Service

Workshop Manual
Audi A6 2019 ➤
Audi A6 China 2019 ➤
Audi A7 Sportback 2018 ➤
Heating, air conditioning
Edition 12.2018

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 D4B807F52E8

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on air conditioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when handling refrigerants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Safety precautions when working on vehicles with high-voltage system . . . . . . . . . . . . . . 2
1.4 Safety precautions when working in the vicinity of high-voltage components . . . . . . . . . . 2
1.5 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 3
1.6 Safety precautions when using testers and measuring instruments during a road test . . . . 3
1.7 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.8 Safety precautions when working on vehicles with auxiliary/supplementary heater . . . . . . 4
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Identification of heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Type plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Notes on odours in vehicles with air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.4 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.5 Routing and attaching pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.6 Installing radiators and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.7 Checking heating output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.8 Checking cooling output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.9 Checking air conditioning system functions - vehicles with high-voltage system . . . . . . . . 12
4.10 Working on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.11 Paintwork repairs on vehicles with air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . 13
4.12 Refrigerant circuit seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.13 Notes on high-voltage components and potential equalisation lines . . . . . . . . . . . . . . . . . . 14
4.14 Use of impact wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.1 Refrigerant capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2 Approved refrigerant oils and refrigerant oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.3 Oil distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

80 - Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1 Overview of fitting locations - heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1 Overview of fitting locations - air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.1 Overview of fitting locations - components not located in passenger compartment . . . . . . 23
1.2 Overview of fitting locations - components in passenger compartment (front) . . . . . . . . . . 27
1.3 Overview of fitting locations - components in passenger compartment (rear) . . . . . . . . . . 29
2 Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.1 System overview - refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.2 Exploded view - condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.3 Removing and installing high-pressure sender G65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.4 Removing and installing refrigerant pressure and temperature sender G395 . . . . . . . . . . 40
2.5 Removing and installing refrigerant pressure and temperature sender 2 G826 . . . . . . . . 42
2.6 Exploded view - refrigerant lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.7 Exploded view - heat exchanger for heat pump operation . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.8 Exploded view - heat exchanger for high-voltage battery . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Contents i
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

