimensions of serv‐ Service connec‐ Service connection
ice connections -B- tion (refrigerant (refrigerant
R134a) R1234yf)
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
Offset -L1- 4.6 mm 6.15 9.0 mm 4.75 mm
mm
Offset -L2- 8.16 mm 9.16 12.5 mm 7.2 mm
mm
Installation position of 6.1 - 7.1 6.1 - 7.1 8.3 - 9.3 8.3 - 9.3
valve (not actuated) mm mm mm mm
-C-
2.15 Removing and installing service con‐

nections (low and high-pressure sides)
Note

service station .
R1234yf)
⇒ “2.14 Differences in service connections depending on re‐
frigerant (R134a or R1234yf)”, page 194 and ⇒ Electronic
parts catalogue

♦ Socket - T10364-

Removing
– Unscrew caps (with seal) -1- or -2-.
WARNING

– Remove service connection -3- using socket - T10364- and a

suitable adapter.
Note
For further information on the service connection, refer to

⇒ “2.14 Differences in service connections depending on refrig‐
erant (R134a or R1234yf)”, page 194 , ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ; General information on air con‐
ditioning systems (Air conditioner with refrigerant R134a; General
information on air conditioning systems), or ⇒ Air conditioner with
refrigerant R1234yf - General notes; Rep. gr. 87 ; Refrigerant
circuit; General description of refrigerant circuit components .
Installing
⇒ page 199 .
ing”).

2.16 Starting up air conditioner after charging

refrigerant circuit
⇒ “2.16.1 Procedure if it is unavoidable to start the engine with an
empty refrigerant circuit”, page 199
⇒ “2.16.2 Procedure when starting the engine for the first time
after charging the refrigerant circuit”, page 201
2.16.1 Procedure if it is unavoidable to start the

engine with an empty refrigerant circuit
Caution
♦ After installing the electrically driven air conditioner com‐

pressor and then charging the refrigerant circuit, first start
up the compressor via the “Compressor run-in” function of
the basic setting routine. Otherwise, the air conditioner
compressor may be damaged if refrigerant oil has accu‐
mulated in the compression chamber of the air conditioner
compressor due to inappropriate storage prior to installa‐
tion ⇒ Vehicle diagnostic tester (“Guided Fault Finding” for
air conditioner).
♦ An electrically driven air conditioner compressor may only
be activated when the refrigerant circuit is charged. Run‐
ning the air conditioner compressor with the refrigerant
circuit empty could lead to compressor damage ⇒ Vehicle
diagnostic tester (“Guided Fault Finding” for air condition‐
er).
♦ All components removed have been re-installed.

♦ To prevent damage to the air conditioner compressor when
the refrigerant circuit is empty, the electrical air conditioner
compressor - V470- is not activated by the operating unit ( Cli‐
matronic control unit - J255- ) ⇒ Vehicle diagnostic tester
(“Guided Fault Finding” for air conditioner).

Note
♦ If the air conditioner compressor was removed or the engine

was detached, start up the electrical air conditioner compres‐
sor - V470- via the “Compressor run-in” function after charging
the refrigerant circuit ⇒ Vehicle diagnostic tester (“Guided
Fault Finding” for air conditioner).
♦ Otherwise, the air conditioner compressor may be damaged if
refrigerant oil has accumulated in the compression chamber
of the air conditioner compressor due to inappropriate storage
(or attachment) prior to installation.
♦ Observe notes on starting up air conditioner after charging ⇒
Air conditioner with refrigerant R134a; Rep. gr. 87 ; General
information on air conditioning systems (Air conditioner with
refrigerant R134a; General information on air conditioning
systems), or ⇒ Air conditioner with refrigerant R1234yf - Gen‐
eral notes; Rep. gr. 87 ; Working with the air conditioner
service station; Starting up air conditioner after charging re‐
frigerant circuit . (before using air conditioner after it has been
re-charged).
Caution
Risk of damage to the air conditioner compressor if the engine

is run with the refrigerant circuit empty ⇒ Air conditioner with
refrigerant R1234yf - General notes; Rep. gr. 87 ; Working with
the air conditioner service station .
♦ The air conditioner compressor is always driven when the
engine is running (there is no magnetic clutch). Therefore
do not start the engine unless the refrigerant circuit has
been properly assembled.
♦ If, for example, the refrigerant lines are not connected to
the air conditioner compressor when the engine is run‐
ning, the compressor might heat up (internal heat gener‐
ation) so much that this can lead to irreparable damage to
the compressor.
♦ If possible, only start the engine with the refrigerant circuit
filled.
♦ Do not start the engine while or after evacuating the re‐
frigerant circuit ⇒ Air conditioner with refrigerant R134a;
Rep. gr. 87 ; Refrigerant circuit (Air conditioner with re‐
frigerant R134a; Refrigerant circuit; Working with the air
conditioner service station), or ⇒ Air conditioner with re‐
frigerant R1234yf - General notes; Rep. gr. 87 ; Working
♦ The engine should only run as long as absolutely neces‐
sary.
Note
The air conditioner compressor is equipped with an internal oil

circuit to prevent damage if the refrigerant circuit is empty. For
this there must still be a residual quantity of refrigerant oil in the
air conditioner compressor.
• The refrigerant circuit must be assembled completely.

• The refrigerant circuit must not be under vacuum.

• The engine speed must not exceed 2500 rpm.
• The engine should only run as long as absolutely necessary
(e.g. to move the vehicle in the workshop).
• If air conditioner compressor was removed previously: There
must be at least a quarter of the amount of refrigerant oil
specified for this refrigerant circuit in the compressor.
Note
If only the refrigerant has been extracted (without removing the

air conditioner compressor), the design of the refrigerant circuit
ensures that there is sufficient refrigerant oil in the compressor to
maintain lubrication of the compressor for a brief operating period.
2.16.2 Procedure when starting the engine for

the first time after charging the refriger‐
ant circuit
Caution
♦ After installing the electrically driven air conditioner com‐

pressor and then charging the refrigerant circuit, first start
up the compressor via the “Compressor run-in” function of
the basic setting routine. Otherwise, the air conditioner
compressor may be damaged if refrigerant oil has accu‐
mulated in the compression chamber of the air conditioner
compressor due to inappropriate storage prior to installa‐
tion ⇒ Vehicle diagnostic tester (“Guided Fault Finding” for
air conditioner).
♦ An electrically driven air conditioner compressor may only
be activated when the refrigerant circuit is charged. Run‐
ning the air conditioner compressor with the refrigerant
circuit empty could lead to compressor damage ⇒ Vehicle
diagnostic tester (“Guided Fault Finding” for air condition‐
er).
♦ All components removed have been re-installed.

♦ The refrigerant circuit is charged ⇒ Air conditioner with refrig‐
erant R134a; Rep. gr. 87 ; Refrigerant circuit (Air conditioner
with refrigerant R134a; Refrigerant circuit; Working with the air
air conditioner service station; Starting up air conditioner after
charging .
– If the air conditioner compressor was removed or the engine
was detached, start up the electrical air conditioner compres‐

sor - V470- via the “Compressor run-in” function ⇒ Vehicle

diagnostic tester (“Guided Fault Finding” for air conditioner).
Note
♦ Otherwise, the air conditioner compressor may be damaged if

refrigerant oil has accumulated in the compression chamber
of the air conditioner compressor due to inappropriate storage
(or attachment) prior to installation.
♦ Observe notes on starting up air conditioner after charging ⇒
Air conditioner with refrigerant R134a; Rep. gr. 87 ; General
information on air conditioning systems (Air conditioner with
refrigerant R134a; General information on air conditioning
systems), or ⇒ Air conditioner with refrigerant R1234yf - Gen‐
service station; Starting up air conditioner after charging re‐
frigerant circuit . (before using air conditioner after it has been
re-charged).

• All components removed have been re-installed.
• The refrigerant circuit is charged ⇒ Air conditioner with refrig‐
erant R134a; Rep. gr. 87 ; General information on air condi‐
tioning systems (Air conditioner with refrigerant R134a;
General information on air conditioning systems), or ⇒ Air
87 ; Working with the air conditioner service station; Starting
up air conditioner after charging .
– Open all dash panel vents and any vents in centre console.
Vehicles with manually controlled air conditioner (without high-
voltage system):
• Lamp in AC or A/C button -5- is off.
– Start engine with air conditioner compressor switched off and
wait for engine idling speed to stabilise.
Make the following settings on the operating unit ( air conditioning
system control unit - J301- ):
♦ Set rotary temperature control -1- to “cold” stop.
♦ Air conditioner compressor on: Lamp in AC or A/C button
-5- on

Vehicles with automatically controlled air conditioner (without

high-voltage system):
• Lamp in AC or A/C button -8- is off.
– Start engine with air conditioner compressor switched off and
wait for engine idling speed to stabilise.
Make the following settings on the operating unit ( Climatronic
-8- on
All vehicles without high-voltage system (continued):
– Run air conditioner compressor with engine at idling speed for
at least 5 minutes.
Note


3 Air conditioner compressor

⇒ “3.1 Exploded view - drive unit for air conditioner compressor”,
page 204
⇒ “3.1.3 Exploded view - drive unit for electrically driven air con‐
ditioner compressor”, page 210
⇒ “3.2 Exploded view - pulley, mechanically driven air conditioner
⇒ “3.3 Detaching and attaching air conditioner compressor at
bracket”, page 216
⇒ “3.4 Detaching and attaching refrigerant lines at air conditioner
⇒ “3.5 Removing and installing air conditioner compressor”, page
229
⇒ “3.6 Removing and installing pulley”, page 234
3.1 Exploded view - drive unit for air condi‐

tioner compressor
⇒ “3.1.1 Exploded view - drive unit for air conditioner compressor,
vehicles with 3-cylinder and 4-cylinder engine”, page 204
⇒ “3.1.2 Exploded view - drive unit for air conditioner compressor,
vehicles with 5-cylinder engine (Audi RS 3)”, page 207
⇒ “3.1.3 Exploded view - drive unit for electrically driven air con‐
ditioner compressor”, page 210
3.1.1 Exploded view - drive unit for air conditioner compressor, vehicles with 3-
cylinder and 4-cylinder engine

1 - Poly V-belt
❑ Check for wear
⇒ Rep. gr. 13 ; Cylinder
block (pulley end); Re‐
moving and installing
poly V-belt
❑ Mark direction; install in
correct position ⇒ Rep.
gr. 13 ; Cylinder block
(pulley end); Removing
and installing poly V-belt
2 - Bracket for ancillaries
bracket for ancillaries
Note
Different versions depending on en‐

gine ⇒ Electronic parts catalogue
3 - O-ring
ic parts catalogue
⇒ page 81
4 - Bolt
⇒ page 146
5 - Refrigerant line (high-pres‐
sure side)
7 - Bolt
8 - O-ring
9 - Air conditioner compressor regulating valve - N280-
3. Air conditioner compressor 205

Note


❑ Detaching and attaching refrigerant line ⇒ page 223
❑ Detaching and attaching at bracket ⇒ page 216
Note
Different versions depending on re‐

frigerant (R134a or R1234yf) ⇒
11 - Bolt
❑ 3x
❑ Tightening torque for steel bolts: 25 Nm
❑ Tightening torque for aluminium bolts: 8 Nm +180°
❑ Use aluminium bolts only once; always renew.
12 - Pulley with overload protection
13 - Dowel sleeve
❑ 2x

3.1.2 Exploded view - drive unit for air condi‐

tioner compressor, vehicles with 5-cyl‐
inder engine (Audi RS 3)
Version 1 (with double-belt pulley) ⇒ page 207
Version 2 (with single-belt pulley) ⇒ page 208
Note
Vehicles with a 5-cylinder engine (Audi RS 3) have 1 or 2 poly V-

belts on the air conditioner compressor (depending on the engine
type). The air conditioner compressor is therefore provided with
a single or double-belt pulley.
Version 1 (with double-belt pulley)

logue
2 - Bolt
❑ Tightening torque ⇒
Rep. gr. 13 ; Cylinder
block (pulley end); Ex‐
ploded view - cylinder
block (pulley end)
3 - Bolt
block (pulley end)
4 - Bolt
block (pulley end)
logue
❑ Detaching and attach‐
ing refrigerant line
⇒ page 223
ing at bracket ⇒ page 217

Note

6 - Bolt
❑ 3x
7 - Dowel sleeve
❑ 2x
❑ Make sure that correct version is being used and that components are properly positioned between
bracket for ancillaries and air conditioner compressor
Version 2 (with single-belt pulley):

logue
2 - Bolts
logue
3 - Dowel sleeves
❑ 2x
❑ Make sure that correct
version is being used
and that components
are properly positioned
between bracket for an‐
cillaries and air condi‐
tioner compressor
logue
ing refrigerant line
⇒ page 223
ing at bracket
⇒ page 217

Note

5 - Bolts
❑ 3x
6 - Poly V-belt
❑ Check for wear
❑ Removing and installing ⇒ Rep. gr. 13 ; Cylinder block (pulley end); Removing and installing poly V-
belt
❑ Mark direction; install in correct position ⇒ Rep. gr. 13 ; Cylinder block (pulley end); Removing and
installing poly V-belt

3.1.3 Exploded view - drive unit for electrically driven air conditioner compressor

tioner compressor
sor - V470-
❑ ⇒ “3.3.3 Detaching and
attaching electrically
compressor at bracket”,
page 219
❑ ⇒ “3.4.2 Detaching and
attaching refrigerant
lines at electrically driv‐
en air conditioner com‐
pressor”, page 227
⇒ “3.5.2 Removing and
Note
♦ Prior to installation, check the at‐

tachment points of the air condi‐
tioner compressor and engine
bracket. The contact surfaces
must be clean and free from rust
and grease. If this is not the case,
treat the contact surfaces ac‐
cordingly with the contact sur‐
face cleaning set - VAS 6410- ⇒
Electrical system; Rep. gr. 97 ;
Cleaning contact surfaces .
♦ The electrical air conditioner
compressor - V470- is supplied
with electric power via a fuse fit‐
ted in the power and control elec‐
tronics for electric drive - JX1-
⇒ “9.8 Removing and installing
fuse for electrical air conditioner
compressor”, page 372 , ⇒ 4-
cylinder direct injection engine
211); Rep. gr. 93 ; Power and
control electronics for electric
drive and ⇒ Current flow dia‐
grams, Electrical fault finding
♦ Different versions depending on
refrigerant (R134a or R1234yf)
❑ High-pressure side
3 - Bolt
❑ Tightening torque: 9 Nm (for bolts with M6 thread) / 25 Nm (for bolts with M8 thread)

4 - O-ring
❑ Renew ⇒ page 81 ; for correct version refer to ⇒ Electronic parts catalogue
❑ Before installing, lubricate lightly with refrigerant oil
5 - Bolt
❑ Tightening torque for steel bolt: 25 Nm
Note
If aluminium bolts have been used

to secure the air conditioner com‐
pressor, (different versions ⇒ Elec‐
tronic parts catalogue ), renew the
aluminium bolts (do not re-use).
Tightening torque for aluminium
bolts 8 Nm +180°.
6 - Earth wire
❑ Check and if necessary clean contact surface before screwing in bolts ⇒ 4-cylinder direct injection engine
(1.2, 1.4 ltr. 4-valve TFSI EA 211); Rep. gr. 93 ; High-voltage components
Note
The contact surfaces must be clean

and free from rust and grease. If this
is not the case, treat the contact sur‐
faces accordingly with the contact
surface cleaning set - VAS 6410- ⇒
Electrical system; Rep. gr. 97 ;
Cleaning contact surfaces .
7 - Bolt
❑ Tightening torque: 9 Nm
8 - O-ring
❑ Renew ⇒ page 81 ; for correct version refer to ⇒ Electronic parts catalogue
❑ Before installing, lubricate lightly with refrigerant oil
❑ Low-pressure side
10 - Bolt
❑ Tightening torque: 9 Nm (for bolts with M6 thread) / 25 Nm (for bolts with M8 thread)
11 - 8-pin connector
❑ With control wire from operating unit ( Climatronic control unit - J255- ) ⇒ Current flow diagrams, Electrical
12 - High-voltage wire to power and control electronics for electric drive - JX1- (with control unit for high-voltage
battery charging unit - J1050- )
❑ Detaching and attaching ⇒ 4-cylinder direct injection engine (1.2, 1.4 ltr. 4-valve TFSI EA 211); Rep. gr.
93 ; High-voltage wires; Overview of fitting locations - high-voltage wires

3.2 Exploded view - pulley, mechanically

driven air conditioner compressor
⇒ “3.2.1 Exploded view - air conditioner compressor pulley (Den‐
so)”, page 212
⇒ “3.2.2 Exploded view - Sanden air conditioner compressor pul‐
ley, version 1”, page 213
ley, version 2”, page 214
3.2.1 Exploded view - air conditioner compressor pulley (Denso)
1 - Bolt
❑ 3x
❑ 4.5 Nm
2 - Cap
3 - Nut
❑ 25 Nm
4 - Drive plate
❑ With overload protec‐
tion device; triggered if
torque is too great (e.g.
if air conditioner com‐
pressor cannot rotate
freely) causing pulley to
free-wheel without driv‐
ing air conditioner com‐
pressor
5 - Circlip
❑ Renew
❑ Install correctly: flat side
must face air condition‐
er compressor
6 - Pulley
logue
❑ Sensitive to impact,
handle with care
⇒ page 234
❑ Clean air conditioner
compressor drive shaft
before fitting pulley
Note


3.2.2 Exploded view - Sanden air conditioner compressor pulley, version 1
1 - Nut
❑ 25 Nm
Note
A plastic cap may be fitted addition‐

ally to protect thread of air condi‐
tioner compressor drive shaft (cap is
not shown in illustration).
– Hold pulley in position

using a commercially
available oil filter strap
wrench when loosening
or tightening hexagon
nut.
– Using e.g. a thread cut‐

ter, clean thread of nut
(screwed in with locking
fluid). Otherwise there is
a danger of the drive
shaft shearing off when
it is removed again.
– Using wire brush, clean

thread of air conditioner
compressor drive shaft.
– Apply locking fluid and

insert nut. For locking
fluid, refer to ⇒ Elec‐
2 - Bolt
❑ 12 Nm
– Hold pulley in position
using a commercially
available oil filter strap
wrench when loosening or tightening bolts.
– Threaded holes which take self-locking bolts or bolts coated with locking fluid must be cleaned using a
thread tap or similar. Otherwise there is a danger of the bolts shearing off when removed again.
– Using wire brush, clean threads of bolts screwed in with locking fluid. Then apply locking fluid and insert
bolts. Locking fluid ⇒ Electronic parts catalogue
3 - Drive plate
❑ With overload protection device (attachment of spring elements); triggered if torque is too great (e.g. if
air conditioner compressor cannot rotate freely) causing pulley to free-wheel without driving air condi‐
tioner compressor
❑ Spring elements of drive plate dampen vibrations and reduce noise
4 - Circlip
❑ Renew
❑ Install in correct position; insertion bevel -A- facing away from air conditioner compressor (flat side to‐
wards compressor)
5 - Pulley
❑ With rubber elements -B- and threaded plates -C- for decoupling pulley from drive shaft of air conditioner
compressor (rubber elements dampen vibrations and reduce noise)

Note
♦ Depending on version, threaded

plates may also be linked via a
ring.
♦ “Cold country” vehicles (e.g. for
Central and Northern Europe)
may be fitted with air conditioner
compressors with a smaller ca‐
pacity. On these air conditioner
compressors, the pulley is slight‐
ly different to the version shown
here (e.g. no rubber elements
-B-) ⇒ Electronic parts cata‐
logue .

❑ Clean air conditioner compressor drive shaft before fitting pulley
Note

3.2.3 Exploded view - Sanden air conditioner

compressor pulley, version 2
Note
♦ Installed on vehicles with 5-cylinder engine (Audi RS 3) with

two poly V-belts on air conditioner compressor
♦ Vehicles with a 5-cylinder engine (Audi RS 3) have 1 or 2 poly
V-belts on the air conditioner compressor (depending on the
engine type). The air conditioner compressor is therefore pro‐
vided with a single or double-belt pulley ⇒ 5-cylinder direct
injection engine (2.5 ltr. 4-valve TFSI); Rep. gr. 13 ; Cylinder
block (pulley end); Removing and installing poly V-belts .
♦ If the pulley overload protection has been tripped, check the
freedom of movement of the air conditioner compressor before
renewing the pulley. If the air conditioner compressor does not
rotate freely, renew the complete unit.
♦ The air conditioner compressor can be detached from the
bracket on the engine and re-attached without opening up the
refrigerant lines.
bracket on the engine and re-attached without opening up the
refrigerant lines.

1 - Hexagon nut
Note
A plastic cap may be fitted addition‐

ally to protect thread of compressor
shaft (cap is not shown in illustra‐
tion).
❑ Hold pulley using a com‐
mercially available strap
wrench (fabric strap)
when loosening or tight‐
ening hexagon nut
❑ Before installing, clean
residual locking fluid off
thread of hexagon nut
and thread of air condi‐
tioner compressor shaft
❑ Apply locking fluid (e.g.
D 000 600 A2) when fit‐
ting hexagon nut ⇒
logue
hexagon nut: 25 Nm
2 - Bolt
❑ To loosen and tighten
bolts, hold pulley in po‐
sition with a commer‐
cially available strap
wrench (with fabric
strap).
❑ Tightening torque:
12 Nm
❑ Before screwing in, re‐
move old locking fluid
from bolt threads and
threads of pulley
❑ Apply locking fluid (e.g. D 000 600 A2) when fitting bolts ⇒ Electronic parts catalogue
3 - Drive plate
❑ With overload protection device (attachment of spring elements); triggered if torque is too great (e.g. if
air conditioner compressor cannot rotate freely) causing pulley to free-wheel without driving air condi‐
tioner compressor
❑ Spring elements of drive plate dampen vibrations and reduce noise
4 - Spacer
5 - Circlip
❑ Renew
❑ Install in correct position; insertion bevel -A- facing away from air conditioner compressor (flat side to‐
wards compressor)
❑ When fitting circlip, take care not to bend it open more than necessary.
6 - Double-belt pulley
❑ Clean air conditioner compressor flange before fitting pulley
❑ With rubber elements -B- and threaded plates -C- for decoupling pulley from air conditioner compressor
drive shaft (rubber elements dampen vibrations and reduce noise)

Note
♦ Depending on version, threaded

plates -C- may also be linked via
a ring.
♦ A double-belt pulley is fitted on
vehicles with 5-cylinder engine
(Audi RS 3).

❑ Different versions may be fitted, depending on engine type and country-specific version of vehicle ⇒
❑ Clean air conditioner compressor flange before fitting pulley
Note

3.3 Detaching and attaching air conditioner

compressor at bracket
⇒ “3.3.1 Detaching and attaching mechanically driven air condi‐
tioner compressor at bracket - vehicles with 3-cylinder and 4-
cylinder engine”, page 216
⇒ “3.3.2 Detaching and attaching air conditioner compressor at
bracket - vehicles with 5-cylinder engine (Audi RS 3)”,
page 217
⇒ “3.3.3 Detaching and attaching electrically driven air conditioner
compressor at bracket”, page 219
3.3.1 Detaching and attaching mechanically

driven air conditioner compressor at
bracket - vehicles with 3-cylinder and 4-
cylinder engine
Removing
– If necessary, remove noise insulation (front) ⇒ General body
repairs, exterior; Rep. gr. 66 ; Noise insulation .
– Vehicles with air hose: Release hose clips -1 and 2- and re‐
move air hose.
– After removing air hose, seal off open lines and connections
with clean plugs from engine bung set - VAS 6122- .