2.9 Removing and installing heat exchanger for heat pump operation with refrigerant receiver
........................................................................ 60
2.10 Removing and installing refrigerant receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.11 Removing and installing heat exchanger for high-voltage battery . . . . . . . . . . . . . . . . . . . . 67
2.12 Removing and installing refrigerant lines with internal heat exchanger . . . . . . . . . . . . . . . . 70
2.13 Removing and installing refrigerant lines in plenum chamber . . . . . . . . . . . . . . . . . . . . . . 74
2.14 Removing and installing refrigerant shut-off valve V424 . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.15 Removing and installing expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.16 Removing and installing non-return valves in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . 84
2.17 Unfastening and assembling connection points in refrigerant lines . . . . . . . . . . . . . . . . . . 91
2.18 Removing and installing condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.19 Detaching and attaching refrigerant lines at condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.20 Removing and installing desiccant bag/desiccant cartridge . . . . . . . . . . . . . . . . . . . . . . . . 103
2.21 Removing and installing evacuating and charging valve (low-pressure and high-pressure
sides) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2.22 Starting up air conditioner after charging refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . 108
2.23 Cleaning air conditioner refrigerant circuit - vehicles with high-voltage system . . . . . . . . . . 110
3 Heat pump valve unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3.1 Exploded view - heat pump valve unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3.2 Removing and installing bracket with heat pump valve unit . . . . . . . . . . . . . . . . . . . . . . . . 131
3.3 Removing and installing heat pump valve unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3.4 Dismantling and assembling heat pump valve unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
3.5 Removing and installing refrigerant expansion valve 2 N637 . . . . . . . . . . . . . . . . . . . . . . 139
4 Air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.1 Exploded view - air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.2 Exploded view - pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.3 Detaching and attaching air conditioner compressor at bracket . . . . . . . . . . . . . . . . . . . . 155
4.4 Detaching and attaching refrigerant lines at air conditioner compressor . . . . . . . . . . . . . . 163
4.5 Removing and installing air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
4.6 Preparations for renewing pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4.7 Removing and installing pulley (without magnetic clutch) . . . . . . . . . . . . . . . . . . . . . . . . . . 188
4.8 Removing and installing pulley with air conditioning system magnetic clutch N25 . . . . . . 192
5 Control motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
5.1 Overview of fitting locations - control motors (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
5.2 Exploded view - control motors (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5.3 Exploded view - control motors (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
5.4 General information and procedure for removing and installing control motors . . . . . . . . . . 211
5.5 Removing and installing fresh air flap control motor V438 . . . . . . . . . . . . . . . . . . . . . . . . 212
5.6 Removing and installing defroster flap control motor V107 . . . . . . . . . . . . . . . . . . . . . . . . 214
5.7 Removing and installing left footwell flap control motor V108 . . . . . . . . . . . . . . . . . . . . . . 217
5.8 Removing and installing right footwell flap control motor V109 . . . . . . . . . . . . . . . . . . . . . . 219
5.9 Removing and installing left centre vent control motor V110 - vehicles with PR number
9AQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
5.10 Removing and installing right centre vent control motor V111 - vehicles with PR number
9AQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
5.11 Removing and installing air recirculation flap control motor V113 . . . . . . . . . . . . . . . . . . . . 224
5.12 Removing and installing rear temperature flap control motor V137 / rear left air quantity flap
control motor V239 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
5.13 Removing and installing left temperature flap control motor V158 . . . . . . . . . . . . . . . . . . 227
5.14 Removing and installing right temperature flap control motor V159 . . . . . . . . . . . . . . . . . . 228
5.15 Removing and installing right B-pillar and footwell shut-off flap control motor V211 / left B-
pillar and footwell shut-off flap control motor V212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
5.16 Removing and installing left side vent control motor V299 - vehicles with PR number 9AQ
........................................................................ 231
5.17 Removing and installing left centre vent control motor V110 - vehicles with PR number 9AK/
KH5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

ii Contents
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

5.18 Removing and installing right centre vent control motor V111 - vehicles with PR number 9AK/
KH5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
5.19 Removing and installing right side vent control motor V300 - vehicles with PR number
9AQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
5.20 Removing and installing rear air distribution flap control motor V427 / rear right air distribution
control motor V594 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
5.21 Removing and installing rear left air distribution control motor V593 . . . . . . . . . . . . . . . . 239
5.22 Removing and installing rear right air quantity flap control motor V240 . . . . . . . . . . . . . . 240
5.23 Removing and installing brackets for control motors on front heater and air conditioning
unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
6 Front heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
6.1 Exploded view - heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
6.2 Exploded view - attachments for front heater and air conditioning unit (air distribution housing,
heat exchanger etc.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
6.3 Exploded view - air intake box of heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . 257
6.4 Exploded view - evaporator housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
6.5 Removing and installing evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
6.6 Cleaning evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
6.7 Removing and installing auxiliary air heater element Z35 . . . . . . . . . . . . . . . . . . . . . . . . . . 268
6.8 Removing and installing heater and air conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . 270
6.9 Detaching and attaching air intake box at heater and air conditioning unit . . . . . . . . . . . . 274
6.10 Removing and installing dust and pollen filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
6.11 Removing and installing fresh air blower V2 with fresh air blower control unit J126 . . . . . . 276
6.12 Removing and installing heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
6.13 Removing and installing condensation drain hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
6.14 Checking condensation drain hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
7 Air duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
7.1 Exploded view - routing of air flow and air distribution in passenger compartment . . . . . . 286
7.2 Air intake and air outlet openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
7.3 Removing and installing air duct to dash panel vents (centre) . . . . . . . . . . . . . . . . . . . . . . 294
7.4 Removing and installing footwell vent (driver side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
7.5 Removing and installing footwell vent (front passenger side) . . . . . . . . . . . . . . . . . . . . . . 295
7.6 Removing and installing air duct for glove box cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
7.7 Removing and installing air duct (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
7.8 Removing and installing air duct for rear vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
7.9 Removing and installing forced ventilation vents in passenger compartment . . . . . . . . . . 297
7.10 Checking forced ventilation vents in passenger compartment . . . . . . . . . . . . . . . . . . . . . . 297
7.11 Removing and installing fresh air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
7.12 Checking plenum chamber water drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
7.13 Cleaning plenum chamber water drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
8 Coolant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
8.1 Exploded view - high-voltage heater (PTC) Z115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
8.2 Incorporation of heater and air conditioning unit into engine coolant circuit . . . . . . . . . . . . 303
8.3 Removing and installing high-voltage heater (PTC) Z115 (with high-voltage heater (PTC)
control unit J848 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
9 Operating and display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
9.1 Overview - operating and display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
9.2 Removing and installing operating and display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
10 Further control components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
10.1 Removing and installing air quality sensor G238 / external air quality and air humidity sensor
G935 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
10.2 Removing and installing ambient temperature sensor G17 . . . . . . . . . . . . . . . . . . . . . . . . 317
10.3 Removing and installing front chest vent temperature sensor G385 / G386 . . . . . . . . . . . . 317
10.4 Removing and installing left footwell vent temperature sender G261 . . . . . . . . . . . . . . . . 318
10.5 Removing and installing right footwell vent temperature sender G262 . . . . . . . . . . . . . . . . 319
10.6 Removing and installing evaporator output temperature sender G263 . . . . . . . . . . . . . . . . 319

Contents iii
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

10.7 Removing and installing rear left chest vent temperature sender G635 / rear right chest vent
temperature sender G636 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
10.8 Removing and installing vent temperature sender for rear left footwell G637 / vent
temperature sender for rear right footwell G638 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
10.9 Removing and installing dash panel temperature sensor G56 . . . . . . . . . . . . . . . . . . . . . . 321
10.10 Removing and installing humidity sender G355 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
10.11 Removing and installing thermal management control unit J1024 . . . . . . . . . . . . . . . . . . 321
11 Air ionisation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
11.1 Overview of fitting locations - air ionisation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
11.2 Exploded view - fragrance diffuser system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
11.3 Removing and installing control unit for fragrance diffuser system J1101 with blower for
fragrance diffuser system V686 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
11.4 Removing and installing function unit for fragrance diffuser system GX43 . . . . . . . . . . . . 327
11.5 Removing and installing control motor for fragrance diffuser system V687 . . . . . . . . . . . . 328
11.6 Removing and installing temperature sensor for fragrance diffuser system G1056 . . . . . . 330
11.7 Removing and installing hoses for fragrance diffuser system . . . . . . . . . . . . . . . . . . . . . . 330
11.8 Removing and installing ioniser control unit J897 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
11.9 Removing and installing driver side ioniser J1105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
11.10 Removing and installing passenger side ioniser J1106 . . . . . . . . . . . . . . . . . . . . . . . . . . 333
11.11 Removing and installing air conditioner sensor for fine particle concentration G930 . . . . 334

iv Contents
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00 – Technical data
1 Safety precautions
(ARL006161; Edition 12.2018)
⇒ “1.1 Safety precautions when working on air conditioners”, page
1
⇒ “1.2 Safety precautions when handling refrigerants”,
page 1
⇒ “1.3 Safety precautions when working on vehicles with high-
voltage system”, page 2
⇒ “1.4 Safety precautions when working in the vicinity of high-
voltage components”, page 2
⇒ “1.5 Safety precautions when working on vehicles with start/
stop system”, page 3
⇒ “1.6 Safety precautions when using testers and measuring in‐
struments during a road test”, page 3
⇒ “1.7 Safety precautions when working on the cooling system”,
page 4
⇒ “1.8 Safety precautions when working on vehicles with auxiliary/
supplementary heater”, page 4

1.1 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.