– Remove poly V-belt ⇒ Rep. gr. 13 ; Cylinder block (pulley

end); Removing and installing poly V-belt .
– Unplug electrical connector -2- at air conditioner compressor
– Unscrew bolts -arrows- and detach air conditioner compressor
-1-.
Caution
Risk of damage to refrigerant lines and hoses

♦ Do not stretch, kink or bend refrigerant lines and hoses.
– Suspend air conditioner compressor from lock carrier with a

piece of wire.
Installing
– Thoroughly clean contact surfaces on air conditioner com‐
pressor and bracket.
– Insert dowel sleeves -arrows- in air conditioner compressor.
Note
Make sure that the dowel sleeves are positioned correctly and
that the contact surfaces are clean. Incorrectly fitted dowel
sleeves or dirty/damaged contact surfaces could lead to mis‐
alignment between the air conditioner compressor and the en‐
gine. After a period of operation, misalignment causes damage
to the air conditioner compressor or belt drive.
Tightening torque
♦ ⇒ “3.1 Exploded view - drive unit for air conditioner compres‐
sor”, page 204
3.3.2 Detaching and attaching air conditioner

compressor at bracket - vehicles with 5-
cylinder engine (Audi RS 3)
Note

bracket for ancillaries and re-attached without disconnecting
refrigerant lines.
♦ The procedure for detaching and attaching a “Sanden” air
conditioner compressor is as follows:
♦ Depending on the engine and the country-specific version,
different air conditioner compressors may be installed; refer to
Removing
– Remove noise insulation (centre) and wheel housing liner
(right-side) ⇒ General body repairs, exterior; Rep. gr. 66 ;
Noise insulation; Removing and installing noise insulation .

Model with two poly V-belts on air conditioner compressor:

– Remove air pipe (right-side) ⇒ Rep. gr. 21 ; Charge air sys‐
tem; Exploded view - charge air system .
– Unscrew bolt -2- and move coolant line -1- clear.
Model with one poly V-belt on air conditioner compressor:

– Remove air hose -1- leading to air pipe (right-side) ⇒ Rep. gr.
21 ; Charge air system; Exploded view - charge air system .

– Remove bolts -arrows-.
Caution

– Suspend air conditioner compressor from lock carrier with a

piece of wire.

Installing
pressor.
– After installing air conditioner compressor, refrigerant lines
and corresponding brackets, check that there is sufficient dis‐
tance between belt, bracket and pulley.
Note
Make sure that the dowel sleeves are positioned correctly and
alignment between the air conditioner compressor and the en‐
gine. After a period of operation, misalignment causes damage
to the air conditioner compressor or poly V-belt.
– Install poly V-belt ⇒ Rep. gr. 13 ; Cylinder block (pulley end);

Removing and installing poly V-belt .
– Install air pipe (right-side) ⇒ Rep. gr. 21 ; Charge air system;
Exploded view - charge air system .
Tightening torques
• ⇒ “3.1.2 Exploded view - drive unit for air conditioner com‐
pressor, vehicles with 5-cylinder engine (Audi RS 3)”,
page 207
3.3.3 Detaching and attaching electrically

driven air conditioner compressor at
bracket
warnings for working on such vehicles ⇒ page 19 and ⇒ 4-cylin‐
der direct injection engine (1.2, 1.4 ltr. 4-valve TFSI EA 211); Rep.
gr. 00 ; Safety precautions; Safety precautions when working on
vehicles with high-voltage system .

Note
♦ With control unit for air conditioning compressor - J842- and

electrical air conditioner compressor - V470-
♦ The control unit for air conditioning compressor - J842- inte‐
grated into the air conditioner compressor regulates the speed
and thus the output of the air conditioner compressor ( elec‐
trical air conditioner compressor - V470- ) on the basis of the
requests received via the data bus from the operating unit
( Climatronic control unit - J255- ) ⇒ Vehicle diagnostic tester
(“Guided Fault Finding” for air conditioner and battery regula‐
tion).
♦ The electrically driven air conditioner compressor is not fitted
with an air conditioner compressor regulating valve - N280- .
The output of the air conditioner compressor is regulated ex‐
ternally via the air conditioner compressor speed ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations and
ditioner and battery regulation).
♦ At present, the electrically driven air conditioner compressor
operates on the principle of a scroll-type supercharger (similar
to the "G-Lader" supercharger).
♦ The control unit for air conditioning compressor - J842- and
the electrical air conditioner compressor - V470- form one
component and cannot be separated at present.
In the following steps, work on the high-voltage system is neces‐

sary; de-energise high-voltage system ⇒ page 19 , ⇒ 4-cylinder
direct injection engine (1.2, 1.4 ltr. 4-valve TFSI EA 211); Rep.
gr. 93 ; De-energising high-voltage system and ⇒ 4-cylinder di‐
rect injection engine (1.2, 1.4 ltr. 4-valve TFSI EA 211); Rep. gr.
00 ; Safety precautions; Safety precautions when working on ve‐
hicles with high-voltage system .
Note
♦ Do not discharge the refrigerant circuit when detaching the air

conditioner compressor from the bracket. Do not detach re‐
frigerant hoses and refrigerant lines from the compressor.
♦ After detaching the air conditioner compressor, secure it to the
vehicle, e.g. with a piece of wire. Do not leave it hanging from
the refrigerant lines.
♦ Depending on the engine and the country-specific version,
different air conditioner compressors may be installed. ⇒
Detaching

– De-energise high-voltage system ⇒ 4-cylinder direct injection

engine (1.2, 1.4 ltr. 4-valve TFSI EA 211); Rep. gr. 93 ; De-
energising high-voltage system .
– Remove noise insulation (front) ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Noise insulation .
– Detach electrical connectors -A- (low voltage) and -B- (high
voltage) from air conditioner compressor ⇒ 4-cylinder direct
93 ; High-voltage wires; Overview of fitting locations - high-
voltage wires .
– Cover high-voltage wire connector and mating plug at air con‐
ditioner compressor to prevent damage and contamination
(e.g. with clean plugs from engine bung set - VAS 6122- ).
– Unscrew bolt -C- and detach earth wire.
Caution
Risk of damage to high-voltage system wire or refrigerant lines

and hoses.
– Remove bolts -D-.

– Detach air conditioner compressor -E- and swivel it away from
engine as far as possible without kinking or straining refriger‐
ant hoses.
– Attach air conditioner compressor -E- to vehicle (e.g. with a
piece of wire) so that refrigerant hoses are not kinked or strain‐
ed.
Note
If the air conditioner compressor cannot be swivelled far enough

away from the engine, the compressor must be removed com‐
pletely
⇒ “3.5.2 Removing and installing electrically driven air conditioner
compressor”, page 232 .
Attaching

• Check and, if necessary, clean contact surfaces on air condi‐

tioner compressor -B- for engine bracket -A- and on engine
bracket -A- itself before bolting on air conditioner compressor
⇒ Electrical system; Rep. gr. 97 ; Cleaning contact surfaces .
• Check and, if necessary, clean contact surfaces for earth wire
(secured with bolt -C-) before bolting on ⇒ Electrical system;
Rep. gr. 97 ; Cleaning contact surfaces .
Note
♦ Prior to installation, check the attachment points of the air

conditioner compressor, engine bracket, and earth wire at bolt
-C-. The contact surfaces must be clean and free from rust and
grease. If this is not the case, treat the contact surfaces ac‐
cordingly with the contact surface cleaning set - VAS 6410- ⇒
Electrical system; Rep. gr. 97 ; Cleaning contact surfaces .
♦ After re-installing the electrically driven air conditioner com‐
pressor (if removed) and then charging the refrigerant circuit,
first start up the compressor via the “Compressor run-in” func‐
tion of the basic setting routine. Otherwise, the air conditioner
compressor may be damaged if refrigerant oil has accumula‐
ted in the compression chamber of the air conditioner com‐
pressor due to inappropriate storage prior to installation
ditioner).
♦ An electrically driven air conditioner compressor may only be
activated when the refrigerant circuit is charged. Running the
air conditioner compressor with the refrigerant circuit empty
could lead to compressor damage ⇒ Vehicle diagnostic tester
♦ After attaching air conditioner compressor, check routing of
refrigerant lines. They must be inserted in the brackets provi‐
ded (if fitted, depends on engine).
♦ Check that refrigerant lines and corresponding brackets have
adequate clearance to other components, ensuring sufficient
distance between belt, bracket and pulley.
– Connect electrical wires to air conditioner compressor (-A- to

-C-) and secure wires at specified positions on engine.
– Re-install remaining components (removed earlier).
– Re-energise power supply of high-voltage system ⇒ 4-cylin‐
der direct injection engine (1.2, 1.4 ltr. 4-valve TFSI EA 211);
Rep. gr. 93 ; Re-energising high-voltage system .
– Interrogate event memory of operating and display unit ( Cli‐
matronic control unit - J255- ) and control unit for air condi‐
tioning compressor - J842- and erase any faults displayed
Tightening torque
♦ ⇒ “3.1.3 Exploded view - drive unit for electrically driven air
conditioner compressor”, page 210

3.4 Detaching and attaching refrigerant

lines at air conditioner compressor
⇒ “3.4.1 Detaching and attaching refrigerant lines at mechanically
driven air conditioner compressor”, page 223
⇒ “3.4.2 Detaching and attaching refrigerant lines at electrically
driven air conditioner compressor”, page 227

lines at mechanically driven air condi‐
tioner compressor
Note

service station .
♦ Depending on the design of the refrigerant line and the pro‐
duction period, the refrigerant line on the low-pressure side
may be provided with an additional weight (vibration damper,
resonator for reducing noise at refrigerant line) ⇒ page 171 .
Make sure that this component is not in contact with other
components and cannot come into contact during operation
(noise) ⇒ Electronic parts catalogue .

♦ Socket - 3320/1-
Removing
– Remove air duct at lock carrier ⇒ Rep. gr. 23 ; Air cleaner;
Removing and installing air cleaner housing (vehicles with
diesel engine) or ⇒ Rep. gr. 24 ; Air cleaner; Removing and
installing air cleaner housing (vehicles with petrol engine).
– If necessary, remove noise insulation (front) ⇒ General body
repairs, exterior; Rep. gr. 66 ; Noise insulation .

Audi RS 3 (continued) - version 1:

– Remove bolts -arrow-.
– Press coolant pipe and coolant line -1- slightly towards rear.
Audi RS 3 (continued) - version 2:

– If necessary, unfasten coolant hoses -1- from brackets and
carefully press them slightly towards rear.
– Remove bolts -2- using e.g. T-bar and socket - 3320/1- .
– Detach refrigerant lines.

Caution

WARNING

– Unscrew bolts -2, 4- using socket - 3320/1- and detach refrig‐

erant lines -1, 3-.
Caution
Risk of irreparable damage to air conditioner compressor.

♦ The air conditioner compressor is always driven when the
engine is running (there is no magnetic clutch). Therefore
do not start the engine unless the refrigerant circuit has
been properly assembled.
♦ If, for example, the refrigerant lines are not connected to
the air conditioner compressor and the connections are
sealed when the engine is running, the compressor might
heat up (internal heat generation) so much that this can
lead to irreparable damage to the compressor.

Installing
catalogue .
correctly.
line -1-.
Note
♦ Do not use O-rings from caps of replacement compressor

connections.
⇒ page 81 .
– Insert refrigerant lines -1 and 3- in corresponding connections

on air conditioner compressor.
– Tighten bolts -2 and 4- using socket - 3320/1- .
After completing the repairs, perform the following work on the
operating unit ( Climatronic control unit - J255- ) ⇒ Vehicle diag‐
– Interrogate event memory of operating unit ( -J255- ) and
erase any faults displayed.
⇒ “2.16 Starting up air conditioner after charging refrigerant
circuit”, page 199 .
Note

mation on air conditioning systems , or ⇒ Air conditioners with
refrigerant R1234yf - General information; Rep. gr. 87 ; Working
Tightening torque


lines at electrically driven air conditioner
compressor
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners
– Remove noise insulation (front) ⇒ General body repairs, ex‐
Caution

WARNING


-1 and 4-.
– Seal off open lines and connections with clean plugs from en‐
gine bung set - VAS 6122- .
Installing
catalogue .

correctly.
line -1-.
Note
♦ Lubricate O-rings lightly with refrigerant oil before fitting

⇒ page 81 .
♦ Make sure O-rings are seated correctly in groove -arrow- of
corresponding refrigerant line.
♦ After attaching the refrigerant lines to the air conditioner com‐
pressor (and after installing the air conditioner compressor)
check the routing of the lines. They must be inserted in the
brackets provided and must not make contact with other com‐
ponents.
tion).
– Insert refrigerant lines -1 and 4- in corresponding connections

on air conditioner compressor.
– Tighten bolts -2 and 3-.
refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air
87 ; Working with the air conditioner service station .
After completing the repairs, perform the following work on the
operating unit ( Climatronic control unit - J255- ) ⇒ Vehicle diag‐
– Interrogate event memory of Climatronic control unit - J255-
and erase any faults displayed.
Note

with the air conditioner service station; Starting up air conditioner
after charging refrigerant circuit .
Tightening torque
♦ ⇒ “3.1.3 Exploded view - drive unit for electrically driven air
conditioner compressor”, page 210

3.5 Removing and installing air conditioner

compressor
⇒ “3.5.1 Removing and installing mechanically driven air condi‐
tioner compressor”, page 229
⇒ “3.5.2 Removing and installing electrically driven air conditioner
3.5.1 Removing and installing mechanically

driven air conditioner compressor
Note

service station .

Removing
– Detach refrigerant lines from air conditioner compressor
⇒ “3.4 Detaching and attaching refrigerant lines at air condi‐
tioner compressor”, page 223 .
– If necessary, remove washer fluid reservoir ⇒ Electrical sys‐
tem; Rep. gr. 92 ; Windscreen washer system; Removing and
installing washer fluid reservoir .
– Vehicles with air hose: Release hose clips -1 and 2- and re‐
move air hose.
– After removing air hose, seal off open lines and connections
with clean plugs from engine bung set - VAS 6122- .


– Unscrew bolts -arrows- and detach air conditioner compressor
-1-.

Installing
pressor and bracket.
Note
♦ Make sure that the dowel sleeves are positioned correctly and
alignment between the air conditioner compressor and the
engine. After a period of operation, misalignment will cause
damage to the air conditioner compressor.
♦ If the air conditioner compressor is renewed due to specific
problems (e.g. internal damage), the refrigerant circuit must
be cleaned ⇒ Air conditioner with refrigerant R134a; Rep. gr.
87 ; Refrigerant circuit (Air conditioner with refrigerant R134a;
Refrigerant circuit; Working with the air conditioner service
station), or ⇒ Air conditioner with refrigerant R1234yf - Gen‐
service station; Cleaning air conditioner service station .
♦ When it is removed, the air conditioner compressor contains
an indeterminate amount of refrigerant oil. For this reason it is
important to observe the notes on renewing the compressor
⇒ Air conditioner with refrigerant R134a; Rep. gr. 87 ; Re‐
newing components of refrigerant circuit , or ⇒ Air conditioner
with refrigerant R1234yf - General notes; Rep. gr. 87 ; Re‐
frigerant circuit; Renewing components .
Caution
Risk of damage to air conditioner compressor.

♦ Depending on the position in which the air conditioner
compressor is stored, refrigerant oil may accumulate in
the compression chamber of the removed compressor.
♦ To prevent damage to the air conditioner compressor
when starting it up for the first time, turn the air conditioner
compressor 10 times by hand before fitting the poly V-belt
(after installing a new air conditioner compressor or add‐
ing fresh refrigerant oil).

refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit (Air condi‐
tioner with refrigerant R134a; Refrigerant circuit; Working with
the air conditioner service station), or ⇒ Air conditioner with
refrigerant R1234yf - General notes; Rep. gr. 87 ; Working
⇒ page 199 .
ing”).

– Observe notes on starting up air conditioner after installing air

conditioner compressor ⇒ Air conditioner with refrigerant
systems (Air conditioner with refrigerant R134a; General in‐
formation on air conditioning systems), or ⇒ Air conditioner
with refrigerant R1234yf - General notes; Rep. gr. 87 ; Work‐
ing with the air conditioner service station; Starting up air
conditioner after charging refrigerant circuit . (before using air
conditioner after it has been re-charged).
Tightening torque
♦ ⇒ “3.1 Exploded view - drive unit for air conditioner compres‐
sor”, page 204
3.5.2 Removing and installing electrically driv‐

en air conditioner compressor
warnings for working on such vehicles ⇒ page 19 .
In the following steps, work on the high-voltage system is neces‐
sary; de-energise high-voltage system ⇒ page 19 , ⇒ 4-cylinder
gr. 93 ; De-energising high-voltage system and ⇒ 4-cylinder di‐
rect injection engine (1.2, 1.4 ltr. 4-valve TFSI EA 211); Rep. gr.
00 ; Safety precautions; Safety precautions when working on ve‐
hicles with high-voltage system .
Removing
–
– Detach refrigerant lines from electrically driven air conditioner
compressor
⇒ “3.4.2 Detaching and attaching refrigerant lines at electri‐
cally driven air conditioner compressor”, page 227 .
– Detach electrically driven air conditioner compressor from
bracket
⇒ “3.3.3 Detaching and attaching electrically driven air condi‐
tioner compressor at bracket”, page 219 .
– Unscrew bolts and remove air conditioner compressor.
Installing
Before installing air conditioner compressor ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ; General information on air con‐
ditioning systems , or ⇒ Air conditioners with refrigerant R1234yf
- General notes; Rep. gr. 87 ; Refrigerant circuit; Renewing com‐
ponents .

Note
♦ When it is removed, the air conditioner compressor contains

an indeterminate amount of refrigerant oil. For this reason it is
important to observe the notes on renewing the compressor
⇒ Air conditioner with refrigerant R134a; Rep. gr. 87 ; Re‐
newing components of refrigerant circuit , or ⇒ Air conditioner
with refrigerant R1234yf - General notes; Rep. gr. 87 ; Re‐
frigerant circuit; Renewing components .
– Attach air conditioner compressor to bracket ⇒ page 219 .

– Attach refrigerant lines to air conditioner compressor
⇒ page 227 .
Note
♦ After installing the electrically driven air conditioner compres‐

sor and then charging the refrigerant circuit, first start up the
compressor by way of the “Compressor run-in” function of the
basic setting routine. Otherwise, the air conditioner compres‐
sor may be damaged if refrigerant oil has accumulated in the
compression chamber of the air conditioner compressor due
to inappropriate storage prior to installation ⇒ Vehicle diag‐
nostic tester (“Guided Fault Finding” for air conditioner).

refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air
87 ; Working with the air conditioner service station .
– Re-install remaining components removed in reverse order.
– Start up electrical air conditioner compressor - V470- via
“Compressor run-in” function ⇒ Vehicle diagnostic tester
tion).

Note

with the air conditioner service station; Starting up air conditioner
after charging refrigerant circuit .
3.6 Removing and installing pulley

⇒ “3.6.1 Removing and installing pulley - Denso air conditioner
⇒ “3.6.2 Removing and installing pulley - Sanden air conditioner
⇒ “3.6.3 Removing and installing pulley - Delphi/Mahle air condi‐
tioner compressor”, page 237
3.6.1 Removing and installing pulley - Denso

air conditioner compressor
Note
♦ The pulley is sensitive to impact and should therefore be trea‐

ted with extreme care.
♦ If pulley overload protection device has been triggered, check
freedom of movement of air conditioner compressor before
renewing pulley. If air conditioner compressor cannot rotate
freely it must be renewed.
♦ If the drive plate overload protection device has been trig‐
gered, the pulley can rotate with the outer section of the drive
plate without the air conditioner compressor shaft and the
hexagon flats attached to the drive plate (inner section of drive
plate) also rotating.
♦ The following illustrations show the air conditioner compressor
on a vehicle with a 4-cyl. engine. The layout of the components
differs on vehicles with a 5-cyl. engine with one poly V-belt on
the air conditioner compressor, but the removal and installa‐
tion procedures are the same. For vehicles with a 5-cyl. engine
with two poly V-belts on the air conditioner compressor, refer
to
⇒ “3.6.2 Removing and installing pulley - Sanden air condi‐
tioner compressor”, page 236 .

♦ Commercially available oil filter strap wrench

Removing
– Detach cap -1-.
– Counterhold pulley with oil filter strap wrench and remove bolts
-arrows-.
– Remove nut -2-; to do so counterhold drive shaft -1- for air

conditioner compressor.
– Detach drive plate -3- with nut.
Note
♦ The torque for driving the air conditioner compressor is applied

to the air conditioner compressor shaft via the thread securing
the drive plate.
♦ If the drive plate has become so firmly attached to the air con‐
ditioner compressor shaft that it can no longer be released (the
7 mm hexagon flats can no longer transmit the necessary tor‐
que), the air conditioner compressor must be renewed.

– Detach circlip -2-.

– Detach pulley -1-.
Installing
⇒ “3.2.1 Exploded view - air conditioner compressor pulley
(Denso)”, page 212
Note
Renew circlip.
– Clean air conditioner compressor drive shaft before fitting pul‐

ley.
– Attach pulley to air conditioner compressor drive shaft.
• It should be possible to attach the component without having
to exert force.
– Insert circlip in correct position.
• Flat side faces air conditioner compressor
– Clean thread of air conditioner compressor drive shaft before
bolting on drive plate.
Note
Thread of new drive plate has been lubricated at factory with a

pre-determined amount of a specific grease.
3.6.2 Removing and installing pulley - Sanden

air conditioner compressor
Note

♦ If pulley overload protection device has been triggered, check
freedom of movement of air conditioner compressor before
renewing pulley. If air conditioner compressor cannot rotate
freely it must be renewed.
plate without the air conditioner compressor shaft and the
hexagon flats attached to the drive plate (inner section of drive
plate) also rotating.

– Removing and installing pulley
⇒ “3.2.2 Exploded view - Sanden air conditioner compressor
pulley, version 1”, page 213 (vehicles with 4-cylinder engine)
or
⇒ “3.2.3 Exploded view - Sanden air conditioner compressor
pulley, version 2”, page 214 (vehicles with 5-cylinder engine)

3.6.3 Removing and installing pulley - Delphi/

Mahle air conditioner compressor
Note

plate without the air conditioner compressor shaft also rotat‐
ing.
Currently the pulley cannot be renewed separately on air condi‐

tioner compressors manufactured by “Delphi/Mahle”. If a custom‐
er reports a problem, the entire air conditioner compressor must
be renewed.
– Renew air conditioner compressor ⇒ page 216 .
Pulley, version “1”
Note
Currently, the pulley of the “Delphi/Mahle” air conditioner com‐

pressor (version “1”) is identical to the pulley of the “Sanden”
compressor
ley, version 1”, page 213 (vehicles with 4-cylinder engine). The
only difference is that the drive plate is attached to the air condi‐
tioner compressor shaft with a self-locking bolt
⇒ Item 2 (page 213) .
Pulley, version “2”
Note
♦ The drive plate -B- is bolted to the air conditioner compressor

shaft with bolt -A- (tightening torque: 20 Nm).
♦ The spring elements (overload protection device) -C- of the
drive plate -B- are triggered if the torque is too great (e.g. if air
conditioner compressor cannot rotate freely), causing the pul‐
ley -D- to free-wheel without driving the compressor.