1.2 Safety precautions when handling refrigerants

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.

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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.

1.3 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.

1.4 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
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.

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– 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.

1.5 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.

1.6 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.

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1.7 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.

1.8 Safety precautions when working on vehicles with auxiliary/supplementary

heater
Danger of accident and injury if the timer for the auxiliary/supple‐
mentary heater is activated
If the timer for the auxiliary/supplementary heater is activated, the
auxiliary/supplementary heater may switch itself on. This may re‐
sult in poisoning from exhaust gases and burn injuries from hot
auxiliary/supplementary heater components; there is a risk of fire
and explosion due to high temperatures.
– Deactivate timer for auxiliary/supplementary heater.

Risk of fire and explosion from auxiliary/supplementary heater

In areas where there is a danger of fire and explosion, a fire or
explosion may be caused by a spark or high temperatures in the
auxiliary/supplementary heater. Risk of burn injuries.
– Switch off auxiliary/supplementary heater in areas where there
is a danger of fire/explosion.

Danger from toxic exhaust gases

The auxiliary/supplementary heater produces toxic exhaust
gases during operation. There is a risk of poisoning and of dam‐
age to the respiratory tract.
– In enclosed spaces, only switch on the auxiliary/supplemen‐
tary heater if there is an exhaust extraction system.
– In enclosed spaces without an exhaust extraction system,
switch off the auxiliary/supplementary heater.

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2 Identification
⇒ “2.1 Identification of heater and air conditioning unit”,
page 5

2.1 Identification of heater and air condition‐

ing unit
⇒ “2.1.1 Identification of Mahle heater and air conditioning unit
(version 1)”, page 5
⇒ “2.1.2 Identification of Mahle heater and air conditioning unit
(version 2)”, page 5

2.1.1 Identification of Mahle heater and air

conditioning unit (version 1)
At the start of production, this vehicle was only fitted with version
1 “Mahle” heaters and air conditioning units. At a later date, this
vehicle may also be fitted with different heater and air conditioning
unit versions from the same or another manufacturer (e.g.
“Mahle”, version 2; introduction not yet finalised).

♦ The manufacturer’s sticker -1- on the heater and air condi‐

tioning unit -2- is visible after the glove box has been removed
⇒ General body repairs, interior; Rep. gr. 68 ; Storage com‐
partments/covers/trim panels; Removing and installing glove
box .
♦ Control motors -1- with open shaft -2- at heater and air condi‐
tioning unit

2.1.2 Identification of Mahle heater and air

conditioning unit (version 2)
At the start of production, this vehicle was only fitted with version
1 “Mahle” heaters and air conditioning units. At a later date, this
vehicle may also be fitted with different heater and air conditioning

2. Identification 5
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unit versions from the same or another manufacturer (e.g.

“Mahle”, version 2; introduction not yet finalised).

♦ The manufacturer’s sticker -1- on the heater and air condi‐

tioning unit -2- is visible after the glove box has been removed
⇒ General body repairs, interior; Rep. gr. 68 ; Storage com‐
partments/covers/trim panels; Removing and installing glove
box .
♦ Control motors -3- with closed shaft -4- at heater and air con‐
ditioning unit

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3 General notes
⇒ “3.1 Type plates”, page 7
⇒ “3.2 Notes on odours in vehicles with air conditioner”,
page 7

3.1 Type plates

The type plate indicating the type of refrigerant and refrigerant
capacity is located on the bonnet.
♦ 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.
♦ Refrigerant and refrigerant oil capacities
⇒ “5 Technical data”, page 16 .
♦ Symbols on the label indicate the hazards which may be en‐
countered when handling the refrigerant or working on the
refrigerant circuit.
♦ Standards and regulations may also be listed, such as certain
SAE standards applicable in the USA.
♦ Depending on the version and production period, the GWP
(global warming potential) value may be included for the re‐
frigerant used.
Version 1
1- Refrigerant oil designation
2- Refrigerant designation
3- Refrigerant capacity

Version 2
♦ Explanation of information on label -A- ⇒ page 7 .