4 Control motors
⇒ “4.1 Removing and installing temperature flap control motor
⇒ “4.2 Removing and installing defroster flap control motor V107
with potentiometer G135 ”, page 240
⇒ “4.3 Removing and installing air recirculation flap control motor
V113 ”, page 242
⇒ “4.4 Removing and installing left temperature flap control motor
⇒ “4.5 Removing and installing right temperature flap control mo‐
tor V159 with potentiometer G221 ”, page 246
⇒ “4.6 Removing and installing fresh air/air recirculation, air flow
flap control motor V425 with potentiometer G644 ”, page 248
⇒ “4.7 Removing and installing actuator for fresh air/air recircu‐
lation, air flow flap”, page 251
⇒ “4.8 Removing and installing air distribution flap control motor
⇒ “4.9 Removing and installing front air distribution flap control
motor V426 with potentiometer G642 ”, page 255
⇒ “4.10 Removing and installing actuator for air distribution flap”,
page 257
4.1 Removing and installing temperature

flap control motor - V68- with potentiom‐
eter -G92-
Heater and manually controlled air conditioner
Removing
– Vehicles with ignition lock: Remove ignition key.
WARNING
Risk of injury from knee airbag.

♦ Before handling pyrotechnic components, the mechanic
must discharge any static electricity. Observe the safety
precautions for working on airbags ⇒ General body re‐
pairs, interior; Rep. gr. 00 ; Safety precautions; Safety
precautions when working on pyrotechnic components .
– Remove dash panel cover (driver side) ⇒ General body re‐

pairs, interior; Rep. gr. 68 ; Storage compartments/covers/trim
panels; Removing and installing dash panel cover (driver
side) .
Note
Right-hand drive vehicles: Remove glove box ⇒ General body

repairs, interior; Rep. gr. 68 ; Storage compartments/covers/trim
panels; Removing and installing glove box .


– Swivel out temperature flap control motor - V68- -item 1- be‐
hind temperature flap operating shaft -3-.
– Detach control motor.
4. Control motors 239

Installing
⇒ “5.1 Exploded view - heater and air conditioning unit”, page
262
Note
♦ Check operation of flaps and hinge mechanism before instal‐

ling.
♦ Make sure levers and shafts are seated correctly in actuator
sockets.
– Position control motor -1- on air distribution housing; gear

wheel -2- on control motor must engage in gear wheel -3- at
temperature flap lever.
• Long tooth -4- must engage in recess -arrow- in actuating arm.
Note
♦ Turn actuator socket in control motor if gear wheels on control

motor and temperature flap lever are not opposite one anoth‐
er. Observe notes ⇒ page 82 .
♦ The control motor is not positioned correctly on the housing if
the bolts cannot be fitted.
– Route electrical wiring harness so that it cannot come into

contact with moving components (e.g. control motor lever).
– To check operation of control motor, connect an adapter cable
⇒ page 82 , or use a test lead from adapter set - V.A.G 1594C-
to connect contacts “5” and “6” of control motor to a 12 V
battery via a 5 A fuse.
Note
Turn control motor until it reaches a convenient position for in‐

stallation. The direction of rotation can be reversed by interchang‐
ing positive and negative.
– Interrogate event memory and erase any entries displayed;

then perform “Basic setting” ⇒ Vehicle diagnostic tester (“Gui‐
– As a final step, check operation of heater/air conditioner.
4.2 Removing and installing defroster flap

control motor - V107- with potentiometer
-G135-
Automatically controlled air conditioner
Removing
– Remove glove box ⇒ General body repairs, interior; Rep. gr.
68 ; Storage compartments/covers/trim panels; Removing and
installing glove box .

Note
Right-hand drive vehicles: Remove dash panel ⇒ General body

repairs, interior; Rep. gr. 70 ; Dash panel; Removing and instal‐
ling dash panel .

– Detach defroster flap control motor - V107- -item 1-.
Installing
262
Note

ling.
sockets.

– The actuator socket in the control motor can only be fitted onto
the actuating arm -2- in one position.
• The actuator socket in the control motor must be opposite the
actuating arm as shown.
Note
If the actuator socket and actuating arm are not opposite one an‐
other, the socket in the control motor must be turned. Observe
notes ⇒ page 82 .
– Position control motor on air distribution housing. The actuat‐

ing arm must engage -arrow- in actuator socket -1-.
• There must not be any play in the connection between the
control motor and actuating arm.
Note
The control motor is not positioned correctly on the housing if the

bolts cannot be fitted.

Note


4.3 Removing and installing air recirculation

flap control motor - V113-
Heater and manually controlled air conditioner
Note
The control motor has end stops with integrated limit switches
instead of a potentiometer.
Removing

Note
Right-hand drive vehicles: Remove centre tube for dash panel ⇒

General body repairs, interior; Rep. gr. 70 ; Centre tube for dash
panel .

– Detach air recirculation flap control motor - V113- -item 3- from
intake duct -2-.

Installing
262
Note

ling.
sockets.
– Fresh air flap must be in “open” position.

• Operating shaft -2- must make contact with stop -1- -arrow-,
as shown.
Note
If the control motor operating shaft is not on the stop for “fresh air
mode”, the actuator socket in the control motor must be turned.
Observe notes ⇒ page 82 .
– Position control motor on air intake box. Operating shaft must

engage in actuator socket.
operating shaft and the actuator socket.
Note


Note



4.4 Removing and installing left tempera‐

ture flap control motor - V158- with po‐
tentiometer -G220-
Removing
WARNING
Risk of injury from knee airbag.

♦ Before handling pyrotechnic components, the mechanic
must discharge any static electricity. Observe the safety
precautions for working on airbags ⇒ General body re‐
pairs, interior; Rep. gr. 00 ; Safety precautions; Safety
precautions when working on pyrotechnic components .

– Remove dash panel cover (driver side) ⇒ General body re‐
pairs, interior; Rep. gr. 68 ; Storage compartments/covers/trim
panels; Removing and installing dash panel cover (driver
side) .
Note


– Swivel out left temperature flap control motor - V158-
-item 1- behind temperature flap operating shaft -3-.
– Detach control motor.

Installing
262
Note

ling.
sockets.

Note


Note


4.5 Removing and installing right tempera‐

ture flap control motor - V159- with po‐
tentiometer -G221-
Removing
– Remove footwell vent (passenger side) ⇒ page 325 .

Note
Right-hand drive vehicles: Remove dash panel cover (driver side)

⇒ General body repairs, interior; Rep. gr. 68 ; Storage compart‐
ments/covers/trim panels; Removing and installing dash panel
cover (driver side) .
– Detach temperature flap operating shaft -1-.

– Detach right temperature flap control motor - V159- -item 2-.

Installing
262
Note

ling.
sockets.

Note


Note


4.6 Removing and installing fresh air/air re‐

circulation, air flow flap control motor -
V425- with potentiometer -G644-
Removing

Note
Right-hand drive vehicles: Remove centre tube for dash panel ⇒

General body repairs, interior; Rep. gr. 70 ; Centre tube for dash
panel .

– Detach fresh air/air recirculation, air flow flap control motor -
V425- -item 1- from intake duct.
Installing
262
Note

ling.
sockets.

Note
notes ⇒ page 82 .

Note


Note



4.7 Removing and installing actuator for

fresh air/air recirculation, air flow flap
Removing
– Remove fresh air/air recirculation, air flow flap control motor
⇒ page 248 .
– Move wiring harness -5- clear.
– Carefully press actuating lever -1- off fresh air/air recirculation
flap lever -8- -arrow-.
– Remove bolts -4, 7-.
– Detach actuator -6-.
Installing
262
Note

ling.
sockets.

Note
notes ⇒ page 82 .

Note


Note

– When fitting actuator, actuating lever -3- must engage in air

flow flap lever -2-.


flap control motor - V428- with potenti‐
ometer -G645-
Heater unit and manually controlled air conditioner
Removing
– Remove steering wheel ⇒ Rep. gr. 48 ; Steering wheel; Re‐
moving and installing steering wheel .
– Remove dash panel insert ⇒ Electrical system; Rep. gr. 90 ;
Dash panel insert; Removing and installing dash panel insert .
– If fitted: Remove entry and start authorisation control unit -
J518- ⇒ Electrical system; Rep. gr. 94 ; Entry and start
authorisation; Overview - entry and start authorisation sys‐
tem .
Note

ling dash panel .
– Remove footwell vent (driver side) ⇒ page 325 .

Note
♦ The bolts are accessible from underneath behind the central

tube.
♦ Use a magnetic screwdriver to remove the bolts, or have a
second mechanic hold a magnet over the bolt through the
opening for the instrument cluster. If the bolt drops down, it will
fall into the wiring duct pan where you cannot reach it. To take
it out, the dash panel must be removed.

– Detach air distribution flap control motor - V428- -item 4- and

take control motor out between heater/air conditioning unit and
central tube -3- through opening -2- for instrument cluster.
Installing
262
Note

ling.
sockets.

Note
notes ⇒ page 82 .

Note


Note


4.9 Removing and installing front air distri‐

bution flap control motor - V426- with
potentiometer -G642-
Removing
– Remove steering wheel ⇒ Running gear, front-wheel drive
and four-wheel drive; Rep. gr. 48 ; Steering wheel; Removing
and installing steering wheel .
– Remove dash panel insert ⇒ Electrical system; Rep. gr. 90 ;
Dash panel insert; Removing and installing dash panel insert .
tem .

Note

ling dash panel .

Note
♦ The bolts are accessible from underneath behind the central

tube.
♦ Use a magnetic screwdriver to remove the bolts, or have a
second mechanic hold a magnet over the bolt through the
opening for the instrument cluster. If the bolt drops down, it will
fall into the wiring duct pan where you cannot reach it. To take
it out, the dash panel must be removed.
– Detach front air distribution flap control motor - V426-

-item 4- and take control motor out between heater/air condi‐
tioning unit and central tube -3- through opening -2- for
instrument cluster.
Installing
262
Note

ling.
sockets.

Note
notes ⇒ page 82 .

Note


Note


4.10 Removing and installing actuator for air

distribution flap
⇒ “4.10.1 Removing and installing actuator for front air distribution
flap - heater and manually controlled air conditioner”, page 257
⇒ “4.10.2 Removing and installing actuator for front air distribution
flap - automatically controlled air conditioner”, page 259
4.10.1 Removing and installing actuator for

front air distribution flap - heater and
Removing
– Move front seats as far back as they will go and extend MMI
display ⇒ Infotainment/MMI Operating Manual .

– Remove dash panel ⇒ General body repairs, interior; Rep. gr.

70 ; Dash panel; Removing and installing dash panel .
– Remove air duct for defroster vent ⇒ page 324 .
– Remove front air distribution flap control motor ⇒ page 253 .
– Carefully press off actuating lever -7- -arrow-.
– Carefully press actuating lever -3- off defroster flap lever -2-.
– Remove bolts -1, 4, 8-.
– Lift off actuator -9-.
Installing
262
Note

ling.
sockets.
– Check that the two gear wheels are correctly positioned.

• Rectangular tooth -2- must engage in gap -3- in gear wheel
-1-.
– When fitting actuator, actuating lever -5- must engage in lever

-6- of centre vent flap.

4.10.2 Removing and installing actuator for

front air distribution flap - automatically
controlled air conditioner
Removing
– Remove air duct for defroster vent ⇒ page 324 .
– Remove front air distribution flap control motor ⇒ page 253 .
– Carefully press off actuating lever -5- -arrow-.
– Lift off actuator -7-.
Installing
262
Note

ling.
sockets.
– Check that the two gear wheels are correctly positioned.

• Rectangular tooth -2- must engage in gap -3- in gear wheel
-1-.

– When fitting actuator, actuating lever -3- must engage in lever

-4- of centre vent flap.

5. Front heater and air conditioning unit 261

5 Front heater and air conditioning unit

⇒ “5.1 Exploded view - heater and air conditioning unit”,
page 262
⇒ “5.2 Exploded view - attachments for heater and air conditioning
unit and air intake box”, page 269
⇒ “5.3 Exploded view - evaporator housing”, page 271
⇒ “5.4 Exploded view - flaps and partitions in air distribution hous‐
ing”, page 273
⇒ “5.5 Removing and installing evaporator”, page 275
⇒ “5.6 Cleaning evaporator”, page 277
⇒ “5.7 Removing and installing evaporator output temperature
sender G263 ”, page 286
⇒ “5.8 Removing and installing vent temperature sender G150 /
G151 ”, page 286
⇒ “5.9 Removing and installing heater and air conditioning unit”,
page 287
⇒ “5.10 Removing and installing retainers for heater and air con‐
ditioning unit”, page 290
⇒ “5.11 Dismantling and assembling heater and air conditioning
unit”, page 291
⇒ “5.12 Removing and installing air distribution housing”,
page 293
⇒ “5.13 Removing and installing dust and pollen filter”,
page 293
⇒ “5.14 Removing and installing fresh air blower V2 ”,
page 296
⇒ “5.15 Removing and installing fresh air blower control unit J126
”, page 297
⇒ “5.16 Removing and installing footwell vent temperature sender
G192 ”, page 297
⇒ “5.17 Removing and installing auxiliary air heater element Z35
”, page 298
⇒ “5.18 Removing and installing heat exchanger”, page 299
⇒ “5.19 Removing and installing coolant pipes at heat exchanger”,
page 310
⇒ “5.20 Checking condensation drain hose”, page 313
⇒ “5.21 Removing and installing condensation drain hose”, page
316
5.1 Exploded view - heater and air condi‐

tioning unit
Note
♦ The heater and air conditioning unit is available in different

versions and from different manufacturers. The individual
components of the various heater and air conditioning units
are similar but not identical; the combination of components
by different manufacturers is therefore not permissible ⇒

♦ The following illustrations show a Valeo heater/air conditioning

unit; distinguishing features compared to heaters from other
manufacturers ⇒ page 1 .
Exploded view - heater and air conditioning unit, flap control (left-
side) ⇒ page 263
Exploded view - heater and air conditioning unit, flap control
(right-side) ⇒ page 264
Exploded view - heater and air conditioning unit, heat exchanger,
Valeo auxiliary air heater element ⇒ page 265
Denso auxiliary air heater element ⇒ page 267
Exploded view - heater and air conditioning unit, flap control (left-
side)
1 - Operating lever
❑ For actuating defroster
flap and air distribution
flap
2 - Air distribution flap control
motor
tions
Heater and manually control‐
led air conditioner:
Air distribution flap control mo‐

tor - V428- with potentiometer
for air distribution flap control
motor - G645-
⇒ page 253
Automatically controlled air
conditioner:
❑ Front air distribution flap
control motor - V426-
with potentiometer for
front air distribution flap
control motor - G642-
⇒ page 255
3 - Bolt
❑ 2x
❑ 1 Nm
4 - Bolt
❑ 3x
❑ 1 Nm
5 - Bolt
❑ 2x
❑ 1 Nm

6 - Temperature flap control motor

Heater and manually controlled air conditioner:
❑ Temperature flap control motor - V68- with potentiometer for temperature flap control motor - G92-
Automatically controlled air conditioner:
❑ Left temperature flap control motor - V158- with potentiometer for left temperature flap control motor -
G220-
7 - Operating lever
❑ For warm air flap
8 - Heater and air conditioning unit
❑ Many components of the heater and heater/air conditioning unit are identical
❑ Different versions ⇒ page 1
❑ It is not permissible to combine components from different manufacturers
⇒ “1.1 Identification of heater and air conditioning unit”, page 1
❑ The following illustrations show a Valeo heater.
9 - Actuator for defroster and air distribution flap
Exploded view - heater and air conditioning unit, flap control

(right-side)


unit
❑ Exploded view
⇒ page 291
2 - Operating lever
❑ For defroster flap
3 - Bolt
❑ 2x
❑ 1 Nm
4 - Defroster flap control motor
- V107-
defroster flap control
motor - G135-
❑ With automatically con‐
trolled air conditioner
only
tions
⇒ page 240
5 - Right temperature flap con‐
trol motor - V159-
right temperature flap
control motor - G221-
only
6 - Bolt
❑ 2x
❑ 1 Nm
7 - Operating lever
❑ For warm air flap

Valeo auxiliary air heater element

1 - Bolt
❑ 2 Nm
changer
logue
gine
⇒ page 299
3 - Clip
❑ Can also be replaced by
a clamp in the course of
service work
changer
logue
⇒ page 299
5 - O-ring
logue
❑ Renewing
installing heat exchang‐
er”, page 299
6 - Cover
❑ For heat exchanger
7 - Bolt
❑ 2 Nm
8 - Foam spacer
9 - Bracket
10 - Foam
❑ For insulation
Z35-
12 - Heat exchanger


Note

are currently not fitted with an auxil‐
iary air heater element - Z35- ; on
these vehicles, the high-voltage
heater (PTC) - Z115- (with high-volt‐
age heater (PTC) control unit -
J848- ) assumes the function of the
auxiliary air heater element
⇒ “4.15 Notes on high-voltage heat‐
er (PTC) Z115 (and high-voltage
heater (PTC) control unit J848 )”,
page 85 .
14 - Bolt
❑ 2x
❑ 2 Nm
16 - Earth wire
❑ Nut, 9 Nm
17 - Bolt
❑ 3x
❑ 2 Nm
18 - Screw-type clip
19 - O-ring

Denso auxiliary air heater element

1 - Heat exchanger
logue
⇒ page 299
2 - Bracket
3 - Bolt
❑ 2 Nm
4 - O-ring
logue
❑ Renewing
installing heat exchang‐
er”, page 299
5 - Screw-type clip
bolt: 2 Nm
changer
logue
gine
⇒ page 299
7 - Screw-type clip
bolt: 2 Nm
8 - O-ring
9 - Coolant pipe for heat exchanger
10 - Bolt
❑ 2 Nm
11 - Foam spacer
12 - Bracket
13 - Foam
❑ For insulation


Z35-
16 - Bolt
❑ 2x
❑ 2 Nm
18 - Earth wire
❑ Nut, 9 Nm
5.2 Exploded view - attachments for heater

and air conditioning unit and air intake
box
Note

♦ The following illustration shows a Valeo air intake box; distin‐
guishing features compared to heater and air conditioning unit
from other manufacturers ⇒ page 1 .

1 - Bolt/clip
❑ 2x
bolt: 1 Nm
Note
♦ Different versions; renew clip

version if necessary ⇒ Electron‐
♦ Use e.g. pliers or a screwdriver
to prise out version with clip.
2 - Cover
3 - Housing (top section)
4 - Bolt
❑ 2x
❑ 1 Nm
5 - Air intake duct
❑ With fresh air and air re‐
circulation flap
logue
⇒ page 328
❑ Do not dismantle
6 - Actuator for fresh air and air
recirculation flap
only
⇒ page 251
7 - Bolt
❑ With automatically controlled air conditioner only
❑ 2x
❑ 1 Nm
8 - Control motor
Heater and manually controlled air conditioner:
❑ Air recirculation flap control motor - V113- without potentiometer, with limit switches at end stops ⇒ Cur‐
rent flow diagrams, Electrical fault finding and Fitting locations
Automatically controlled air conditioner:
❑ Fresh air/air recirculation, air flow flap control motor - V425- with potentiometer for fresh air/air recircu‐
lation, air flow flap control motor - G644-
9 - Bolt
❑ 2x
❑ 1 Nm

10 - Dust and pollen filter

Note
Not fitted with an activated charcoal

filter insert at the factory on vehicles
without air conditioner and vehicles
with manually controlled air condi‐
tioner ⇒ page 83
❑ Change interval ⇒ Maintenance tables
11 - Cover
❑ For dust and pollen filter
12 - Fresh air blower - V2-
13 - Fresh air blower control unit - J126-
14 - Bolt
❑ 2x
❑ 1 Nm
5.3 Exploded view - evaporator housing
Note

♦ The following illustration shows a Valeo evaporator housing;
distinguishing features compared to heater and air condition‐
ing unit from other manufacturers ⇒ page 1 .

1 - Evaporator housing (bottom

section)
2 - Evaporator
❑ Vehicles with air condi‐
tioner only
❑ Check that foam seals
are not damaged and
are bonded on properly
⇒ page 275
3 - O-ring
ic parts catalogue
⇒ page 81
4 - Retaining plate
tioner only
❑ For fixing refrigerant line
in position and securing
expansion valve
5 - Expansion valve
tioner only
❑ Exploded view
pansion valve”,
page 146
Note

6 - Bolt
❑ Vehicles with air conditioner only
❑ Tightening torque ⇒ Item 22 (page 153)
7 - Seal/insulation
❑ Heat insulation for expansion valve
❑ On vehicles without an air conditioner, there is no opening for the expansion valve in the seal in the
plenum chamber back panel, or it is sealed off by a foam pad.
8 - O-ring
❑ Vehicles with air conditioner only
9 - Bolt
❑ 8x
❑ 1.5 Nm

10 - Evaporator housing (top section)

11 - Honeycomb element
❑ Only fitted on vehicles with heater (without air conditioner)
5.4 Exploded view - flaps and partitions in air distribution housing

View from front
Note
♦ -Arrow- = direction of travel

♦ ⇒ “5.1 Exploded view - heater and air conditioning unit”, page 262
1 - Warm air flap (right-side)

❑ From heat exchanger
❑ Activated via cold air
flap (right-side)
2 - Operating lever
❑ For flap control
3 - Cold air flap (right-side)
❑ From evaporator
❑ Different versions
Heater unit and manually con‐
❑ Activated jointly via
shaft of cold air flap (left-
side) by temperature
flap control motor -V68-
via actuating lever (left-
side)
conditioner
❑ Activated by tempera‐
ture flap control motor -
V159- via actuating lev‐
er (right-side)
4 - Actuating lever (right-side)
for temperature control flap
❑ Depending on version
❑ Automatically controlled
air conditioner only
❑ Activated by tempera‐
ture flap control motor -
V159-
5 - Actuating lever of defroster
flap
❑ To windscreen and door windows
❑ Automatically controlled air conditioner only
❑ Activated by defroster flap control motor -V107-

6 - Actuating lever of defroster flap

❑ To windscreen and door windows
❑ Heater unit and manually controlled air conditioner only
❑ Activated by air distribution flap control motor -V428- via defroster and air distribution actuator
7 - Actuating lever for air distribution flap
❑ Activated by air distribution flap control motor -V428- via defroster and air distribution actuator
❑ Activated by front air distribution flap control motor -V426- via defroster and air distribution actuator
8 - Actuating lever (left-side)
❑ Activated by temperature flap control motor -V68-
❑ Activated by temperature flap control motor -V158-
9 - Cold air flap (left-side)
❑ From evaporator
❑ Activated by temperature flap control motor -V68- via actuating lever (left-side)
❑ Activated by temperature flap control motor -V158- via actuating lever (left-side)
10 - Operating lever
11 - Warm air flap (left-side)
❑ From heat exchanger
❑ Activated via cold air flap (left-side)
View from rear
Note
♦ -Arrow- = direction of travel

♦ ⇒ “5.1 Exploded view - heater and air conditioning unit”, page 262

1 - Flap for air duct (rear)

Heater unit and manually con‐
❑ Air duct is sealed with a
plug
❑ Depending on manufac‐
turer, not always fitted
on version with heater
and manually controlled
air conditioner (not re‐
quired as air duct is
sealed off)
conditioner
❑ For centre console vent
2 - Operating lever
❑ Equipment-specific
(with automatically con‐
trolled air conditioner)
❑ Not always fitted on ver‐
sion with heater unit and
manually controlled air
conditioner
⇒ Item 1 (page 275)
3 - Flap (left-side) for dash pan‐
el vent (left-side)
4 - Operating lever
❑ For activation of vent
flaps
❑ Activated via actuator
5 - Flap (left-side) for dash pan‐
el vent (centre)
6 - Flap (right-side) for dash panel vent (right-side)
7 - Flap (right-side) for dash panel vent (centre)
5.5 Removing and installing evaporator
WARNING


Note

Removing
– Remove heater and air conditioning unit ⇒ page 287 .
– Remove fresh air blower - V2- ⇒ page 296 .
– Remove intake duct ⇒ page 328 .
– Remove coolant pipes from heat exchanger ⇒ page 310 .
– Separate air distribution housing and evaporator housing.
– Remove bolts -1-.
– Release retaining tabs -4 and 5- -arrows-.
– Detach top section of evaporator housing -3- from bottom sec‐
tion -2-.