3.2 Notes on odours in vehicles with air con‐

ditioner
Odours coming from the air conditioner can have various causes.
Only some of these odours originate in the evaporator of the
heater and air conditioning unit and can therefore be eliminated
by cleaning the evaporator.

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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 heat
exchanger of front or rear heater and air conditioning unit 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.
♦ Dirt or moisture in passenger footwell or under front seats
– Check passenger footwell for moisture; dry and clean footwell.
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 and air conditioning unit
⇒ “7.11 Removing and installing fresh air intake”, page 298 .
♦ Deposits (leaves, pine needles etc.) may have accumulated in plenum cham‐
ber.
– Check plenum chamber for deposits
⇒ “7.12 Checking plenum chamber water drain”, page 301 .
♦ Water may not be able to drain out of plenum chamber.
– Check water drains
⇒ “7.12 Checking plenum chamber water drain”, page 301 .
Odour from heater and air ♦ Too much condensation in heater and air conditioning unit
conditioning unit
– Check condensation drain of heater and air conditioning unit
⇒ “6.13 Removing and installing condensation drain hose”, page 284 .
♦ Old or severely contaminated dust and pollen filter
– Check dust and pollen filter
⇒ “6.10 Removing and installing dust and pollen filter”, page 275 .
♦ Deposits on evaporator fins
– Clean evaporator ⇒ “6.6 Cleaning evaporator”, page 262 .

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4 Repair instructions
⇒ “4.1 Rules for cleanliness”, page 9
⇒ “4.2 General notes”, page 9
⇒ “4.3 General repair instructions”, page 10
⇒ “4.4 Contact corrosion”, page 10
⇒ “4.5 Routing and attaching pipes, hoses and wiring”,
page 10
⇒ “4.6 Installing radiators and condensers”, page 11
⇒ “4.7 Checking heating output”, page 11
⇒ “4.8 Checking cooling output”, page 11
⇒ “4.9 Checking air conditioning system functions - vehicles with
high-voltage system”, page 12
⇒ “4.10 Working on refrigerant circuit”, page 12
⇒ “4.11 Paintwork repairs on vehicles with air conditioning sys‐
tem”, page 13
⇒ “4.12 Refrigerant circuit seals”, page 14
⇒ “4.13 Notes on high-voltage components and potential equali‐
sation lines”, page 14
⇒ “4.14 Use of impact wrenches”, page 14

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 ⇒ “3.1 Type plates”, page 7 .
♦ 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
conditioners with refrigerant R1234yf - General information;
Rep. gr. 00 ; Repair instructions; Refrigerant and refrigerant
oil .

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4.3 General repair instructions

Servicing work must not be performed on any components of the
heater and air conditioning unit. Always use genuine parts when
renewing faulty components.
– On vehicles with high-voltage system, switch off (deactivate)
auxiliary air conditioner function ⇒ Owner’s Manual .
The air conditioner refrigerant circuit may only be discharged and
opened:
♦ If this is required by the safety precautions
( ⇒ “1.2 Safety precautions when handling refrigerants”, page
1 ).
♦ 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.
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 .

4.4 Contact corrosion

Contact corrosion can occur if unsuitable connecting elements
(bolts, nuts, washers), rivets, plugs, grommets, adhesives, etc.
are used.
For this reason, the manufacturer only fits connecting elements
with a special coating. In addition, rubber components, plastic
components and adhesives are made of non-conductive materi‐
als. These tested, aluminium-compatible components are also
available as replacement parts ⇒ Electronic parts catalogue .
Please note:
♦ If you have any doubts about whether certain parts can be re-
used, always use new components.
♦ We recommend the use of genuine replacement parts only as
these have been checked and are compatible with aluminium
⇒ Electronic parts catalogue .
♦ We recommend using Audi Accessories ⇒ Electronic parts
catalogue .
♦ Damage caused by contact corrosion is not covered by the
warranty.

4.5 Routing and attaching pipes, hoses 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.

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♦ To avoid damaging pipes, hoses and wiring, ensure sufficient

clearance from all moving or hot components in engine com‐
partment (limited space in engine compartment).
♦ 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

The heating output test is performed using a test routine in the
⇒ Vehicle diagnostic tester; for this test, proceed as follows:
Procedure
– Connect ⇒ Vehicle diagnostic tester.
– Select Diagnosis mode and begin diagnosis.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 0009 - Electronic central electrics - J519
♦ 0009 - Electronic central electrics, functions
♦ 0009 - Other functions, air conditioner
♦ ⇒ Vehicle heating not functioning

4.8 Checking cooling output

The cooling output test is performed using a test routine in the
⇒ Vehicle diagnostic tester; for this test, proceed as follows:
Procedure
– Connect ⇒ Vehicle diagnostic tester.
– Select Diagnosis mode and begin diagnosis.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 0009 - Electronic central electrics - J519

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♦ 0009 - Electronic central electrics, functions

♦ 0009 - Other functions, air conditioner
♦ ⇒ Vehicle cooling not functioning

4.9 Checking air conditioning system func‐

tions - vehicles with high-voltage system
On vehicles with high-voltage system, a check of the system
functions can be performed in the thermal management control
unit - J1024- ⇒ Vehicle diagnostic tester.
Procedure
– Connect ⇒ Vehicle diagnostic tester.
– Select Diagnosis mode and begin diagnosis.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ General body repairs
♦ Self-diagnosis compatible systems
♦ 00C5 - Thermal management control unit J1024
♦ 00C5 - Thermal management control unit J1024, functions
♦ 00C5 - Basic setting

4.10 Working on refrigerant circuit

Always perform work on the refrigerant circuit in well ventilated
areas. Make sure that there are no inspection pits, shafts or cellar
entrances within a radius of 5 metres. Switch on extraction sys‐
tems. Take note of the information in the Workshop Manual for
the specific refrigerant type ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; General information on air conditioning sys‐
tems and ⇒ Air conditioners with R1234yf - General information;
Rep. gr. 00 ; Repair notes .
Reason:
The refrigerant emerging is not only colourless and odourless, but
also heavier than air and thus displaces oxygen. Should refriger‐
ant gas escape even though the safety precautions have been
observed, this can result in an imperceptible danger of asphyx‐
iation in poorly ventilated areas and inspection pits.
Welding, brazing and soldering work must not be performed 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 components becoming hot.
Reason:
Exposure to heat generates considerable pressure in the system,
which could cause it to burst.
Remedy:
Discharge refrigerant circuit.
When servicing the air conditioner, re-seal all open components
and pipe connections immediately.
Reason:
Moisture will enter air conditioner components if they are left open
for more than a certain amount of time. For this reason, air con‐

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ditioners which have been left open for a long period cannot be
re-charged without renewing parts of the system.
♦ For information on working on air-conditioned vehicles with the
air conditioner service station , refer to ⇒ Air conditioners with
refrigerant R1234yf - General information; Rep. gr. 87 ; Work‐
ing with the air conditioner service station , or ⇒ Air conditioner
with refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit .
Vehicles with high-voltage system
In order to discharge, evacuate and fill the refrigerant circuit on
vehicles with high-voltage system, the electrically actuated valves
installed in the refrigerant circuit must be open. The valves must
be activated and opened via a routine stored in the thermal man‐
agement control unit - J1024- ⇒ Vehicle diagnostic tester (“Gui‐
ded Fault Finding”).
– Initiate basic setting of air conditioner via thermal manage‐
ment control unit - J1024- ; use the “Extract, evacuate and
charge refrigerant circuit” routine stored there to open electri‐
cally actuated valves ⇒ Vehicle diagnostic tester.
Reason:
Various electrically operated valves and non-return valves are in‐
stalled in the refrigerant circuit. These electrically operated valves
are closed or open, depending on the air conditioner's most recent
operating state (cooling the passenger compartment, cooling the
high-voltage system components, or heat pump mode). If more
than one electrically operated valve is closed, the refrigerant cir‐
cuit may no longer be able to be fully discharged, evacuated or
charged
⇒ “2.1.2 System overview - refrigerant circuit, vehicles with high-
voltage system”, page 35 and ⇒ Vehicle diagnostic tester.
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.