– Pull evaporator -2- out of evaporator housing (bottom section)

-1-.
– Remove expansion valve ⇒ page 171 .
– Detach seal/insulation -3-; to do so, pull movable part -5- to
the side -arrow-.
– Detach locking element -4- for refrigerant lines.
Installing
⇒ “5.3 Exploded view - evaporator housing”, page 271
Note
Even very small leaks at the "tongue-and-groove" joint between

the top and bottom sections of the evaporator housing can lead
to whistling noises caused by escaping air. For this reason, lubri‐
cate the connection points lightly with silicone grease or similar
to completely seal the connection points. For silicone grease, re‐
fer to ⇒ Electronic parts catalogue

⇒ page 199 .
ing”).
5.6 Cleaning evaporator

⇒ “5.6.1 Cleaning evaporator with an ultrasonic A/C cleaner”,
page 277
⇒ “5.6.2 Cleaning evaporator using pressure-feed spray gun
V.A.G 1538 and spray lance”, page 280
5.6.1 Cleaning evaporator with an ultrasonic

A/C cleaner
Note
There are numerous evaporator cleaning methods with different

effects available on the market. For the cleaning method for e.g.
the evaporator currently checked and approved by Audi, use an
ultrasonic A/C cleaner and a pressure-feed spray gun. Other
methods checked and approved by Audi and the corresponding
information can be found e.g. in the “Audi
ServiceNet” ( ⇒ “2.3 Notes on odours in vehicles with air condi‐
tioner”, page 6 ).

♦ Ultrasonic A/C cleaner - VAS 6189A- (for currently available
ultrasonic A/C cleaners, refer to ⇒ Electronic parts catalogue )
♦ Cleaning fluid - VAS 6189/1-

♦ Vacuum cleaner attachment - VAS 6288-

♦ Vacuum cleaner (commercially available)
Procedure
– Check whether the air conditioning unit evaporator is really the
source of the odour by switching from fresh air to air recircu‐
lation mode
⇒ “2.3 Notes on odours in vehicles with air conditioner”, page
6.
– Check and if necessary clean plenum chamber water drain
⇒ page 333 .
– Remove dust and pollen filter ⇒ page 293 .
– Clean installation slot for dust and pollen filter.
– Seal opening for dust and pollen filter at air conditioning unit.
– Start engine.
– Close windows, sun roof and rear lid.
• Air conditioner compressor off: Lamp in AC or A/C button
-5- is off.
• Press Air recirculation button -2-: Lamp lights up.
• Set rotary control -3- for fresh air blower to speed “1”.

Vehicles with automatically controlled air conditioner:

• Air conditioner compressor off: Lamp in AC or A/C button
-11- is off.
• Press buttons -5 and 6- for dash panel vents.
• Set rotary control -9- for fresh air blower to minimum speed: -
V2- runs at minimum speed.
– Shake bottle of cleaning fluid - VAS 6189/1- and pour fluid into
ultrasound A/C cleaner - VAS 6189A- .
Note
For information on how to use the ultrasound A/C cleaner, refer

to the ⇒ Operating instructions of -VAS 6189A- .
– Position ultrasound A/C cleaner - VAS 6189A- in front pas‐

senger's footwell.
– Start up ultrasound A/C cleaner - VAS 6189A- (in accordance
with operating instructions) and position outlet hose so that
vapour emerging is drawn in by fresh air blower - V2- via
opening for air recirculation of air conditioning unit (in pas‐
senger's footwell behind glove box).
– Close vehicle doors.
Note
The cleaning procedure takes 15 to 20 minutes. It is completed

when no further vapour emerges from the outlet hose of the ul‐
trasound A/C cleaner - VAS 6189A- .
– Switch off ultrasonic A/C cleaner - VAS 6189A- .

– Open vehicle doors and vent vehicle for at least 10 minutes.
– Remove ultrasound A/C cleaner - VAS 6189A- from vehicle
and clean it.
– Install dust and pollen filter ⇒ page 293 .

5.6.2 Cleaning evaporator using pressure-

feed spray gun - V.A.G 1538- and spray
lance
Note
There are numerous evaporator cleaning methods with different

effects available on the market. For the cleaning method for e.g.
the evaporator currently checked and approved by Audi, use an
ultrasonic A/C cleaner and a pressure-feed spray gun. Other
methods checked and approved by Audi and the corresponding
information can be found e.g. in the “Audi
ServiceNet” ( ⇒ “2.3 Notes on odours in vehicles with air condi‐
tioner”, page 6 ).

♦ Pressure-feed spray gun - V.A.G 1538- (for currently available
pressure-feed spray guns, refer to ⇒ Electronic parts cata‐
logue )
♦ Probe for evaporator cleaning, straight - V.A.G 1538/5- -A-
(short version: approx. 500 mm, curved or probe - VAS1538/9-
as specified for this vehicle); for currently available probes,
refer to ⇒ Electronic parts catalogue
♦ Cleaning solution for evaporator in air conditioner “D 600 100

A2” (for currently available cleaning fluids, refer to ⇒ Elec‐
tronic parts catalogue )
♦ Vacuum cleaner attachment - VAS 6288-
♦ Vacuum cleaner (commercially available)
WARNING
Other materials can form deposits in the air conditioning unit.

♦ Only use pressure-feed spray guns and spray lances that
have not been used with other fluids.

Note
♦ The vacuum cleaner is only required if dirt has accumulated

in the plenum chamber or the intake shaft of the air conditioner,
or if dirt has entered the evaporator housing through the dust
and pollen filter.
♦ The suction nozzle - VAS 6288- is only required if dirt has en‐
tered the evaporator housing through the dust and pollen filter.
♦ It is advisable to have several short and long spray lances at
hand, as a straight lance is required for some vehicles, while
for other vehicles it must be curved or bent into different
shapes. It is not a good idea to change the shape of the spray
lance repeatedly as this will damage it.

Recommended bend radius of spray lance VAG 1538/5 (short)

-A- for this vehicle
Note
♦ The guide washer -B- is fitted opposite the holes -C- on the
spray lance; this allows you to identify the spray direction even
when the spray lance is inserted.
♦ Spray lance V.A.G 1538/5 -A- with this bend radius is also
compatible with the following additional vehicles, for example:
Audi A1 from 2011 onwards, Audi A4 from MY 2008 onwards,
Audi A5 from MY 2008 onwards, Audi Q5 from MY 2009 on‐
wards, Audi A6 from 2011 onwards, Audi A7 from 2011 on‐
wards and Audi A8 from 2010 onwards.
Preparations
– Switch on air conditioner.
– Check whether the air conditioning unit evaporator is really the
source of the odour by switching from fresh air to air recircu‐
lation mode
⇒ “2.3 Notes on odours in vehicles with air conditioner”, page
6.
Note
♦ Identify the cause or origin of the odour before cleaning the

evaporator.
♦ Even if the cause of the odour is not inside the evaporator (e.g.
contamination in the dust and pollen filter), it is worth cleaning
the evaporator after eliminating the cause of the odour (the
evaporator absorbs odours from the air which passes through
it).
– Set air conditioner to air recirculation mode.

– Switch off ignition (this also switches off air conditioner and
fresh air blower - V2- ).
– Remove fresh air blower - V2- ⇒ page 297 .
– Remove and check dust and pollen filter; renew if necessary
after cleaning evaporator ⇒ page 293 .
Note
We recommend renewing the used dust and pollen filter every

time the evaporator is cleaned.
– Check the area between the dust and pollen filter and the
mounting slot for the fresh air blower - V2- in the evaporator
housing for contamination and clean it if necessary
⇒ page 297 .
– Check plenum chamber and water drain of plenum chamber
and clean if necessary ⇒ page 333 .

Note
Prior to cleaning, check and, if necessary, clean the water drains

in the plenum chamber as described in the Workshop Manual.
– Place a drip tray under vehicle to collect cleaning fluid draining

from condensation drain (for location of condensation drain
opening, refer to
⇒ “5.20 Checking condensation drain hose”, page 313 ).
– Cover floor in passenger footwell with waterproof sheeting and
absorbent paper.
Cleaning evaporator
WARNING
The cleaning fluid is flammable, vapours can combine with the

air to form an explosive mixture.
♦ Keep away from ignitions sources; do not smoke.
♦ Use the cleaning fluid only in well ventilated areas.
Cleaning fluid poses a potential health hazard!
Wear safety goggles to protect your eyes.
♦ Use safety equipment such as safety goggles and gloves.
♦ Keep an eye-bath to hand.
♦ Should cleaning fluid come into contact with your eyes,
rinse them thoroughly with cold or lukewarm water for
about 15 minutes.
♦ Then apply eye drops and consult a doctor immediately,
even if your eyes do not hurt.
♦ Inform the doctor which cleaning fluid made contact with
your eyes.
Wear rubber gloves to protect your hands.
♦ Use safety equipment such as safety goggles and gloves.
♦ If cleaning fluid comes into contact with your hands or skin,
wash with water and soap and then rinse thoroughly.
Never swallow cleaning fluid, and do not inhale cleaning fluid
vapours.
♦ Use the cleaning fluid only in well ventilated areas.
♦ If liquid cleaning agent has been swallowed, do not induce
vomiting; consult a doctor immediately.
♦ Inform the doctor which type of cleaning agent was swal‐
lowed.

Caution
Cleaning fluid can cause damage to the vehicle.

♦ Ensure that fluid does not come into contact with elec‐
tronic components.
♦ Do not spray cleaning fluid into the air ducts in or leading
to the vehicle interior!
♦ Thoroughly clean any components in the passenger com‐
partment which have come into contact with the cleaning
fluid.
• The ignition (and therefore the air conditioner) is switched off.

• Preliminary work has been carried out and affected compo‐
nents are removed ⇒ page 282 .
– Connect spray lance to pressure-feed spray gun and fill with
1 litre of cleaning solution for air conditioner evaporators.
– Set compressed-air supply for pressure-feed spray gun to a
pressure of approx. 7.5 bar (minimum pressure 5 bar / maxi‐
mum pressure 10 bar).
Note
Setting this pressure on the compressed-air supply means that

the spray lance has an operating pressure between 3.5 and 4 bar.
– Connect pressure-feed spray gun VAS 1538 to compressed-

air supply.

– Insert spray lance -A- through opening for removed fresh air
blower - V2- -B- and into evaporator housing with spray direc‐
tion towards evaporator.
Note
The spray direction is fixed by the guide washer -C- on the spray
lance -A-.
Caution
Ensure that no cleaning fluid escapes from the evaporator

housing of the air conditioning unit into the passenger com‐
partment during cleaning.
♦ Cover the area under the spray lance in the evaporator
housing with absorbent paper.
♦ After spraying about 0.1 to 0.2 litres of cleaning fluid,
check that it actually drains through the condensation
drain and into the drip tray under the vehicle. If the fluid
only drips out, the condensation drain must be cleaned
before the cleaning process can continue
⇒ “5.20 Checking condensation drain hose”, page 313 .
– Clean and rinse evaporator and surrounding area of housing

with cleaning solution by operating metering lever on pres‐
sure-feed spray gun and moving spray lance -A- back and
forth.
Note
♦ The dirty cleaning agent runs out through the condensation

drain.
♦ During the cleaning process, always check that the cleaning
fluid is flowing out through the condensation drain.
– Use entire contents of pressure-feed spray gun to clean evap‐

orator.
– Remove drip tray and dispose of collected cleaning agent.
Note
Used cleaning agent can be disposed of e.g. via the wastewater

disposal system (observe official local regulations) ⇒ Audi Serv‐
iceNet, HSO Environmental Protection (or ⇒ Volkswagen Serv‐
iceNet, Handbooks, Service Handbook; Environmental Protec‐
tion, Emission Control ).
Allow at least 30 minutes for cleaning solution to take effect.
Note
The removed components can be installed again during this time.
– Re-install all components previously removed.

– Open all doors or open the windows.

– Open all vents in dash panel and in vehicle interior.

– Adjust direction of air flow on all vents using air conditioner
operating unit.
– Set fresh air blower - V2- to maximum speed on air conditioner
operating unit.
– Then start engine and switch on air conditioner (indicator lamp
in AC or A/C button lights up).
– Allow air conditioner to run on this setting for approx. 10 mi‐
nutes (air conditioner compressor is switched on), switching
vent temperature setting on air conditioner operating unit from
cold to warm and back several times.
5.7 Removing and installing evaporator out‐

put temperature sender - G263-
Note
Vehicles with air conditioner only. On vehicles with a heater, the

opening in the heater is sealed off.
Removing
Note
Right-hand drive vehicles: Remove dash panel cover (driver side)

⇒ General body repairs, interior; Rep. gr. 68 ; Storage compart‐
ments/covers/trim panels; Removing and installing dash panel
cover (driver side) .
– Release retaining tabs -arrows- with a narrow screwdriver.

– Pull evaporator output temperature sender - G263- -item 2-
out of housing.
Installing
Installation is carried out in reverse sequence.
5.8 Removing and installing vent tempera‐

ture sender -G150- / -G151-
Note
Vehicles with automatically controlled air conditioner only. On ve‐

hicles with a heater or manually controlled air conditioner, the
openings in the air ducts are sealed with plugs.

Removing
– Left vent temperature sender - G150- (driver side): Remove
dash panel trim (driver side) ⇒ General body repairs, interior;
Rep. gr. 68 ; Storage compartments/covers/trim panels; Re‐
moving and installing dash panel trim .
– Right vent temperature sender - G151- (passenger side): Re‐
move glove box ⇒ General body repairs, interior; Rep. gr. 68 ;
Storage compartments/covers/trim panels; Removing and in‐
stalling glove box .
– Turn vent temperature sender -2- anti-clockwise -arrow- and
pull it out of mounting.
Installing
– Renew seal -3- if damaged or defective.
Note
An incorrectly installed vent temperature sender will cause flow

noise.

ing”).
5.9 Removing and installing heater and air

conditioning unit
Note


♦ Hose clamps up to 25 mm - 3094-
♦ Commercially available compressed-air gun
Removing

WARNING
The cooling system is under pressure when the power unit is

hot. Risk of scalding due to hot steam and hot coolant.
Danger of scalding skin and other parts of the body.
• Put on protective gloves.
• Put on safety goggles.
• Cover filler cap on expansion tank with a cloth and open
carefully to release pressure.
– Open filler cap -arrow- on coolant expansion tank.

– Vehicles with air conditioner: Discharge refrigerant circuit ⇒
Air conditioner with refrigerant R134a; Rep. gr. 87 ; Refriger‐
ant circuit (Air conditioner with refrigerant R134a; Refrigerant
circuit; Working with the air conditioner service station), or ⇒
Air conditioner with refrigerant R1234yf - General notes; Rep.
– Vehicles with air conditioner: Disconnect refrigerant line with
internal heat exchanger at expansion valve
– Mark installation position of coolant hoses -1 and 4-.
Note
The heat exchanger is designed for a certain coolant flow direc‐

tion. Therefore it is important to connect the coolant hoses cor‐
rectly.
– Clamp off coolant hoses using hose clamps -3094- .

– Lift retaining clips -2 and 3- and detach coolant hoses from
heat exchanger for heater.
– Fit a short hose -A- to upper connection.

– Insert compressed air gun in end of hose.
– Hold container -B- under lower connection -C- and carefully
blow coolant out of heat exchanger with compressed-air gun.
– Remove footwell vent (rear) ⇒ page 326 .
– Remove centre tube for dash panel ⇒ General body repairs,
interior; Rep. gr. 70 ; Centre tube for dash panel .
tem .
– If fitted: Remove air duct to rear vent ⇒ page 327 .

– Unplug electrical connector -3- at fresh air blower -1-.

– Protect floor covering beneath heater and air conditioning unit
with absorbent paper.
– Remove airbag control unit ⇒ General body repairs, interior;

Rep. gr. 69 ; Airbag control unit; Exploded view - airbag control
unit .
WARNING
Risk of airbag control unit malfunctioning due to corrosion in

electrical connector.
♦ After unplugging connector for airbag control unit, cover it
or seal it off to prevent the ingress of moisture.
– Detach condensation drain -2- from heater and air condition‐

ing unit -1-.

– Detach heater and air conditioning unit -1- from retainers.

– Move duct -3- clear.
– Move wiring harness -2- clear at mountings -4- -arrows-.
– Take heater and air conditioning unit out towards right.
Installing
Note
Renew O-rings.
– Top up coolant ⇒ Engine, mechanics; Rep. gr. 19 ; Cooling

system/coolant; Draining and filling cooling system .
– Vehicles with air conditioner: Evacuate and charge refrigerant
circuit ⇒ Air conditioner with refrigerant R134a; Rep. gr. 87 ;
Refrigerant circuit (Air conditioner with refrigerant R134a; Re‐
frigerant circuit; Working with the air conditioner service sta‐
tion), or ⇒ Air conditioner with refrigerant R1234yf - General
notes; Rep. gr. 87 ; Working with the air conditioner service
station .
– Vehicles with air conditioner: Start up air conditioner after
charging refrigerant circuit ⇒ page 199 .
– Interrogate event memory and erase any entries displayed
5.10 Removing and installing retainers for

heater and air conditioning unit
Note
Leave the retainers in the vehicle when removing the heater and
air conditioning unit.
Removing
– Fold heat insulation -2- behind ABS unit to the side.
– Unscrew nuts -3 and 5-.
– Detach retainers -4- in passenger compartment.
Note
The refrigerant pipe with internal heat exchanger must be re‐

moved if the nut above the ABS unit is not accessible as described
⇒ page 189 .

Installing
⇒ “5.11 Dismantling and assembling heater and air condition‐
– Insert retainers -1 and 3- in mounting on heater and air con‐
ditioning unit -2- and place air conditioning unit in installation
position.
– Install heater and air conditioning unit ⇒ page 287 .
– Tighten nuts at retainers.
– Install remaining components.
5.11 Dismantling and assembling heater and

air conditioning unit
Note

♦ The following illustrations show a Valeo heater/air conditioning
unit; distinguishing features compared to heaters from other
manufacturers ⇒ page 1 .

1 - Air distribution housing

⇒ page 1
❑ It is not permissible to
combine components
from different manufac‐
turers
⇒ “1.1 Identification of
heater and air condition‐
ing unit”, page 1
❑ The following illustra‐
tions show a Valeo heat‐
er.
❑ With or without auxiliary
air heater element -
Z35- , depending on
equipment
❑ Distinguishing features
of components from dif‐
ferent manufacturers
⇒ page 1
⇒ page 293
2 - Electrical wiring harness
logue
3 - Evaporator housing
❑ Exploded view
⇒ page 271
4 - Bolt
❑ 3x
❑ 1 Nm
5 - Retainer (left-side)
❑ For heater and air conditioning unit
6 - Nut
❑ 4.5 Nm
7 - Nut
❑ 4.5 Nm
8 - Retainer (right-side)
❑ For heater and air conditioning unit
9 - Air intake box
10 - Bolt
❑ Tightening torque ⇒ Item 4 (page 270)


housing
Removing
– Remove coolant pipes from heat exchanger ⇒ page 299 .
– Unplug electrical connector at fresh air and air recirculation
flap control motor and move wiring harness clear.
Note
Five bolts -2- are currently fitted (three at top and two in lower
area).
– Release retaining tabs -1 and 3-.

– Swivel air distribution housing -4- to rear -arrow- and disen‐
gage it.
Installing
⇒ “5.11 Dismantling and assembling heater and air condition‐
Note
Even very small leaks at the "tongue-and-groove" joint between

the air distribution housing and the evaporator housing can lead
to whistling noises caused by escaping air. For this reason, lubri‐
cate the connection points lightly with silicone grease or similar
to completely seal the connection points. For silicone grease, re‐
fer to ⇒ Electronic parts catalogue

5.13 Removing and installing dust and pollen

filter

♦ Hook - T40207- (only necessary if there is no hook -E- on

service cover -A-)
♦ Commercially available vacuum cleaner (only for vehicles ex‐

posed to high levels of dust or dirt)
♦ Cover plate - T10532- (only for vehicles exposed to high levels
of dust or dirt)
Note
♦ If the retaining tabs -B- for the service cover -A- have broken
off at the heater/air conditioning unit or at the service cover,
the service cover -A- can also be attached to the heater/air
conditioning unit using two collar bolts -C- (e.g. 3.5 x 16 mm
or 4.0 x 16 mm) and two corresponding washers ⇒ Electronic
parts catalogue . To do so, drill holes (4.5 mm diameter) in the
service cover -A- at both attaching points marked -D-.
♦ The service cover -A- is provided with a hook -E- for removing
the dust and pollen filter. If there is no hook -E-, use hook -
T40207- instead.
♦ From model year 2017 onwards, Audi A3 vehicles are gradu‐
ally fitted with a dust and pollen filter with bioactive substances
(from the start of production onwards on Audi Q2 vehicles).
These bioactive substances reduce the amount of allergens
in the air flowing through the filter. These filters can be retro‐
fitted in all vehicles ⇒ Electronic parts catalogue .
Removing
Caution
Always handle the customer's belongings in the glove box with

care.
♦ Store any items taken out of the glove box in a sealable
plastic bag.
– Clean out glove box and line with paper.

– Unclip service cover -1- in glove box by releasing retaining tab
-2- -arrow-.

– Release retaining tabs -arrows A-.

– Swivel cover -2- to the rear.
• This disengages guide tabs from mounting points.
Caution
To avoid risk of damage, ensure that dirt from the dust and
pollen filter does not fall into the fresh air blower -V2- .
♦ If the dust and pollen filter is severely contaminated, insert
a cover plate - T10532- underneath the dust and pollen
filter and vacuum the dirt off the top of the cover plate after
removing the dust and pollen filter.
♦ Carefully pull the dust and pollen filter out of the installation
slot.
♦ If you suspect that dirt has entered the area between the
dust and pollen filter and the fresh air blower - V2- , remove
the fresh air blower ⇒ page 296 and clean the fresh air
blower as well as the area between the fresh air blower
and the installation slot for the dust and pollen filter.
– On vehicles exposed to high levels of dust or dirt, insert cover

plate - T10532- -2- as far as possible into slot underneath dust
and pollen filter -1-.
Note
♦ You can assess the levels of dust and dirt the dust and pollen
filter has been exposed to e.g. on the basis of the dirt deposits
in the plenum chamber
⇒ “6.10 Checking plenum chamber water drain”, page 333 .
♦ Dimensions of cover plate - T10532- : 252 mm x approx.
300 mm x 0.8 mm (round edges)
– Pull out dust and pollen filter -1- (using hook on service cover
or hook - T40207- ) -arrow B-; at the same time hold cover
plate - T10532- -2- in slot for dust and pollen filter in position
it has been inserted.
– If necessary, vacuum dust and dirt off top of cover plate -
T10532- -2-.
Installing
• Note installation position of dust and pollen filter (arrow on filter
indicating direction of flow).
– Switch ignition on and check operation of -V2- .


- V2-
Removing
– Use a screwdriver (or pliers) to unfasten quick-release fasten‐
er (bolt or clip) -1-.
Note
♦ There are different types of fastener for the cover -2- (bolt or
clip -1-); renew clip version if necessary ⇒ Electronic parts
catalogue .
♦ Use e.g. pliers or a screwdriver to prise out version with clip.
– Detach cover -2-.

– If fitted, remove bolt -2-.
– Lift retaining tab -4- and turn fresh air blower -1- clockwise
-arrow-.
– Pull fresh air blower out of evaporator housing (bottom sec‐
tion).
Caution
Risk of fan wheel imbalance.

♦ Do not touch the fan wheel of the fresh air blower -V2- .
Applying force to the fan wheel or moving the balancing
weights attached to the fan wheel could cause imbalance
and therefore lead to operating problems.
Note
Right-hand drive vehicles: Unscrew bolts -2-, unclip retaining tabs

-arrows- and take out fresh air blower - V2- -1- downwards in di‐
rection of -arrow-.
Installing
⇒ “5.2 Exploded view - attachments for heater and air condi‐
– As a final step, check operation of fresh air blower - V2- .


control unit - J126-
Removing
– Use a screwdriver (or pliers) to unfasten quick-release fasten‐
er (bolt or clip) -1-.
Note
♦ There are different types of fastener for the cover -2- (bolt or
clip -1-); renew clip version if necessary ⇒ Electronic parts
catalogue .
♦ Use e.g. pliers or a screwdriver to prise out version with clip.
– Detach cover -2-.
– Unplug electrical connectors -1 and 3-.

WARNING
Risk of burns.
♦ The fresh air blower - V2- with fresh air blower control unit
- J126- may be hot if it was in operation prior to removal.
♦ Do not touch the hot cooling surface of the fresh air blower
control unit - J126- .
– Detach control unit -2- from fresh air blower.

Installing
⇒ “5.2 Exploded view - attachments for heater and air condi‐
– As a final step, check operation of fresh air blower - V2- .
5.16 Removing and installing footwell vent

temperature sender - G192-
Note
Vehicles with automatically controlled air conditioner only. On ve‐

hicles with a heater or manually controlled air conditioner, the
opening in the air duct is sealed with plugs.

Removing
Note
Right-hand drive vehicles: The footwell vent temperature sender

- G192- is installed in the right footwell vent connection.

– Release retaining tabs (left and right) -arrows- with a narrow
screwdriver.
– Lift out footwell vent temperature sender - G192- -item 2-.
Installing
5.17 Removing and installing auxiliary air

heater element - Z35-
Note
Vehicles with high-voltage system are currently not fitted with an

auxiliary air heater element - Z35- ; on these vehicles, the high-
voltage heater (PTC) - Z115- (with high-voltage heater (PTC)
control unit - J848- ) assumes the function of the auxiliary air
heater element
⇒ “4.15 Notes on high-voltage heater (PTC) Z115 (and high-volt‐
age heater (PTC) control unit J848 )”, page 85 .
Removing
– Remove knee airbag (driver side) ⇒ General body repairs,
interior; Rep. gr. 69 ; Knee airbags; Exploded view - knee
airbag .
– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Exploded view - centre console .
Note


– Unscrew nut -3- and detach earth wire -4-.
WARNING
Risk of burns.
♦ The auxiliary air heater element - Z35- may be hot if it was
in operation prior to removal.
♦ Do not take hold of the hot metal surface of the auxiliary
air heater element -Z35- .
– Unplug electrical connector -2- by sliding locking element -5-

upwards and pressing catch inwards.
– Pull auxiliary air heater element - Z35- -item 1- to the left out
of housing -6-.
Installing
• Tightening torques
262

⇒ “5.18.1 Removing and installing Valeo heat exchanger”,
page 299
⇒ “5.18.2 Removing and installing Denso heat exchanger”, page
305
5.18.1 Removing and installing Valeo heat ex‐

changer
Note
The heater and air conditioning unit is available in different ver‐

sions and from different manufacturers. The individual compo‐
nents of the various heaters and air conditioning units are similar
but not identical (distinguishing features ⇒ page 1 ); the combi‐
nation of components by different manufacturers is therefore not
permissible ⇒ Electronic parts catalogue .


Removing
WARNING


– Move front seats as far back as they will go.
– Set direction of air flow to “defroster vent” for windscreen.
Vehicles with 1.8 ltr. TFSI engine:




Note

rectly.


Insert compressed air gun in end of hose.
airbag .
gr. 68 ; Centre console; Removing and installing centre con‐
sole .
Note
♦ Right-hand drive vehicles: Remove glove box ⇒ General body

repairs, interior; Rep. gr. 68 ; Storage compartments/covers/
trim panels; Removing and installing glove box .
♦ Right-hand drive vehicles: Remove fresh air blower
⇒ page 296 .
– Vehicles with auxiliary air heater: Remove auxiliary air heater

element - Z35- ⇒ page 298 .
– Cover area beneath connections for coolant hoses in plenum
chamber e.g. with impermeable sheeting and absorbent pa‐
per.

– Lift locking element -6-, remove securing clip -5- and detach
coolant line (top) -4- from heat exchanger.
– Remove screw-type clip -2- and detach coolant line (bottom)
-1- from heat exchanger.

– Release retaining tabs -4- -arrows- and detach cover -2-.

– Cut open tab at cover -arrows-.

– Take out heat exchanger towards left side.
Installing
Tightening torques:
• ⇒ “5.1 Exploded view - heater and air conditioning unit”, page
262
• ⇒ Engine, mechanics; Rep. gr. 21 ; Turbocharger; Exploded
view - turbocharger
Note
Renew O-rings.
– Check heater slot for dirt (heat exchanger removed).

– Remove any dirt or residual coolant.
– Vehicles with TDI engine: With auxiliary air heater element re‐
moved, check heating element slot for dirt and clean if neces‐
sary.
– If fitted, check foam seals -2- attached to heat exchanger -1-

for damage and renew if necessary.
Note
♦ Depending on the version and production period, the foam

seals -2- are not fitted on all vehicles.
♦ The foam seal may curl up when it is inserted if it has not been
bonded on properly.
♦ Cold air may flow past the heat exchanger if the foam seal is
damaged or not fitted properly.

– Check connection -3- of heat exchanger and connection -2- of

coolant pipes for damage or dirt.
– Clean and smooth sealing surface for O-ring.
– Coat new O-ring -4- lightly with coolant (or lubricate lightly with
silicone grease) and attach to coolant pipe -1-.
– Carefully slide heat exchanger into heater/air conditioning unit
as far as it will go.
Note
When inserting the heat exchanger, take care not to damage the
connections and coolant pipes.
– Slide coolant pipes into heat exchanger as far as stop.
Caution
Risk of leaks at heat exchanger.

♦ Crushed O-rings and coolant pipes that are not fitted
straight or are not attached fully will lead to leaks.
– If cover cannot be attached to heat exchanger, cuts must be

made at rubber support -arrows- as shown.

– Fit new securing clip -5- or screw-type clip -2- at connection of

coolant pipe to heat exchanger.
Note
♦ When performing repairs, a screw-type clip can also be fitted

instead of securing clip -5-.
♦ -Arrow- can be ignored.
– Tighten bolt -3-

262 .
– Check that screw-type clamps are seated correctly on con‐
nections of heat exchanger and coolant pipes. They must not
make contact with air distribution housing or other compo‐
nents.
– As a final step, check operation of heater and air conditioner.
5.18.2 Removing and installing Denso heat ex‐

changer
Note


♦ Pliers - T40147-

Removing
WARNING


– Move front seats as far back as they will go.
– Set direction of air flow to “defroster vent” for windscreen.
Vehicles with 1.8 ltr. TFSI engine:




Note

rectly.


– Insert compressed air gun in end of hose.
airbag .
Note

– Vehicles with auxiliary air heater: Unplug electrical connector

⇒ page 298 .
– Cover area beneath connections for coolant hoses in plenum
chamber e.g. with impermeable sheeting and absorbent pa‐
per.

– Unscrew bolts -2- and detach screw-type clips -3-.

– Disconnect coolant pipes.
Note
♦ If the coolant pipes cannot be disconnected because the O-

ring is gummed up, cut through the coolant pipes at the marked
locations -arrows- using pliers - T40147- .
♦ Bend remaining coolant pipes -5 and 8- at heat exchanger to‐
wards rear (as seen in direction of travel) far enough so that
heat exchanger can be pulled out of housing.
♦ Detach severed coolant pipes -4 and 7- of heat exchanger
from coolant pipes -1 and 11- to engine.
– Remove bolt -10- and detach bracket -9- for heat exchanger.
– Pull out heat exchanger -6- towards left side.
Installing
Tightening torques:
• ⇒ “5.1 Exploded view - heater and air conditioning unit”, page
262
• ⇒ Engine, mechanics; Rep. gr. 21 ; Turbocharger; Exploded
view - turbocharger
Note
Renew O-rings.
– Check heater slot for dirt (heat exchanger removed).

– Remove any dirt or residual coolant.
– Vehicles with TDI engine: With auxiliary air heater element re‐
moved, check heating element slot for dirt and clean if neces‐
sary.
– Check foam seals -2- attached to heat exchanger -1- for dam‐
age and renew if necessary.
Note
♦ The foam seal may curl up when it is inserted if it has not been
bonded on properly.
♦ Cold air may flow past the heat exchanger if the foam seal is
damaged or not properly fitted.

– Check connection -3- of heat exchanger and connection of

coolant pipes -1- for damage or dirt.
silicone grease) and attach to coolant pipe.
– Carefully slide heat exchanger into air conditioning unit as far
as it will go.
Note
When inserting the heat exchanger, take care not to damage the
connections and coolant pipes.
Caution

– Position bracket -3- for heat exchanger on air distribution

housing and tighten bolt -4- to torque (2 Nm).
– Fit new screw-type clips -2- at connection of coolant pipe to
heat exchanger.
– Tighten bolt -1-
262 .
nents.
– As a final step, check operation of heater and air conditioner.

5.19 Removing and installing coolant pipes at

heat exchanger
⇒ “5.19.1 Removing and installing coolant pipes at Valeo heat
⇒ “5.19.2 Removing and installing coolant pipes at Denso heat
5.19.1 Removing and installing coolant pipes at

Valeo heat exchanger
Note

Removing
– Detach sealing collar -3- at plenum chamber partition panel.
– Detach bracket -4- for coolant pipe to the left.
– Detach foam -1-.
– Lift locking element -7-, remove securing clip -6- and detach
coolant line (top) -5- from heat exchanger.
– Remove screw-type clip -9- and detach coolant line (bottom)
-10- from heat exchanger.
– Detach coolant pipes.

Installing
262
– Check connection -3- of heat exchanger and connection -2- of
coolant pipes for damage or dirt.
Caution

– Fit new screw-type clip -2- at connection of coolant pipe to heat

exchanger.
Note
When performing repairs, a screw-type clip can also be fitted in‐

stead of clip -5-; -arrow- can be ignored.
– Tighten bolt -3- to torque.

nents.
5.19.2 Removing and installing coolant pipes at

Denso heat exchanger
Note


Removing
– Detach sealing collar -3- at plenum chamber partition panel.
– Detach bracket -4- for coolant pipe to the left.
– Detach foam -1-.
– Unscrew bolt -5- and detach screw-type clip -6-.
– Detach coolant pipes -7, 8- from heat exchanger.
Installing
262
– Check connection -3- of heat exchanger and connection of
coolant pipes -2- for damage or dirt.
Caution


– Fit new screw-type clips -2- at connection of coolant pipe to

heat exchanger.
– Tighten bolt -1- to torque.
nents.
5.20 Checking condensation drain hose
Note
There are different versions of the condensation drain hose. On

version -A-, the hose is engaged in the floor panel -2- with three
retainers -1-. On version -B-, the hose is attached to the floor
panel -2- with a lug -3- and engaged with a retainer -4-. Make sure
the condensation drain hose is seated and engaged correctly in
the floor panel.
Procedure
sole .
WARNING

♦ Cover or seal off connector for airbag control unit to pre‐
vent the ingress of moisture.

– Cover airbag control unit -3-.

– Carefully fold back floor covering in vicinity of condensation
drain hose until hose is visible.
– Retainers -arrows- at condensation drain hose must be prop‐
erly engaged (pre-tensioned) in body opening in floor panel
-1- (illustration shows version “A”).
• The sealing lip must be fitted firmly at the body opening.

• The retainers -1- (on version -A-) / -4- (on version -B-) must be
engaged properly.
• If not sufficiently tensioned, seal the joint between the body
and the bracket with silicone adhesive sealant or similar ⇒
– Check that condensation drain -3- is seated firmly at connec‐

tion of heater and air conditioning unit -1-.
• Condensation drain -3- must not be loose at connection of
heater and air conditioning unit -1- as otherwise condensate
could escape.
• If not sufficiently tensioned, secure condensation drain -3- at
connection of heater and air conditioning unit -1- with a cable
tie or hose clip.
– If the bracket with the condensation drain hose is properly
positioned in the body opening and at the connection of the
heater and air conditioning unit, the condensation drain hose
must be checked for dirt.
– Remove condensation drain hose ⇒ page 316 .

– Check distance between condensation drain opening -1- and

heat shield -3-.
• The clearance (dimension -x-) must be sufficient to allow con‐
densate to drain out of condensation drain hose -2-.
– Check for dirt in condensation drain of air conditioning unit and
clean with a piece of wire if necessary.
• The cross-section of the condensation drain hose must not be
constricted (squashed).
If there are problems with moisture in the passenger compart‐
ment, check the following components in addition to the conden‐
sation drain:
• Water drain for plenum chamber ⇒ page 333 .
• Drip rail for damage and correct installation ⇒ page 328 .
• Check that plenum chamber cover is installed correctly and
not damaged ⇒ General body repairs, exterior; Rep. gr. 50 ;
Bulkhead; Exploded view - plenum chamber cover .
• Dust and pollen filter for dirt and correct installation
⇒ page 293
• Forced ventilation vents in luggage compartment
⇒ page 329 .
• Activation and operation of air recirculation flap (e.g. in “Final
control diagnosis”) ⇒ Vehicle diagnostic tester (“Guided Fault
Finding”)
If there are problems with moisture in the passenger compartment
which only occurs when the air conditioner compressor is switch‐
ed on under certain ambient conditions, also check the tempera‐
ture of the air flowing out of the evaporator ⇒ Vehicle diagnostic
• “Read measured value” for evaporator output temperature
sender - G263-
– Check temperature of air flowing out of evaporator under us‐
age conditions described by customer or with the following
settings on operating unit:

-5- on
• Fresh air mode: Lamp in Air recirculation button -2- is
off.
• Set rotary control -3- for fresh air blower to speed “1”.

Vehicles with automatically controlled air conditioner:

• Set rotary control -9- for fresh air blower to medium speed with
a voltage of approx. 7 V at fresh air blower - V2- .
• Fresh air mode: Lamp in Air recirculation button -10- is
off.
– Open dash panel vents.
– If measured value of evaporator output temperature sender -
G263- is too low (at ambient temperature above 0 °C, colder
than 0 °C for lengthy period) or too high (above e.g. 10 °C
although air conditioner is functioning properly), observe notes
on checking cooling output ⇒ page 49 .
5.21 Removing and installing condensation

drain hose
Note
There are different versions of the condensation drain hose. On

version -A-, the hose is engaged in the floor panel -2- with three
retainers -1-. On version -B-, the hose is attached to the floor
panel -2- with a lug -3- and engaged with a retainer -4-. Make sure
the condensation drain hose is seated and engaged correctly in
the floor panel.
Removing
sole .
WARNING

♦ Seal off connector for airbag control unit to prevent the
ingress of moisture.

– Cover airbag control unit -4-.

– Carefully press floor covering to the side and protect area be‐
neath condensation drain hose with waterproof sheeting and
absorbent paper.
– Detach condensation hose -3- at heater and air conditioning
unit -1- and at body -5-.
Installing
– Condensation drain hose can only be pressed properly as far
as stop onto heater and air conditioning unit in one position.
• Lug -arrow- at connection must engage in guide -2-.
– Additionally secure condensation drain -3- at connection of
heater and air conditioning unit -1- with a cable tie or hose clip.
Note
Condensation drain -3- must not be loose at connection of heater

and air conditioning unit -1- as otherwise condensate could es‐
cape.
– Insert condensation drain hose -6- in body opening in floor

panel so that it engages audibly (illustration shows version
“A”).
Note
♦ The sealing lip must be flush at the body opening in the floor
panel.
♦ The retainers -1- (on version -A-) / -4- (on version -B-) must be
engaged properly.
♦ If not sufficiently tensioned, seal the joint between the body
and the condensation drain with silicone adhesive sealant or
similar ⇒ Electronic parts catalogue .

• Retainers -arrows- (illustration shows version “A”) on conden‐

sation drain hose must be properly engaged (pre-tensioned)
in body opening -1-.
• Check that sealing lip is flush at body opening.
• If not sufficiently tensioned, seal the joint between the body
floor panel and the condensation drain with silicone adhesive
sealant or similar ⇒ Electronic parts catalogue .
Note
♦ Install condensation drain hose so that it is neither twisted nor

crushed.
♦ When fitting floor covering, make sure that it does not squash
condensation drain hose.
♦ If the condensation drain hose is not fitted firmly enough at the
heater and air conditioning unit connection, secure it e.g. with
a hose clip or cable tie to prevent it from slipping and liquid
from escaping. Cable tie and hose clip ⇒ Electronic parts
catalogue .

6 Air duct
⇒ “6.1 Exploded view - routing of air flow and air distribution in
⇒ “6.2 Removing and installing vents (front)”, page 323
⇒ “6.3 Removing and installing vents (rear)”, page 326
⇒ “6.4 Removing and installing air ducts”, page 327
⇒ “6.5 Removing and installing intake duct”, page 328
⇒ “6.6 Removing and installing drip rail”, page 328
⇒ “6.7 Removing and installing fresh air intake”, page 329
⇒ “6.8 Checking forced ventilation vents in passenger compart‐
ment”, page 329
⇒ “6.9 Removing and installing forced ventilation vents in pas‐
senger compartment”, page 332
⇒ “6.10 Checking plenum chamber water drain”, page 333
6.1 Exploded view - routing of air flow and

air distribution in passenger compart‐
ment
Note
For the A3 Cabriolet, neck heating is available as optional equip‐

ment. Vehicles with neck heating are equipped with an additional
vent in the seat and with additional buttons for switching the neck
heating on and off in the air conditioner operating unit ( Clima‐
tronic control unit - J255- ). For further information, refer to
Air distribution housing, air ducts (front)
6. Air duct 319

1 - Bolt
❑ 1.5 Nm
2 - Air duct for footwell vent
(left-side) - driver side
⇒ page 325
3 - Air duct
❑ To defroster vents
⇒ page 324
4 - Left vent temperature send‐
er - G150-
❑ For equipment version
with automatically con‐
❑ Incorrectly installed vent
temperature senders
will cause flow noise
⇒ page 286
5 - Sealing plug for vent (left-
side)
with heater or manually
controlled air condition‐
er
ing plug will cause flow
noise
⇒ General body repairs,
interior; Rep. gr. 70 ;
Dash panel; Exploded
view - dash panel
7 - Dash panel vent (centre left)
❑ Removing and installing ⇒ General body repairs, interior; Rep. gr. 70 ; Dash panel; Exploded view -
dash panel
8 - Defroster vent (left-side)
9 - Defroster vent (centre)
10 - Loudspeaker trim (centre)
11 - Defroster vent (right-side)
dash panel
13 - Right vent temperature sender - G151-
❑ For equipment version with automatically controlled air conditioner
❑ Incorrectly installed vent temperature senders will cause flow noise

14 - Sealing plug for vent (right-side)

❑ For equipment version with heater or manually controlled air conditioner
❑ A loose or missing sealing plug will cause flow noise
15 - Dash panel vent (centre right)
dash panel
16 - Air duct to dash panel vent (centre)
17 - Plug
❑ For equipment version without glove box cooling
❑ Secure loose sealing plug with clamp ⇒ page 321
Note
♦ Introduction of glove box cooling

not yet finalised
♦ Depending on version, connec‐
tion may also be sealed off di‐
rectly at heater and air condition‐
ing unit.
18 - Bolt
❑ 1.5 Nm
19 - Air duct to footwell vent (right-side) - front passenger side
Sealing plug for glove box cooling

– If sealing plug -3- is loose, it must be secured with a hose clip
-2- at heater and air conditioning unit -1-. Hose clips ⇒ Elec‐
tronic parts catalogue
Air distribution housing, air ducts (rear)
6. Air duct 321

1 - Air duct to footwell vent

(rear left)
⇒ page 326
❑ There may be noise if
the wiring harness
bracket is damaged or
loose
2 - Plug
without air duct (rear)
Note
Depending on version, connection

may also be sealed off directly at
heater and air conditioning unit
⇒ page 273 .

unit
logue
⇒ page 287
4 - Air duct to footwell vent
(rear right)
⇒ page 326
❑ There may be noise if
the wiring harness
bracket is damaged or
loose
5 - Air duct (rear)
6 - Air duct to rear vent
7 - Rear centre console vent
❑ Equipment-specific version

6.2 Removing and installing vents (front)

⇒ “6.2.1 Removing and installing vent (front centre)”, page 323
⇒ “6.2.2 Removing and installing side defroster vent”, page 323
⇒ “6.2.3 Removing and installing dash panel vents”, page 324
⇒ “6.2.4 Removing and installing air duct for defroster vent”, page
324
⇒ “6.2.5 Removing and installing air duct for dash panel vent
(centre)”, page 324
⇒ “6.2.6 Removing and installing footwell vent (driver side)”, page
325
⇒ “6.2.7 Removing and installing footwell vent (front passenger
side)”, page 325
6.2.1 Removing and installing vent (front cen‐

tre)
Removing and installing ⇒ General body repairs, interior; Rep.
gr. 70 ; Dash panel; Exploded view - dash panel
6.2.2 Removing and installing side defroster

vent
6. Air duct 323

6.2.3 Removing and installing dash panel

vents
Note
Depending on the version, the dash panel vents are operated in

different ways.
6.2.4 Removing and installing air duct for de‐

froster vent
Removing
– Lift off air duct -2-.
Installing
– Renew damaged or defective foam seals -1-.
Note
♦ Take care not to squash the foam seal on the air duct when
inserting the dash panel, as otherwise the flow of air to the
windscreen will be uneven or inadequate.
♦ After installing the dash panel, check the direction and distri‐
bution of air flow from the defroster vent to the windscreen.
6.2.5 Removing and installing air duct for

dash panel vent (centre)
Removing


– Detach air duct for dash panel vent (centre) -1-.
Installing
– Renew damaged or defective foam seals -2-.
Note
♦ Take care not to squash the foam seal on the air duct when
inserting the dash panel, as otherwise the flow of air to the
dash panel vents will be uneven or inadequate.
♦ After installing the dash panel, check the direction and distri‐
bution of air flow from the dash panel vents.
– Make sure that guides at air duct are correctly positioned in

mountings.
6.2.6 Removing and installing footwell vent

(driver side)
Removing
airbag .
Note

– Remove bolt -1- and detach footwell vent (driver side) -2-.
Installing
6.2.7 Removing and installing footwell vent

(front passenger side)
Removing
– If fitted, remove bolt -3-.
– Release retaining tab -arrow A-, pull footwell vent (passenger
side) -1- off air distribution housing -4- in direction of
-arrow B- and detach from vent -2-.
Installing
6. Air duct 325

6.3 Removing and installing vents (rear)

⇒ “6.3.1 Removing and installing rear footwell vent”, page 326
⇒ “6.3.2 Removing and installing rear centre console vent”, page
327
6.3.1 Removing and installing rear footwell

vent
Note
The illustration shows the left side as an example.
Removing
– Remove sill panel trim ⇒ General body repairs, interior; Rep.
gr. 70 ; Passenger compartment trim panels; Removing and
installing sill panel trim .
– Remove front seat ⇒ General body repairs, interior; Rep. gr.
72 ; Front seats; Removing and installing front seat .
– Remove belt end fitting (front) ⇒ General body repairs, inte‐
rior; Rep. gr. 69 ; Seat belts; Removing and installing three-
point seat belt (front) .
sole .
– Unfasten and lift floor covering in vicinity of vent.
Note
If necessary, remove A-pillar trim and fold back floor covering as

far as possible ⇒ General body repairs, interior; Rep. gr. 70 ;
Passenger compartment trim panels; Removing and installing
floor covering .
– Prise off cable clip -3-.

– Lift up rear footwell vent -1- -arrows B-, detach from heater and
air conditioning unit -2- -arrow A- and take out to the side.
Installing
– Check cable clip -1- for damage before pressing it on at foot‐
well vent -2-.
Note
A loose cable clip or damaged seal can lead to flow noise.
Tightening torques
• ⇒ General body repairs, interior; Rep. gr. 72 ; Front seats;
Exploded view - front seat
• ⇒ General body repairs, interior; Rep. gr. 69 ; Seat belts;
Exploded view - three-point seat belt (front)
• ⇒ General body repairs, interior; Rep. gr. 68 ; Centre console;
Exploded view - centre console

6.3.2 Removing and installing rear centre

console vent
gr. 68 ; Centre console; Exploded view - centre console .
6.4 Removing and installing air ducts

⇒ “6.4.1 Removing and installing air duct for rear vent”,
page 327
⇒ “6.4.2 Removing and installing air duct for rear centre console
vent”, page 327
6.4.1 Removing and installing air duct for rear

vent
Removing
– Remove rear centre console vent ⇒ page 327 .
– Pull off air duct -1- towards rear.
Installing
– Renew damaged or defective foam seal -2- at air duct.
6.4.2 Removing and installing air duct for rear

centre console vent
Removing
– Remove centre console mounting bracket ⇒ General body
repairs, interior; Rep. gr. 68 ; Centre console; Removing and
installing bracket for centre console .
– Remove retaining frame for selector housing ⇒ Power trans‐
mission; Rep. gr. 34 ; Selector mechanism .
– Swivel air duct -1- upwards at rear -arrow A-, release it from
fastener at air distribution housing -2- -arrow B- and detach.
Installing
6. Air duct 327

6.5 Removing and installing intake duct

Removing
– Remove dust and pollen filter ⇒ page 293 .
– Unplug electrical connector -4- and move wiring harness clear.
– Release retaining tabs -1- -arrow A-.
– Swivel intake duct -3- upwards -arrow B- and disengage.
Installing
262
6.6 Removing and installing drip rail

Removing
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Bulkhead; Exploded view - plenum cham‐
ber cover .
– If fitted: Remove control unit for structure-borne sound - J869-
⇒ Rep. gr. 23 ; Senders and sensors; Exploded view -
actuator for structure-borne sound and control unit for
structure-borne sound, vehicles with diesel engine , or ⇒ Rep.
gr. 24 ; Senders and sensors; Exploded view - actuator for
structure-borne sound and control unit for structure-borne
sound, vehicles with petrol engine .
– If fitted: Unplug electrical connector -3- from air quality sensor
- G238- .
– Remove nuts -arrows-.
– Detach drip rail -2- from threaded pin -4- and remove from
plenum chamber.
Note
♦ Water can enter the fresh air intake if the drip rail is damaged
or not installed properly. This may result in complaints about
odour from the heater/air conditioner and/or moisture in the
passenger compartment.
♦ Water can enter the fresh air intake via the drip rail if the ple‐
num chamber cover is damaged or not installed properly.
Installing
⇒ Fig. ““Tightening torque for nuts at drip rail”“ , page 116

6.7 Removing and installing fresh air intake

Removing
– Remove drip rail ⇒ page 328 .
– Remove nuts -arrows-.
– Take fresh air intake -1- out of plenum chamber.
Note
Water can enter the fresh air intake if the fresh air intake grille is
damaged or not installed properly. This may result in complaints
about odour from the heater/air conditioner and/or moisture in the
passenger compartment.
Installing
⇒ Fig. ““Tightening torque for nuts at fresh air intake”“ ,
page 116
– Check bonded seal -2- between fresh air intake and body for
damage.
6.8 Checking forced ventilation vents in

6. Air duct 329

Note
♦ The routing of air flow from the passenger compartment to the

luggage compartment differs depending on the vehicle ver‐
sion.
♦ On the A3 Saloon, the passenger compartment is vented via
a gap in the area between the rear shelf -A- and the cross
member for the rear window. There are openings in the top
part of the back panel -B- through which the air from the pas‐
senger compartment enters the luggage compartment.
♦ The air then flows from the luggage compartment via openings
in the luggage compartment side trim -C- (different versions;
illustration shows luggage compartment side trim in an Audi
A3 Saloon) to the forced ventilation frame.
♦ On the Audi A3 Cabriolet, the passenger compartment is ven‐
ted via area -A- (at C-pillar) into the convertible roof compart‐
ment.
♦ Some of the air flows from the convertible roof compartment
into the luggage compartment via areas -B and C- and out of
the luggage compartment via openings in the luggage com‐
partment side trim -A and D- to the forced ventilation frames.
The rest of the air flows to the forced ventilation frames behind
the luggage compartment side trim.
♦ The routing of air flow and forced ventilation frames differ de‐
pending on the vehicle version ⇒ Electronic parts catalogue .
The Audi A3 and Audi A3 Sportback for example are fitted with
ventilation frame -A-, whereas the Audi A3 Saloon and Audi
A3 Cabriolet are equipped with ventilation frame -B-.
♦ The following illustrations show the components fitted on the
Audi A3 and Audi A3 Sportback. They differ on other vehicle
versions (e.g. on the Audi A3 Saloon and the Audi A3 Cabrio‐
let).

Checking ventilation slot in luggage compartment:

– Check flow of air through ventilation openings -arrow- in lug‐
gage compartment side trim -1- (both sides).
Note
If the air ducts to the forced ventilation frames are blocked or ob‐
structed, the windows may mist up.
Checking forced ventilation frame from inside:
Note
♦ Gummed up sealing lips could cause the windows to mist up.

♦ The sealing lips in the ventilation frame must move freely and
close automatically.
♦ If the air ducts to the ventilation frames are sealed off or
blocked, the windows may mist up.
– Open cover in luggage compartment side trim.
Note
On vehicles with no cover in the luggage compartment side trim

(e.g. on left side in A3 Saloon, and in Audi A3 Cabriolet), you can
also check whether the sealing lips -1- are functioning properly
from outside (with bumper cover fitted).
– Check that ventilation frame -2- is not blocked, and check that
sealing lips -1- are functioning properly.
– To ensure proper ventilation of passenger compartment, ven‐

tilation openings in luggage compartment must not be
blocked.
• It must be possible for the air -arrows A- to flow to the outside
-arrow B- via ventilation openings -1 and 2- in the luggage
compartment side trim to forced ventilation frames -3-.
6. Air duct 331

6.9 Removing and installing forced ventila‐

tion vents in passenger compartment
Note
♦ The routing of air flow and forced ventilation frames differ de‐
pending on the vehicle version ⇒ Electronic parts catalogue .
The Audi A3 and Audi A3 Sportback for example are fitted with
ventilation frame -A-, whereas the Audi A3 Saloon and Audi
A3 Cabriolet are equipped with ventilation frame -B-.
♦ The following illustrations show the components fitted on the
Audi A3 and Audi A3 Sportback. They differ on other vehicle
versions (e.g. on the Audi A3 Saloon and the Audi A3 Cabrio‐
let).
♦ If the forced ventilation frame is to be re-used after it has been
removed on vehicles with no cover in the luggage compart‐
ment side trim (e.g. on left side in A3 Saloon, or on both sides
in Audi A3 Cabriolet), the side trim must not be removed (to
ensure that the retaining tabs on the ventilation frame can be
released for removal).
Removing
Audi A3 Saloon, Audi A3 Cabriolet and Audi Q2
– Remove bumper cover (rear) ⇒ General body repairs, exteri‐
or; Rep. gr. 63 ; Bumper (rear); Exploded view - bumper
cover .
Audi A3 Saloon
– If left ventilation frame is to be removed and re-used, remove
left luggage compartment lining (side trim) - vehicles with lug‐
gage compartment lining without cover ⇒ General body re‐
pairs, interior; Rep. gr. 70 ; Luggage compartment trim panels;
Exploded view - luggage compartment side trim .
Audi A3 Cabriolet and Audi Q2
– If ventilation frame (left and/or right) is to be removed and re-
used, remove corresponding luggage compartment lining (lug‐
gage compartment lining without cover) ⇒ General body
repairs, interior; Rep. gr. 70 ; Luggage compartment trim pan‐
els; Exploded view - luggage compartment side trim .
Audi A3 and Audi A3 Sportback
– Left side: Detach cover in luggage compartment side trim.
All vehicles (except Audi A3 Cabriolet and Audi Q2)
– Right side: Take out vehicle tool kit.
With bumper cover (rear) removed:
– Release retaining clips -arrows- and pull or press forced ven‐
tilation frame -1- outwards out of body opening.
With bumper cover (rear) installed:
– Release retaining clips -arrows- and press forced ventilation
frame -1- outwards out of body opening.

– Take out ventilation frame -3- downwards between body -2-

and bumper cover -1- (e.g. Audi A3, Audi A3 Sportback)
Note
♦ This illustration shows the ventilation frame -3- on the right

side on an Audi A3 Sportback. It applies accordingly to the left
side.
♦ For greater clarity the rear bumper cover of the Audi A3 Sport‐
back has been removed.
Installing
– Check seal -1- for damage.
– Fit ventilation frame -2- in correct position to make sure sealing
lips -3- close properly.
Note
To make sure that the sealing lips -3- close properly, the ventila‐
tion frame -2- may only be installed in one position e.g. on the
Audi A3 and Audi A3 Sportback. On these vehicles, the large ra‐
dius -arrow- is at the top.
– Press forced ventilation vent into body opening until all retain‐
ing clips engage audibly.
6.10 Checking plenum chamber water drain
6. Air duct 333

Note
♦ Drainage of water out of the plenum chamber may be obstruc‐

ted by deposits such as leaves and pine needles accumulating
in the water drain -arrow-. The water level in the plenum cham‐
ber then rises if the vehicle is taken to a car wash or in the
event of heavy rain; water enters the heater and air condition‐
ing unit via the fresh air intake and is blown onto the evaporator
by the fresh air blower together with the air delivered.
♦ If the water drains (left and right) -arrow- are clogged with
leaves and pine needles, the drains may freeze up in winter
and prevent water drainage. After a short journey, the heat
emitted by engine and exhaust system melts the ice in the
drains again. By the time the vehicle arrives at the workshop,
the water may have already drained out of the plenum cham‐
ber.
♦ Water can enter the fresh air intake via the drip rail -1- if the
plenum chamber cover -2- is damaged or not installed prop‐
erly. This may result in complaints about odour from the heat‐
er/air conditioner and/or moisture in the passenger compart‐
ment.
♦ The plenum chamber cover must be fully engaged in the wind‐
screen frame -3- ⇒ General body repairs, exterior; Rep. gr.
50 ; Bulkhead; Exploded view - plenum chamber cover .
Procedure
ber cover .
– Check for dirt in water drains -arrow-.
• The water must be able to drain off.
– Clean water drains if obstructed with dirt.

7 Operating and display unit

⇒ “7.1 Overview of fitting locations - operating and display unit”,
page 335
⇒ “7.2 Removing and installing operating and display unit J65 /
J301 / J255 ”, page 340
7.1 Overview of fitting locations - operating

and display unit
J301 , vehicles with manually controlled air conditioner”,
page 335
J255 , vehicles with automatically controlled air conditioner”, page
336

and display unit -J301- , vehicles with
Air conditioning system control unit - J301-
A - Operating unit ( air condi‐

tioning system control unit -
J301- ) for vehicles without
seat heating
2 - Button for air recirculation
mode
❑ If LED lights up, “air re‐
circulation mode” is se‐
lected
❑ “Air recirculation mode”
is cancelled when air
distribution is set to “de‐
frost” function (air to
windscreen)
3 - A/C button for air condi‐
tioner compressor
❑ If LED lights up, “air con‐
ditioner compressor on”
is selected.
blower - V2-
❑ If LED lights up, “Rear
window heating on” is
selected
❑ Rear window heating
can be permanently
switched on by pressing
and holding button
⇒ page 13
6 - Rotary control for setting air
distribution

different symbols) ⇒
B - Operating unit ( air conditioning system control unit - J301- ) for vehicles with seat heating
❑ “Air recirculation mode” is cancelled when air distribution is set to “defrost” function (air to windscreen)
❑ Selected setting is reduced by one level after a pre-set time has elapsed ⇒ page 11
5 - Rotary control for setting air distribution
❑ Different versions (with different symbols) ⇒ Electronic parts catalogue
7 - A/C button for air conditioner compressor
❑ If LED lights up, “air conditioner compressor on” is selected.

and display unit -J255- , vehicles with
Climatronic control unit - J255-

Note
♦ For the A3 Cabriolet, neck heating is available as optional

equipment. Vehicles with neck heating are equipped with an
additional vent in the seat and with additional buttons
-1 and 2- for switching the neck heating on and off in the air
conditioner operating unit ( Climatronic control unit - J255- ).
♦ There are different versions of the air conditioner operating
and display unit ( Climatronic control unit - J255- ) on vehicles
with or without a high-voltage system ⇒ Electronic parts cata‐
logue . On vehicles with a high-voltage system, a version of -
J255- is fitted which has additional functions for activating the
shut-off valves -N541- , -N542- , the electrical air conditioner
compressor - V470- etc.; however, it does not have the option
of activating a retro-fitted auxiliary heater or the air conditioner
compressor regulating valve - N280- .
♦ There are different versions for vehicles with a high-voltage
system e.g. for Europe or for North America. Vehicles for North
America e.g. are fitted with a refrigerant pressure and tem‐
perature sender - G805- instead of the pressure sender for
refrigerant circuit - G395- , and a different version of the elec‐
trical air conditioner compressor - V470- (with control unit for
air conditioner compressor - J842- ) ⇒ Vehicle diagnostic test‐
er (“Guided Fault Finding”) and ⇒ Electronic parts catalogue .
♦ The following illustrations show an air conditioner operating
and display unit ( Climatronic control unit - J255- ) without but‐
tons for switching the neck heating on and off.

A - Operating unit ( Climatronic

control unit - J255- ) for vehi‐
cles without seat heating
(driver side)
2 - Display
blower - V2-
4 - A/C button for air condi‐
tioner compressor
❑ If LED lights up, “air con‐
ditioner compressor on”
is selected.
(front passenger side)
6 - Button for setting air distri‐
bution at top
❑ If LED lights up, “air dis‐
tribution at top” is selec‐
ted
different symbols on
button) ⇒ Electronic
parts catalogue
bution to centre
tribution to centre” is se‐
lected
bution at bottom
tribution at bottom” is

selected
❑ The “air recirculation mode” function is cancelled on pressing the button for defrost mode (air to wind‐
screen)
11 - Button for defrost mode
❑ If LED lights up, “defrost mode” is selected
❑ Different versions (with different lettering on button) ⇒ Electronic parts catalogue
12 - Auto button for automatic air conditioner control
❑ If LED lights up, “automatic control” is selected
B - Operating unit ( Climatronic control unit - J255- ) for vehicles with seat heating
1 - Rotary temperature control (driver side)
2 - Display
4 - A/C button for air conditioner compressor
❑ If LED lights up, “air conditioner compressor on” is selected.
5 - Rotary temperature control (front passenger side)
7 - Button for setting air distribution at top
❑ If LED lights up, “air distribution at top” is selected
❑ Different versions (with different symbols on button) ⇒ Electronic parts catalogue
8 - Button for setting air distribution to centre
❑ If LED lights up, “air distribution to centre” is selected
9 - Button for setting air distribution at bottom
❑ If LED lights up, “air distribution at bottom” is selected
❑ The “air recirculation mode” function is cancelled on pressing the button for defrost mode (air to wind‐
screen)
12 - Button for defrost mode
❑ If LED lights up, “defrost mode” is selected
❑ Different versions (with different lettering on button) ⇒ Electronic parts catalogue
13 - Auto button for automatic air conditioner control
❑ If LED lights up, “automatic control” is selected

7.2 Removing and installing operating and

display unit -J65- / -J301- / -J255-
♦ Hook - T40207- (or hook - 3438- ).
♦ Commercially available plastic wedge (see illustration below)
Removing
– Position hook - T40207- (or hook - 3438- ) in openings -3- and
carefully pull operating unit -1- out of mounting -2- -arrow-.
Note
♦ If the operating unit -1- cannot be removed as described, use

a plastic wedge -3- (e.g. removal wedge - T40233- or wedge
T10383/2 from set of wedges - T10383- ) while at the same
time pulling with the hook -T40207- or -3438- , and carefully
press the operating unit out of the mounting -2- -arrow-, as
shown in illustration.
♦ If the operating unit -1- is seated so firmly in the mounting in
the dash panel that the plastic wedge -3- becomes deformed
when attempting to press out the operating unit, you can ad‐
ditionally insert a screwdriver between the plastic wedge -3-
and the operating unit -1-.
♦ Depending on the version of the dash panel, a retaining clip
(usually bottom right clip) may become caught in the dash
panel fascia after the operating unit -1- is released; in this
case, press the clip towards the operating unit -1- with your
finger or a screwdriver.
– Unplug electrical connectors -1, 2, 3- by sliding locking ele‐

ment -4- upwards -arrow- and pressing catch -5- inwards.

Installing
– Vehicles with automatically controlled air conditioner: Check
infrared sensor -arrow- for contamination and clean if neces‐
sary.
– Check the four retaining clips on the operating unit; if a clip has
been bent open too far, bend it back.

Note
♦ A contaminated infrared sensor will cause problems with air

conditioner control ⇒ Vehicle diagnostic tester (“Guided Fault
Finding”).
♦ There are different versions of the operating units -J65- / -
J301- / -J255- (different functions, different symbols and let‐
tering on buttons and rotary controls); for correct version refer
to ⇒ Electronic parts catalogue .
♦ On vehicles with a manually controlled air conditioner, the op‐
erating unit ( air conditioning system control unit - J301- ) is
available with different lettering on the buttons. At the start of
production, -J301- with an AC button was installed. In model
year 2013, the lettering for the button was gradually changed
to A/C ⇒ Electronic parts catalogue .
♦ The operating unit ( heater control unit - J65- on vehicles with‐
out air conditioner, air conditioning system control unit - J301-
on vehicles with manually controlled air conditioner) are
available with different symbols on the rotary control for air
distribution. Note the different versions (gradual change-over
from model year 2014 onwards) ⇒ Electronic parts catalogue .
♦ On vehicles with an automatically controlled air conditioner,
the operating unit ( Climatronic control unit - J255- ) is available
with different lettering on the buttons. At the start of production,
operating units -J255- with a Front button (for defrost mode)
were installed. In model year 2014, the lettering for the button
was gradually changed to MAX ⇒ Electronic parts catalogue .
♦ There are different versions of the air conditioner operating
and display unit ( Climatronic control unit - J255- ) on vehicles
with or without a high-voltage system ⇒ Electronic parts cata‐
logue
⇒ “7.1.2 Overview of fitting locations - operating and display
unit J255 , vehicles with automatically controlled air condition‐
er”, page 336 .
♦ If an operating unit is installed on which the clips are bent too
far open, it might not be possible to remove it from the dash
panel again (clips can become caught in mounting).
♦ For the A3 Cabriolet, neck heating is available as optional
equipment. Vehicles with neck heating are equipped with an
additional vent in the seat and with additional buttons
-1 and 2- for switching the neck heating on and off in the air
conditioner operating unit ( Climatronic control unit - J255- ).

then perform basic setting ⇒ Vehicle diagnostic tester (“Gui‐

8 Coolant circuit
⇒ “8.1 Incorporation of high-voltage heater (PTC) Z115 into cool‐
ant circuit”, page 343
into coolant circuit of high-voltage system”, page 347
⇒ “8.3 Removing and installing coolant valve for high-voltage bat‐
tery N688 ”, page 350
⇒ “8.4 Removing and installing coolant pump for high-voltage
battery V590 ”, page 350
⇒ “8.5 Removing and installing continued coolant circulation
pump V51 ”, page 351
⇒ “8.6 Removing and installing coolant shut-off valve N82 ”, page
351
⇒ “8.7 Removing and installing coolant changeover valve 1 N632
”, page 351
⇒ “8.8 Removing and installing coolant changeover valve 2 N633
”, page 351
⇒ “8.9 Removing and installing heat exchanger for high-voltage
battery”, page 352
⇒ “8.10 Removing and installing high-voltage heater (PTC) Z115
(with high-voltage heater (PTC) control unit J848 )”, page 356
8.1 Incorporation of high-voltage heater

(PTC) - Z115- into coolant circuit
Note
♦ On vehicles with high-voltage system, the supplementary

heating function is provided by the high-voltage heater (PTC)
- Z115-
♦ On vehicles with a high-voltage system and an auxiliary heater
fitted as an optional extra, the high-voltage heater (PTC) -
Z115- can be activated instead of the auxiliary heater to heat
up the passenger compartment. For further information, refer
to ⇒ Auxiliary/supplementary heater; Rep. gr. 00 ; General
notes .
♦ On vehicles with high-voltage system which do not feature an
auxiliary heater as an optional extra, the passenger compart‐
ment can be heated via the “Auxiliary air conditioner” function
and - Z115- when ambient temperatures are low (or cooled via
the air conditioner when ambient temperatures are high). For
further information, refer to
system only”, page 16 .
♦ Topping up coolant and bleeding coolant circuit ⇒ Engine,
mechanics; Rep. gr. 19 ; Cooling system/coolant; Draining
and filling cooling system
♦ For incorporation of heat exchanger for air conditioner and
high-voltage heater (PTC) - Z115- into engine coolant circuit,
refer to ⇒ Engine, mechanics; Rep. gr. 19 ; Cooling system/
coolant; Connection diagram - coolant hoses .
8. Coolant circuit 343

Note
The -arrows- indicate the direction of coolant flow.
1 - Heat exchanger for heater

in air conditioning unit
❑ Incorporation of heat ex‐
changer into engine
coolant circuit ⇒ En‐
gine, mechanics; Rep.
gr. 19 ; Cooling system/
coolant; Connection di‐
agram - coolant hoses
2 - High-voltage heater (PTC)
- Z115- (with high-voltage
heater (PTC) control unit -
J848- )
Fault Finding” for air
conditioner) and ⇒ Cur‐
rent flow diagrams,
Electrical fault finding
and Fitting locations
⇒ page 356
❑ Notes on - Z115- (and -
J848- )
⇒ “4.15 Notes on high-
voltage heater (PTC)
Z115 (and high-voltage
heater (PTC) control
unit J848 )”, page 85
❑ For further information
on vehicles with an aux‐
iliary heater (optional
extra), refer to ⇒ Auxili‐
ary/supplementary
heater; Rep. gr. 00 ;
General notes .
3 - Coolant valve for gearbox -
N488-
4 - Coolant supply to gearbox
❑ Incorporation of auxiliary heater into coolant circuit of engine (and gearbox) ⇒ Engine, mechanics; Rep.
gr. 19 ; Cooling system/coolant; Connection diagram - coolant hoses
5 - Coolant supply from engine
❑ Incorporation of auxiliary heater into engine coolant circuit ⇒ Engine, mechanics; Rep. gr. 19 ; Cooling
system/coolant; Connection diagram - coolant hoses
6 - Coolant return to engine

Note
Depending on the engine, a valve

may be fitted in the coolant return
between the coolant changeover
valve 2 - N633- and the engine; this
valve prevents coolant from flowing
from the engine to -N633- when the
engine is running ⇒ Engine, me‐
chanics; Rep. gr. 19 ; Cooling sys‐
tem/coolant; Connection diagram -
coolant hoses .
7 - Coolant changeover valve 2 - N633-

❑ Removing and installing ⇒ page 351 and ⇒ Engine, mechanics; Rep. gr. 19 ; Coolant pump/thermostat
assembly
Note
♦ -N633- is activated by the corre‐

J623- ) if heat output is being
requested by the air conditioner
and the vehicle is in electric
mode ⇒ Current flow diagrams,
Electrical fault finding and Fitting
locations and ⇒ Vehicle diagnos‐
tic tester (“Guided Fault Find‐
ing”).
tion and operation if there is a
problem with insufficient heat
output from the air conditioner
with engine stopped and/or run‐
ning, regardless of whether -
Z115- is activated ⇒ Current flow
diagrams, Electrical fault finding
and Fitting locations and ⇒ Vehi‐
cle diagnostic tester (“Guided
Fault Finding”).
the coolant pump for high-tem‐
perature circuit - V467- and the
coolant valve for gearbox -
N488- must also be activated (by
trol unit). To ensure that the cool‐
ant flows in the right direction,
the non-return valves fitted in the
coolant circuit must also be in‐
stalled correctly and they must
operate correctly. For further in‐
formation, refer to ⇒ Engine, me‐
chanics; Rep. gr. 19 ; Cooling
system/coolant; Connection dia‐
gram - coolant hoses , ⇒ Vehicle
Finding”) and ⇒ Current flow di‐
agrams, Electrical fault finding

8 - Coolant pump for high-temperature circuit - V467-

❑ Incorporated into engine coolant circuit ⇒ Engine, mechanics; Rep. gr. 19 ; Cooling system/coolant;
Connection diagram - coolant hoses
Note
♦ -V467- is activated by the corre‐

J623- ) if heat output is being
requested by the air conditioner
tions and ⇒ Vehicle diagnostic
tion and operation of -Z115- if
there is a problem with insuffi‐
cient heat output from the air
conditioner with engine stopped
and/or running, regardless of
whether -V467- is activated
tions and ⇒ Vehicle diagnostic
the coolant changeover valve 2 -
N633- and the coolant valve for
gearbox - N488- must also be
activated (by the corresponding
engine control unit). To ensure
that the coolant flows in the right
direction, the non-return valves
fitted in the coolant circuit must
also be installed correctly and
they must operate correctly. For
further information, refer to ⇒
Engine, mechanics; Rep. gr. 19 ;
Cooling system/coolant; Con‐
nection diagram - coolant hoses ,
(“Guided Fault Finding”) and
tions.
9 - Coolant return from gearbox

❑ Incorporation of auxiliary heater into coolant circuit of engine (and gearbox) ⇒ Engine, mechanics; Rep.
gr. 19 ; Cooling system/coolant; Connection diagram - coolant hoses

8.2 Incorporation of heat exchanger for

high-voltage battery into coolant circuit
of high-voltage system
Note
♦ Topping up coolant and bleeding coolant circuit ⇒ 4-cylinder

system (vehicles with high-voltage system).
♦ The following illustration only shows part of the components
of the coolant circuit for the high-voltage system. For further
components not shown here, refer to ⇒ 4-cylinder direct in‐
jection engine (1.2, 1.4 ltr. 4-valve TFSI EA 211); Rep. gr. 19 ;
Cooling system/coolant; Connection diagram - coolant hoses,
cooling components for high-voltage system .
♦ Incorporation of heat exchanger for high-voltage battery into
refrigerant circuit
⇒ “2.1.2 System overview - refrigerant circuit, vehicles with
high-voltage system”, page 138
♦ If there is a problem because the components of the high-volt‐
age system are not cooled and the air conditioner cooling
output is OK, check that the heat exchanger for the high-volt‐
age battery is cooled down via the cooling output test
controlled air conditioner (with high-voltage system)”,
page 64 . Make sure that the heat exchanger for high-voltage
battery is actually cooled down. The refrigerant shut-off valve
for high-voltage battery heat exchanger - N542- must operate
correctly, and the restrictor fitted in the refrigerant circuit must
be OK
⇒ “2.1.2 System overview - refrigerant circuit, vehicles with
high-voltage system”, page 138 . If no fault is found in the re‐
frigerant circuit, check the incorporation of the coolant pump
for high-voltage battery - V590- , the coolant circulation pump
before power and control electronics for electric drive - V508- ,
the coolant changeover valve 1 - N632- and the coolant valve
for high-voltage battery - N688- into the coolant circuit of the
high-voltage system as well as these components' activation
and operation ⇒ 4-cylinder direct injection engine (1.2, 1.4 ltr.
4-valve TFSI EA 211); Rep. gr. 19 ; Cooling system/coolant;
Connection diagram - coolant hoses, cooling components for
high-voltage system and ⇒ Vehicle diagnostic tester (“Guided
Fault Finding” for air conditioner and hybrid battery energy
management system).

1 - Coolant valve for high-volt‐

age battery - N688-
❑ Incorporation into cool‐
ant circuit of high-volt‐
age system ⇒ 4-cylin‐
der direct injection en‐
gine (1.2, 1.4 ltr. 4-valve
TFSI EA 211); Rep. gr.
19 ; Cooling system/
agram - coolant hoses,
cooling components for
high-voltage system
⇒ page 350 and ⇒ 4-
cylinder direct injection
engine (1.2, 1.4 ltr. 4-
valve TFSI EA 211);
Rep. gr. 19 ; Coolant
pump/thermostat as‐
sembly; Removing and
installing coolant valves
❑ Checking operation and
activation of coolant
pump for high-voltage
battery - V590- and -
N688- ⇒ 4-cylinder di‐
rect injection engine
(1.2, 1.4 ltr. 4-valve
TFSI EA 211); Rep. gr.
19 ; Cooling system/
agram - coolant hoses,
cooling components for
high-voltage system
and ⇒ Vehicle diagnos‐
tic tester (“Guided Fault
Finding” for air condi‐
tioner and hybrid battery
energy management
system)
2 - Coolant return from hybrid battery unit - AX1-
❑ Incorporation into coolant circuit of high-voltage system ⇒ 4-cylinder direct injection engine (1.2, 1.4 ltr.
components for high-voltage system
3 - Coolant supply to hybrid battery unit - AX1-
4 - Bleeder screw
❑ Bleeding coolant circuit ⇒ 4-cylinder direct injection engine (1.2, 1.4 ltr. 4-valve TFSI EA 211); Rep. gr.
19 ; Cooling system/coolant; Draining and filling cooling system (vehicles with high-voltage system)
❑ Check operation and cooling of heat exchanger via air conditioner
⇒ “4.8.5 Checking cooling output - vehicles with automatically controlled air conditioner (with high-voltage
system)”, page 64 and ⇒ Vehicle diagnostic tester (“Guided Fault Finding” for air conditioner and hybrid
battery energy management system).

6 - Coolant pump for high-voltage battery - V590-

EA 211); Rep. gr. 19 ; Coolant pump/thermostat assembly; Removing and installing electric coolant
pump
❑ Checking operation and activation of -V590- and coolant valve for high-voltage battery - N688- ⇒ 4-
cylinder direct injection engine (1.2, 1.4 ltr. 4-valve TFSI EA 211); Rep. gr. 19 ; Cooling system/coolant;
Connection diagram - coolant hoses, cooling components for high-voltage system and ⇒ Vehicle diag‐
nostic tester (“Guided Fault Finding” for hybrid battery energy management system)
Note
♦ -V590- (and -N688- ) are activa‐

ted by the hybrid battery unit -
AX1- (by the battery regulation
control unit - J840- ) if there is a
request for cooling the compo‐
nents of the high-voltage system
( hybrid battery unit - AX1- , pow‐
er and control electronics for
electric drive - JX1- and/or con‐
trol unit for high-voltage battery
charging unit - J1050- ) ⇒ Vehicle
Finding” for hybrid battery ener‐
gy management system) and ⇒
4-cylinder direct injection engine
211); Rep. gr. 19 ; Cooling sys‐
tem/coolant; Connection dia‐
gram - coolant hoses, cooling
components for high-voltage
system .
♦ If there is a problem with lack of
cooling output for the compo‐
nents of the high-voltage sys‐
tem, make sure they are correct‐
ly installed and function properly
(“Guided Fault Finding” for hy‐
brid battery energy management
system) and ⇒ 4-cylinder direct
injection engine (1.2, 1.4 ltr. 4-
Cooling system/coolant; Con‐
nection diagram - coolant hoses,
cooling components for high-
voltage system .

♦ In order for the power and control

electronics for electric drive -
JX1- and the control unit for high-
voltage battery charging unit -
J1050- to be cooled, the coolant
circulation pump before power
and control electronics for elec‐
tric drive - V508- and the coolant
changeover valve 1 - N632- must
also be activated correctly (by
trol unit) and they must be func‐
tioning properly. For further in‐
formation, refer to ⇒ Vehicle
Finding” for hybrid battery ener‐
gy management system) and ⇒
4-cylinder direct injection engine
211); Rep. gr. 19 ; Cooling sys‐
tem/coolant; Connection dia‐
gram - coolant hoses, cooling
components for high-voltage
system .
7 - Coolant supply from cooler for high-voltage system

8 - Coolant supply to coolant circulation pump before power and control electronics for electric drive - V508-
8.3 Removing and installing coolant valve

for high-voltage battery - N688-
Note
-N688- is installed in the coolant circuit of the high-voltage system

⇒ 4-cylinder direct injection engine (1.2, 1.4 ltr. 4-valve TFSI EA
211); Rep. gr. 19 ; Cooling system/coolant; Connection diagram
- coolant hoses, cooling components for high-voltage system .
Removing and installing ⇒ 4-cylinder direct injection engine (1.2,

1.4 ltr. 4-valve TFSI EA 211); Rep. gr. 19 ; Coolant pump/ther‐
mostat assembly; Removing and installing coolant valves
8.4 Removing and installing coolant pump

for high-voltage battery - V590-
Note
-V590- is installed in the coolant circuit of the high-voltage system



8.5 Removing and installing continued cool‐

ant circulation pump - V51-
Note
-V51- is installed in the coolant circuit (depending on engine ver‐

sion) ⇒ Engine, mechanics; Rep. gr. 19 ; Cooling system/coolant;
Connection diagram - coolant hoses and ⇒ Current flow dia‐

Cooling system/coolant (Connection diagram - coolant hoses, or
Coolant pump/thermostat assembly)
8.6 Removing and installing coolant shut-off

valve - N82-
Note
-N82- is installed in the coolant circuit (depending on engine ver‐

sion) ⇒ Engine, mechanics; Rep. gr. 19 ; Cooling system/coolant;
Connection diagram - coolant hoses and ⇒ Current flow dia‐

Cooling system/coolant (Connection diagram - coolant hoses, or
Coolant pump/thermostat assembly)
8.7 Removing and installing coolant

changeover valve 1 - N632-
Note
-N632- is installed in the coolant circuit of the high-voltage system


8.8 Removing and installing coolant

changeover valve 2 - N633-
Note
-N633- is installed in the engine coolant circuit

⇒ “8.1 Incorporation of high-voltage heater (PTC) Z115 into cool‐
ant circuit”, page 343 , ⇒ 4-cylinder direct injection engine (1.2,
1.4 ltr. 4-valve TFSI EA 211); Rep. gr. 19 ; Cooling system/cool‐
ant; Connection diagram - coolant hoses, cooling components for
high-voltage system and ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.



for high-voltage battery
Note


♦ Spring-type clip pliers - VAS 5024A-
♦ Cooling system tester - V.A.G 1274 B-
Removing
WARNING

– Open cap on coolant expansion tank for high-voltage system

⇒ 4-cylinder direct injection engine (1.2, 1.4 ltr. 4-valve TFSI
EA 211); Rep. gr. 19 ; Cooling system/coolant; Draining and
filling cooling system (vehicles with high-voltage system).
– Unfasten coolant expansion tank for engine coolant circuit
from vehicle and tilt it slightly to the side ⇒ Engine, mechanics;
Rep. gr. 19 ; Cooling system/coolant .

– Use hose clamps -3094- to pinch off coolant hoses -A- and
-B-.
Note

rectly.
– Cover area beneath connections for coolant hoses at heat ex‐

changer -E- with absorbent paper.
– Detach coolant hoses -A- and -B- from connections at heat
exchanger -E-.
– Seal off open connections for coolant hoses on heat exchang‐
er -E- with clean plugs from engine bung set - VAS 6122- .
WARNING

– Remove bolts -F- at refrigerant lines leading to heat exchanger

-E-.
– Unfasten heat exchanger -E- from refrigerant lines -B- and

-C- and remove them together with bracket -F-.
– Seal off open connections for coolant hoses on heat exchang‐
er -E- and refrigerant lines -B- and -C- with clean plugs from
engine bung set - VAS 6122- .
Note
Bracket -F- is secured to heat exchanger -E- with two bolts -G-.
Installing
– Renew O-rings -D-; for correct version, refer to ⇒ Electronic
parts catalogue .
– Check connections -B- and -C- of refrigerant lines and on heat
exchanger -E- for dirt and damage.


line -1-.
Note
♦ If fitted, check that dowel pin -4- is not damaged and is seated
correctly.
⇒ page 81 .
– Bracket -F- is secured to heat exchanger -E- with two bolts

-G-. If bolts -G- have been loosened, insert them, but do not
tighten them yet.
– Connect refrigerant lines -B- and -C- to heat exchanger -E-
and secure them with bolts -A- (do not tighten bolts -A- yet).

– Align heat exchanger -E- so it is not under strain and insert

bolts -D-.
– Tighten bolts -G- (tightening torque: 8 Nm).
– Tighten bolts -D- (tightening torque: 8 Nm).
– Tighten bolts -F- (tightening torque: 8 Nm).
– Attach coolant hoses -A- and -B- to connections on heat ex‐
changer -E-.
– Fill coolant into coolant expansion tank for high-voltage sys‐
tem ⇒ 4-cylinder direct injection engine (1.2, 1.4 ltr. 4-valve
TFSI EA 211); Rep. gr. 19 ; Cooling system/coolant; Draining
and filling cooling system (vehicles with high-voltage system).
– Slightly increase pressure in coolant expansion tank for high-
voltage system using e.g. cooling system tester - V.A.G 1274
B- ⇒ 4-cylinder direct injection engine (1.2, 1.4 ltr. 4-valve
TFSI EA 211); Rep. gr. 19 ; Cooling system/coolant; Draining
and filling cooling system (vehicles with high-voltage system).
– Carefully open bleeder screw -C-.
– Carefully open hose clamp up to 25 mm - 3094- at coolant
hose -A- and allow coolant to flow into heat exchanger -E-.
– Close bleeder screw -C- again as soon as coolant emerges at
bleeder screw.
Note
If the removal and installation of the heat exchanger for the high-
voltage battery -E- has been performed as described above, there
should be no air in the coolant circuit of the high-voltage system.
If there is still any air in the coolant circuit despite this, it must be
bled ⇒ 4-cylinder direct injection engine (1.2, 1.4 ltr. 4-valve TFSI
EA 211); Rep. gr. 19 ; Cooling system/coolant; Draining and filling
cooling system (vehicles with high-voltage system).
– If necessary, fill coolant into coolant expansion tank for high-

voltage system ⇒ 4-cylinder direct injection engine (1.2, 1.4
ltr. 4-valve TFSI EA 211); Rep. gr. 19 ; Cooling system/cool‐
ant; Draining and filling cooling system (vehicles with high-
voltage system).
– Remove hose clamps up to 25 mm - 3094- and re-install all
components removed or unfastened before.
⇒ page 199 .
ing”).

8.10 Removing and installing high-voltage

heater (PTC) - Z115- (with high-voltage
heater (PTC) control unit - J848- )
Note
A different heating element was introduced in place of the old one

during the model cycle. The procedure for removal and installa‐
tion is identical. For allocation of parts refer to ⇒ Electronic parts
catalogue .

The following procedure requires work to be performed in the vi‐
cinity of high-voltage components
voltage components”, page 19 .
The following procedure requires work to be performed on the
high-voltage system; de-energise the high-voltage system.
♦ Five-point star bit (TS30H) with centre hole (commercially
available)
♦ Cooling system tester - V.A.G 1274 B-
♦ Spring-type clip pliers - VAS 5024A-

Removing
WARNING

– Open cap -arrow- on coolant expansion tank for engine cool‐

ant circuit ⇒ Engine, mechanics; Rep. gr. 19 ; Cooling system/
coolant; Draining and filling cooling system .
– Remove noise insulation (rear) ⇒ General body repairs, ex‐
Note
The high-voltage heater (PTC) - Z115- is installed together with

the bracket and the heat shield -C- in the centre tunnel on the
underbody in the vicinity of the catalytic converter.
– Remove bolts -A- and -B-.

– Carefully tilt high-voltage heater (PTC) - Z115- with bracket
and heat shield -C- downwards.
Note
At the start of production, the heat shield is secured with thread-

forming M6x12 pan-head bolts -D-. Use a five-point star bit
(TS30H) with centre hole (commercially available) to remove and
install these bolts.
– Detach heat shield -B- and bracket -C- from high-voltage heat‐
er (PTC) - Z115- -D-.

– Pinch off coolant hoses -A- and -B- using hose clamps up to
25 mm - 3094- -D-.
Note
♦ The high-voltage heater (PTC) - Z115- -E- is designed for a

certain coolant flow direction. Therefore it is important to con‐
nect the coolant hoses correctly.
♦ On vehicles with an auxiliary heater (optional extra), a non-
return valve is fitted in the coolant line -C- ⇒ Auxiliary/supple‐
mentary heater; Rep. gr. 82 ; Coolant circuit with auxiliary/
supplementary heater .
– Detach coolant hoses -A- and -B- from connections at high-

voltage heater (PTC) - Z115- -E-.
– Seal off open connections for coolant hoses on high-voltage
heater (PTC) - Z115- -E- with clean plugs from engine bung
set - VAS 6122- .
– Detach electrical connectors -A- (low voltage) and -B- (high

voltage) from high-voltage heater (PTC) - Z115- ⇒ 4-cylinder
gr. 93 ; High-voltage wires; Overview of fitting locations - high-
voltage wires .
– Cover high-voltage wire connector and mating plug at -Z115-
-G- to prevent damage and contamination (e.g. with clean
plugs from engine bung set - VAS 6122- ).
Unscrew nut -F- (or -E-) and detach earth wire -C- (or earth wire
-C- with bracket -D-).
Installing
Heat shield -B- and bracket -C- are bolted onto high-voltage heat‐
er (PTC) - Z115- -D- with thread-forming M6x12 pan-head bolts
-A-. If a new high-voltage heater (PTC) - Z115- -D- is installed,
note that the holes are not threaded yet. To make it easier to insert
the bolts when installing a new -Z115- -D-, position bolts -A- and
screw them in approx. 6 mm before installing -Z115- -D-.

Check and, if necessary, clean contact surfaces for earth wire

-C- on bracket -D- and for bracket -D- on -Z115- -G- before bolting
on ⇒ Electrical system; Rep. gr. 97 ; Cleaning contact surfaces .
Note
Prior to installation, check attachment points on -Z115- -G- and

on bracket -D- as well as earth wire -C- at nut -F-. The contact
surfaces must be clean and free from rust and grease. If this is
not the case, treat the contact surfaces accordingly with the con‐
tact surface cleaning set - VAS 6410- ⇒ Electrical system; Rep.
gr. 97 ; Cleaning contact surfaces .
Bolt bracket -D- and earth wire -C- onto -Z115- -G-.
Component Tightening torque
Nuts -E- and -F- (M6 thread) 8 Nm
– Plug in electrical connectors -A- (low voltage) and -B- (high
voltage) at -Z115- -G- ⇒ 4-cylinder direct injection engine (1.2,
1.4 ltr. 4-valve TFSI EA 211); Rep. gr. 93 ; High-voltage wires;
Overview of fitting locations - high-voltage wires .
– If necessary, fill coolant into coolant expansion tank for engine
⇒ Engine, mechanics; Rep. gr. 19 ; Cooling system/coolant;
Draining and filling cooling system .
– Attach coolant hose -A- to -Z115- -E-.

– Carefully open hose clamp up to 25 mm - 3094- -D- at coolant
hose -A- and allow coolant to flow into high-voltage heater
(PTC) - Z115- -E-.
– As soon as coolant emerges from connection for coolant hose
-B- at -Z115- -E- ( -Z115- -E- filled completely with coolant),
connect coolant hose -B- to -Z115- -E-.
Note
♦ Hold connection for coolant hose -B- up as high as possible

while allowing coolant to flow into -Z115- -E- to make sure it is
filled completely with coolant.
♦ If the removal and installation of -Z115- -E- has been per‐
formed as described above, there should be no air in the
engine coolant circuit. Should there still be air in the coolant
circuit despite this, it must be bled ⇒ Engine, mechanics; Rep.
system .
– Remove both hose clamps -D-.

– Check and, if necessary, clean contact surfaces for bracket
-C- on -Z115- -D- and on heat shield -B- before bolting on ⇒
Electrical system; Rep. gr. 97 ; Cleaning contact surfaces .

– Fit heat shield -B- and bracket -C- at high-voltage heater (PTC)
- Z115- -D-.
Note
Heat shield -B- and bracket -C- are bolted onto high-voltage heat‐
er (PTC) - Z115- -D- with thread-forming M6x12 pan-head bolts
-A-.
Tightening torques:
Bolts -A- 8 Nm
– Install bracket -C- with high-voltage heater (PTC) - Z115- .

Tightening torques:
Bolts -A- 8 Nm
Bolts -B- 20 Nm
– Re-install all removed/unfastened components.
– If necessary, fill coolant into coolant expansion tank for engine
coolant circuit ⇒ Engine, mechanics; Rep. gr. 19 ; Cooling
– Remove hose clamps up to 25 mm - 3094- and re-install all
components removed or unfastened before.
– After installing high-voltage heater (PTC) - Z115- , switch on
ignition and activate drive system (READY - engine does not
have to be running), set air conditioner to maximum heat out‐
put and allow it to run in this setting for two minutes.

9 Further control components

⇒ “9.1 Removing and installing sunlight penetration photosensor
G107 ”, page 361
”, page 362
⇒ “9.3 Operation of air quality sensor G238 ”, page 364
⇒ “9.4 Checking air quality sensor G238 ”, page 366
⇒ “9.5 Operation of humidity sender in fresh air intake duct G657
”, page 370
⇒ “9.6 Removing and installing air quality sensor G238 / humidity
sender in fresh air intake duct G657 ”, page 371
⇒ “9.7 Removing and installing sensors G355 / G397 / G107 ”,
page 372
⇒ “9.8 Removing and installing fuse for electrical air conditioner
9.1 Removing and installing sunlight pene‐

tration photosensor - G107-
Only installed on Audi A3 vehicles with automatic air conditioner
Note
♦ On Audi Q2 vehicles with automatic air conditioner, the sun‐

light penetration photosensor is fitted in the mirror base
⇒ “9.7 Removing and installing sensors G355 / G397 / G107
”, page 372 .
♦ The sunlight penetration photosensor - G107- is only installed
on vehicles with automatically controlled air conditioners.
♦ Checking sunlight penetration photosensor - G107- ⇒ Vehicle
diagnostic tester (“Guided Fault Finding” for air conditioner)
Removing
– Remove loudspeaker trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Dash panel; Removing and installing loudspeak‐
er trim .
– Press sunlight penetration photosensor - G107- -item 2- up‐
wards out of defroster vent -3- -arrow-.
Installing
ing”).

9.2 Removing and installing ambient tem‐

perature sensor - G17-
⇒ “9.2.1 Removing and installing ambient temperature sensor
G17 - A3”, page 362
G17 - Q2, Q2 China”, page 362
G17 - SQ2”, page 363
9.2.1 Removing and installing ambient tem‐

perature sensor - G17- - A3
Note
An incorrect measured value for ambient temperature sensor -

G17- may lead to problems with the control of the air conditioner
and supplementary heater on vehicles with TDI engine. Checking
⇒ Vehicle diagnostic tester (“Guided Fault Finding” for instrument
cluster)
Removing
– Reach through opening in radiator grille, carefully compress
retaining clips -arrow- and pull ambient temperature sensor -
G17- -item 3- out of bracket -2-.
Note
If the ambient temperature sensor cannot be removed as descri‐

bed, the closure plate for the front bumper cover must be removed
⇒ General body repairs, exterior; Rep. gr. 63 ; Bumper (front) ;
Exploded view - bumper (front).
Installing

perature sensor - G17- - Q2, Q2 China
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Removing and installing noise
insulation .


– Pull ambient temperature sensor - G17- -1- out of air duct -2-
in direction of -arrow-.
Installing
Tightening torque
♦ Noise insulation ⇒ General body repairs, exterior; Rep. gr.
66 ; Noise insulation; Exploded view - noise insulation

perature sensor - G17- - SQ2
Note
If the measured value for the ambient temperature sensor - G17-

-A- is incorrect, the air conditioner (and the supplementary heater
on vehicles with TDI engine) may be regulated incorrectly; check‐
ing measured value ⇒ Vehicle diagnostic tester (“Guided Fault
Finding”).
Removing
– Remove closure plate for bumper cover ⇒ General body re‐
pairs, exterior; Rep. gr. 63 ; Bumper (front); Exploded view -
bumper cover .
– Carefully squeeze together retaining clips -arrows- while de‐
taching ambient temperature sensor - G17- -A- from duct on
radiator (left-side) -B-.
– Unplug electrical connector -C-.
Installing

9.3 Operation of air quality sensor -G238-
Note
♦ The air quality sensor - G238- -3- is only installed on vehicles

with automatically controlled air conditioners. It is integrated
in housing -2- together with the humidity sender in fresh air
intake duct - G657- -1-.
♦ There are different versions of -G238- -3- and -G657- -1-. For
correct versions refer to ⇒ Electronic parts catalogue .
♦ -G238- uses one sensor each to determine the NOx (nitrogen

oxide) content and the CO (carbon monoxide) content of the
air flowing past and exchanges this information with the on‐
board supply control unit - J519- via the data bus.
♦ The measured value of -G238- is evaluated by -J519- and
transmitted to the operating unit ( Climatronic control unit -
J255- ) via the data bus. When it detects a request, -J255-
switches on air recirculation mode if there is no shut-off
criterion ⇒ Vehicle diagnostic tester (“Guided Fault Finding”).
Note
Certain air conditioner functions (including e.g. regulation of “au‐

tomatic air recirculation mode”) can be activated and deactivated
on the MMI (Multi Media Interface) using the “A/C” function on the
“Car”/“Car systems” menu.
♦ After the ignition is switched on, it takes -G238- a short while

to reach its operating temperature; the function of -G238- is
restricted during the warm-up phase.
♦ -G238- detects pollutants in the ambient atmosphere (gener‐
ally petrol and/or diesel emissions) and causes -J255- to
switch the air conditioner to air recirculation mode.
♦ The operating unit ( Climatronic control unit - J255- ) recogni‐
ses the nature and level of the air pollution from the signal it
receives from -G238- . In addition, -J255- receives the sensi‐
tivity setting from the multimedia system operating unit - E380-
via the data bus. -J255- then uses this information to
determine if and when to switch the air conditioner to air re‐
circulation mode.
Example:
– At ambient temperatures above approx. +2 °C, even a slight
increase in the pollutant concentration causes the system to
switch to air recirculation mode when requested to do so by -
G238- .
– At ambient temperatures below approx. -1 ℃ with the air con‐
ditioner compressor switched off, switch-over only occurs if
there is a major increase in the pollutant concentration for ap‐
prox. 15 seconds. If there is a renewed increase in the pollu‐
tant concentration within approx. 2 minutes, -J255- does not
switch to “automatic air recirculation mode” within this period.
• If the lamp in the A/C button is not on, the maximum duration
of “automatic air recirculation” is restricted to approx. 15 sec‐
onds by -J255- to prevent the windows in the passenger
compartment from misting up.
– A decrease in the concentration of pollutants in the fresh air
drawn in results in the air conditioner being switched back to
fresh air mode.

• The duration of “automatic air recirculation mode” depends on

the version of -J255- , the setting on -E380- and the measured
values for -G355- .
– At ambient temperatures below approx. +10 °C and with max‐
imum sensitivity set on -E380- , the system remains in “auto‐
matic air recirculation mode” for e.g. approx. 30 sec. After this
period, the system switches to fresh air mode. If there is a
renewed increase in the pollutant concentration within approx.
2 minutes, -J255- does not switch to “automatic air recircula‐
tion mode” within this period.
♦ The “automatic air recirculation” function can be deactivated
at any time. If the function is active, the air conditioner com‐
pressor will be switched on even at ambient temperatures
below + 2 °C when there is a request for “automatic air recir‐
culation”. However, at temperatures below approx. -5 °C,
compressor operation is no longer possible.
♦ If “automatic air recirculation” mode has been set on the MMI
(Multi Media Interface), the air conditioner compressor may be
switched on down to temperatures of approx. -5 °C.
♦ To prevent the air conditioner from constantly operating in air
recirculation mode in areas with a persistently high level of
pollutant emissions, -G238- is adaptive (sensitivity is matched
to environmental conditions).
♦ If the pollutant level in the ambient air remains relatively high
for a lengthy period, -G238- starts to adapt to the change in
ambient conditions via an adaption program, with the result
that a request for air recirculation is generally applied for less
than 12 minutes if the ambient air pollution remains the same.
If there are several consecutive peak pollutant levels, the air
conditioner may also operate in air recirculation mode for a
longer period.
♦ It takes the air conditioner compressor a certain length of time
to re-position the flaps. To prevent gaseous pollutants from
entering the passenger compartment together with the fresh
air drawn in before the air flow/fresh air flaps can close (and
the air recirculation flaps can open) when there is a sudden
increase in pollutant levels (e.g. when driving through a cloud
of diesel emissions), the vehicle is fitted with a dust and pollen
filter with an activated charcoal layer. Once a filter is saturated
with pollutants, it can no longer perform this function and must
be renewed.
♦ To prevent the air flow/fresh air flap and the air recirculation
flap from being switched too frequently, switching does not
take place immediately if there is a slight increase in the pol‐
lutant level in the ambient atmosphere ( -G238- does not
transmit a request to -J255- ). In such cases, the filter effect of
the activated charcoal layer in the dust and pollen filter is
enough.
♦ To prevent the air flow/fresh air and air recirculation flaps from
being switched too frequently, a request from -G238- for “au‐
tomatic air recirculation mode” is applied for at least 25 sec‐
onds (minimum dwell time) even if the pollutant concentration
in the air has decreased to such an extent that air recirculation
mode would no longer be necessary.
♦ To demist the windscreen, rear window and door windows as
quickly as possible, -J255- does not permit air recirculation in
“Defrost” mode (a request from -G238- is not implemented).
♦ After the ignition is switched on, the air quality sensor - G238-
requires a short period before it is ready for operation (warm-
up time). During this period, no request is transmitted to the
operating unit ( Climatronic control unit - J255- ) for “automatic
air recirculation mode”.

♦ When the ignition is switched on, certain ambient influences

(e.g. high pollutant content in the air) during the warm-up
phase of the air quality sensor - G238- may result in a fault
being stored for the -G238- in the onboard supply control unit
- J519- although the sensor is OK. In this case, proceed as
follows:
– Switch off the ignition for at least 2 minutes.
– Switch on ignition and wait at least 2 minutes.
– Interrogate event memory of onboard supply control unit -
J519- . If a static fault is still displayed for the air quality sensor
- G238- , perform “Guided Fault Finding” (⇒ Vehicle diagnostic
tester). If -G238- is no longer displayed as being faulty or if the
fault becomes sporadic, -G238- is OK (and requires no further
attention). Erase the event memory.
9.4 Checking air quality sensor - G238-
Note
♦ After switching on the ignition, it takes -G238- -item 3- a short

while to reach its operating temperature.
♦ Operation is restricted during the warm-up phase, and a fault
may be indicated under certain ambient conditions. Only re‐
new -G238- if the entry indicates that it is permanently defec‐
tive. If the fault display for -G238- changes from “static” to
“sporadic” after the ignition is switched off and on again (wait
at least 2 minutes in each case), -G238- is OK and the event
memory entry requires no further attention (erase event mem‐
ory) ⇒ Vehicle diagnostic tester (“Guided Fault Finding”).
♦ Certain air conditioner functions (including e.g. regulation of
“automatic air recirculation mode”) can be activated and de‐
activated on the MMI (Multi Media Interface) using the “A/C”
function on the “Car” / “Car systems” menu. In addition, the
operation of the air conditioner can also be influenced by the
settings on the MMI (Multi Media Interface) in the “A/C” func‐
tion of the “Car” / “Car systems” menu. Therefore, if there are
problems with these components, first check the settings on
the MMI ⇒ Infotainment/MMI Operating Manual .

♦ Commercially available gas lighter
Test requirements
• The vehicle must be stationary in a clean atmosphere, away
from running engines, air extractor outlets etc.
• The engine compartment and plenum chamber must be clean
(not contaminated with oil or fuel).
• The engine compartment and plenum chamber must not have
been sprayed with solvent-based cleaning agents or anti-cor‐
rosion material.
• The “automatic air recirculation” function must be activated.

Note
The “automatic air recirculation” function can be activated and

deactivated via the “AC” function in the “Car”/“Car systems” menu
of the MMI (Multi Media Interface) ⇒ Infotainment/MMI Operating
Manual .
Checking operation
– Remove air quality sensor - G238- . Leave connector plugged
in ⇒ page 371 .
– Start engine.
– Set -J255- to “Auto” mode.
– Use MMI (Multi Media Interface) to set -J255- to automatic air
recirculation mode ⇒ Infotainment/MMI Operating Manual .
• The -G238- is ready for operation after a warm-up period of
approx. 2 minutes.
trol unit - J255- ) and select “Read measured values” ⇒ Vehicle
diagnostic tester in “Guided Fault Finding” mode.
– Select “Read measured values” function and read out current
status for fresh air or air recirculation mode ⇒ Vehicle diag‐
nostic tester in “Guided Fault Finding” mode.
Note
♦ For explanatory notes on possible displays, refer to ⇒ Vehicle

♦ -E87- uses the measured values from -G238- (for air pollution)
and various settings to determine the status for fresh air or air
recirculation mode ⇒ Vehicle diagnostic tester in “Guided Fault
Finding” mode.
• The heating and air conditioning system is operating in fresh

air mode.

– Allow a small quantity of gas from cigarette lighter -B- to flow

past section -A- of -G238- (from above).
Note
The air quality sensor - G238- reacts when exposed to cigarette

smoke or cigarette lighter gas. Cigarette lighter gas is heavier
than air. Therefore -G238- must be removed and the gas applied
from above.
– Select “Read measured values” for status of fresh air mode

and air recirculation mode (observe measured values for air
quality sensor - G238- ) ⇒ Vehicle diagnostic tester in “Guided
Fault Finding” mode.
• Specification: In the display zones, the measured values for
fresh air mode/air recirculation mode change with respect to
the initial value, thereby indicating that the air quality sensor -
G238- is functioning properly and that the electronics of the -
G238- are correctly evaluating the measured values.
• Specification: The display zone shows that the air conditioner
is operating in air recirculation mode.
Note
It is not currently possible to check the sensor itself using work‐

shop equipment. However, if the composition of the air surround‐
ing the sensor changes, the signal from the air quality sensor -
G238- changes together with value displayed for the requested
status of fresh air and air recirculation mode ⇒ Vehicle diagnostic
– Wait briefly (approx. 1 minute, depending on amount of gas

applied to sensor).
– Select “Read measured values” for status of fresh air mode
and air recirculation mode (depending on measured value of
-G238- ).
• Specification: The measured values in the display fields refer
to the initial levels, thereby indicating that the sensors in -
G238- are functioning properly and the -G238- electronics are
evaluating the measured values correctly ⇒ Vehicle diagnostic
tester in “Guided Fault Finding” mode.
Note
Due to changes in pollutant levels, the values currently displayed

may differ from those measured initially.
– “Read measured value” for air recirculation/fresh air mode of

air conditioner.
• Specification: The display zone shows that the air conditioner
is operating in fresh air mode.
– Install air quality sensor - G238- ⇒ page 371 .
Proceed as follows if the air quality sensor -G238- functions prop‐
erly in this test but a customer complaint has been received:
– Check dust and pollen filter for dirt ⇒ page 293 .
– Select “Read measured values” ⇒ Vehicle diagnostic tester

Note
A second person is required to read out the values displayed while

the other is driving.
Observe safety precautions

⇒ “3.6 Safety precautions when using testers and measuring in‐
struments during a road test”, page 21 .
– “Read measured values” alternately for air quality sensor -
G238- and request for air recirculation/fresh air mode.
– Start by driving vehicle into an area with a relatively clean at‐
mosphere.
• Specification: System operating in fresh air mode.
– Then drive vehicle into an area where the atmosphere is pol‐
luted (e.g. onto an uphill road with heavy commercial traffic).
• Specification: The displays in the various zones should
change, e.g. when driving through a cloud of diesel emissions.
Note
Also refer to description of operation of -G238- / -G657-

⇒ page 364 .

9.5 Operation of humidity sender in fresh air

intake duct -G657-
Note
♦ Vehicles with automatically controlled air conditioner: Air qual‐

ity sensor - G238- -item 3- is integrated in the housing -2- in
addition to humidity sender in fresh air intake duct - G657-
-item 1-.
♦ -G657- is a highly sensitive electronic component which could

be damaged irreparably by direct exposure to liquids, sol‐
vents, fuels and certain chemical compounds.
♦ Direct contact with water can impair the function of -G657- to
such an extent that the values for humidity levels can no longer
be measured correctly (either temporarily or permanently, de‐
pending on the composition of the fluid). Sensors that have
come into contact with such substances must not be installed
in the vehicle.
♦ -G657- determines the temperature and the moisture content
of the air flowing past and exchanges information with the on‐
board supply control unit - J519- via the data bus.
♦ The measured value of -G657- is evaluated by -J519- and
transmitted to the operating unit ( Climatronic control unit -
J255- ) via the data bus.
Note
Certain air conditioner functions (including e.g. regulation of “au‐

tomatic air recirculation mode”) can be activated and deactivated
on the MMI (Multi Media Interface) using the “A/C” function on the
“Car”/“Car systems” menu. In addition, the operation of the air
conditioner can also be influenced by the settings on the MMI
(Multi Media Interface) in the “A/C” function of the “Car” / “Car
systems” menu. Therefore, if there are problems with these com‐
ponents, first check the settings on the MMI ⇒ Infotainment/MMI
Operating Manual .
♦ -J255- uses the measured values to calculate the current rel‐

ative humidity of the fresh air drawn in and uses the measured
values of -G355- to calculate the humidity in the passenger
compartment. The calculated humidity value then indicates
whether there is a risk of the windscreen, rear window and
door windows misting up from the inside. If this is the case, -
J255- takes corrective action by altering various characteristic
curves. This may involve reducing the evaporator temperature
(by activating air conditioner compressor), increasing the re‐
sponse thresholds for the request for “automatic air recircula‐
tion mode” or preventing engine shut-off via the start/stop
function etc.
Note
Checking humidity sender in fresh air intake duct - G657- ⇒ Ve‐

hicle diagnostic tester (“Guided Fault Finding”) and ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations

9.6 Removing and installing air quality sen‐

sor - G238- / humidity sender in fresh air
intake duct - G657-
Note
♦ -G238- -3- is only installed in vehicles with automatically con‐
trolled air conditioners. It is integrated in housing -2- together
with -G657- -1-.
Removing
ber cover .
– Release retaining tab -4- and turn housing -2- for -G238- / -
G657- anti-clockwise -arrow-.
– Take housing out of fresh air intake grille -1-.
Note
Following removal, do not set down air quality sensor - G238- with
humidity sender in fresh air intake duct - G657- in areas where it
could come into contact with solvents, fuels or certain chemical
compounds (liquids or vapours).
Installing
Note
Water can enter the fresh air intake via the drip rail if the plenum
chamber cover is damaged or not installed properly.

ing”).

9.7 Removing and installing sensors -

G355- / -G397- / -G107-
Note
♦ On Audi Q2 vehicles with automatic air conditioner, the sun‐

light penetration photosensor is combined as one unit with
humidity sender - G355- / rain and light sensor - G397- / sun‐
light penetration photosensor - G107- (depending on equip‐
ment version) ⇒ Current flow diagrams, Electrical fault finding
♦ On Audi A3 vehicles, humidity sender - G355- / rain and light
sensor - G397- are installed if an automatic air conditioner is
fitted (depending on equipment version).
♦ -G355- and sunlight penetration photosensor - G107- are only
installed on vehicles with Climatronic control unit - J255- (with
automatic air conditioner).
♦ On vehicles with air conditioning system control unit - J301-
no -G355- or sunlight penetration photosensor - G107- is
installed. The permissible stop time is calculated using char‐
acteristic curves which are influenced by the measured out‐
side temperature, the “air recirculation” function and the status
of the windscreen wipers. In order for -J301- to allow the stop
function, the time calculated must be greater than approx. 20
seconds. To prevent the front and door windows from misting
up, the stop time may be reduced at low outside temperatures
when the air recirculation mode is active or if it is raining. If the
time calculated for the stop function is less than approx. 20
seconds, this will be prevented.
♦ Humidity sender - G355- is integrated into rain and light sensor
- G397- and cannot be renewed separately in the event of a
fault ⇒ Electronic parts catalogue .
♦ The removal procedure for rain and light sensor - G397- (with
humidity sender - G355- ) is described in different assembly
groups depending on the vehicle.
– Renewing rain and light sensor - G397- (with humidity sender

- G355- ) ⇒ General body repairs, exterior; Rep. gr. 64 ;
Windscreen; Exploded view - windscreen or ⇒ Electrical sys‐
tem; Rep. gr. 92 ; Windscreen wiper system .
9.8 Removing and installing fuse for electri‐

cal air conditioner compressor
Removing and installing
– Removing and installing fuse for electrical air conditioner com‐
pressor ⇒ 4-cylinder direct injection engine (1.2, 1.4 ltr. 4-
valve TFSI EA 211); Rep. gr. 93 ; Power and control
electronics for electric drive .

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Service

Service Department. Technical Information

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Copyright © 2019 Audi AG, Ingolstadt D3E804C6E50

87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

1.1 Identification of heater and air condition‐

1.1.1 Identification of Valeo heater and air

When renewing the components, make sure they are correctly

♦ The manufacturer's sticker -1- on the heater and air condition‐

1.1.2 Identification of Denso heater and air

When renewing the components, make sure they are correctly

♦ The manufacturer's sticker -1- on the heater and air condition‐

2 Rep. gr.00 - Technical data

2.1 Type plates

♦ For refrigerant R134a and refrigerant oil capacities, as well as

♦ For refrigerant R134a and refrigerant oil capacities, as well as

4 Rep. gr.00 - Technical data

Explanation of information on label -A- ⇒ page 4 .

2.2 Notes on odours in vehicles without air

2.3 Notes on odours in vehicles with air con‐

6 Rep. gr.00 - Technical data

♦ Cleaning with the ultrasound A/C cleaner - VAS 6189A- or a

2.4 Notes on operation of auxiliary/supple‐

2.4.1 Notes on supplementary heater ( auxili‐

2.4.2 Checking activation of supplementary

8 Rep. gr.00 - Technical data

♦ To protect the battery - A- on vehicles with start/stop system,

Cut-in criteria for activation of supplementary heater ( -Z35- )

Shut-off criteria for activation of supplementary heater

Activation is switched off as soon as the “Automatic supplemen‐

The operating unit ( -J65- , -J301- or -J255- ) deactivates the re‐

2.5 Seat heating

2.5.1 Checking front seat heating

♦ Currently seat ventilation is not available for this vehicle.

Components involved in activation of seat heating:

10 Rep. gr.00 - Technical data

♦ Depending on the model and vehicle equipment, the various

Checking operation of seat heating and servicing ⇒ General body

2.6 Heated rear window

2.6.1 Checking heated rear window - Z1-

12 Rep. gr.00 - Technical data

♦ The “Read measured values” function of the Guided Fault

2.7 Neck heating

2.7.1 Checking neck heating

♦ The neck heating function is currently only available in the Audi

Components involved in activation of neck heating:

14 Rep. gr.00 - Technical data

♦ Conditions preventing the activation of the driver's or front

Checking operation of neck heating and servicing ⇒ General

2.8 Auxiliary air conditioner - vehicles with

2.8.1 Notes on auxiliary air conditioner

16 Rep. gr.00 - Technical data

telephone , ⇒ Current flow diagrams, Electrical fault finding

18 Rep. gr.00 - Technical data

3.1 Safety precautions when working on vehicles with high-voltage system

Risk of injury - engine may start unexpectedly

Risk of injury if auxiliary air conditioner is activated

3.2 Safety precautions when working in the vicinity of high-voltage components

electric arcs if high-voltage components or high-voltage wiring are