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.

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4.12 Refrigerant circuit seals

♦ O-rings can only be used once and must then be renewed.
♦ Lubricate O-rings lightly with refrigerant oil before fitting.
♦ Make sure O-rings are positioned correctly on pipe or in
groove.
♦ Check connections at components and refrigerant lines for
damage (even slight scratches can cause leaks).
♦ Ensure absolute cleanliness when working (even the slightest
contamination, e.g. a single hair, could cause leakage).
♦ Only install O-rings which are resistant to refrigerant R134a
and/or R1234yf and the corresponding refrigerant oils ⇒ Elec‐
tronic parts catalogue .
Dimensions -a- and -b- differ depending on where the O-ring is
fitted ⇒ Electronic parts catalogue .

4.13 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

4.14 Use of impact wrenches

In general, it is permitted to use an impact wrench to unscrew
bolts and nuts. An exception to this is when work is performed
inside an open high-voltage battery. For this work, it is not per‐
mitted to use an impact wrench.
An impact wrench may be used to screw in bolts and nuts when
performing repair work if the following requirements are observed.
In general, electric and compressed-air impact wrenches should
be used.
Requirements:
• Only screw in bolts with locking fluid or self-locking nuts at low
speed.
• Use a suitable impact wrench with variable speed and adjust‐
able torque range.
• Use suitable bits when working in the vicinity of sensitive sur‐
faces, e.g. plastic-coated bits for aluminium rims.

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• When working in the vicinity of natural gas systems, observe

the information in the Workshop Manual “Natural gas engines
- General information”.
Use:
• Fit bolts/nuts by hand.
• Only use an impact wrench to screw in bolts/nuts until the head
of the bolt/nut makes contact and then continue tightening with
a torque wrench.
• Clean threaded pins before unscrewing the bolt/nut.

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5 Technical data
⇒ “5.1 Refrigerant capacities”, page 16
⇒ “5.2 Approved refrigerant oils and refrigerant oil capacities”,
page 17
⇒ “5.3 Oil distribution”, page 21

5.1 Refrigerant capacities

⇒ “5.1.1 Capacities for refrigerant R134a”, page 16
⇒ “5.1.2 Capacities for refrigerant R1234yf”, page 16

5.1.1 Capacities for refrigerant R134a

Vehicle model Capacity in grams Differing characteristics of this refrigerant cir‐
cuit
Audi A6/Audi A7, all engines 590 ± 15 • None
except 2.0 ltr. TDI engine
(150kW) with PR no. D7U
and 2.9 ltr. TFSI engine with
PR no. TV8
Audi A6/Audi A7 with 2.0 ltr. 700 ± 15 • None
TDI engine (150kW) with PR
no. D7U, and with 2.9 ltr.
TFSI engine with PR no. TV8
Audi A7 TFSI e 660 ± 15 • Electrical air conditioner compressor

5.1.2 Capacities for refrigerant R1234yf

Vehicle model Production period Capacity in grams Differing characteristics of this refrig‐
erant circuit
Audi A7 From 10/2017 to 505 ± 15 • None
2/2018
Audi A6/Audi A7, all From 3/2018 on‐ 510 ± 15 • None
engines except 2.0 ltr. wards
TDI engine (150kW)
with PR no. D7U and
2.9 ltr. TFSI engine
with PR no. TV8
Audi A6/Audi A7 with 620 ± 15 • None
2.0 ltr. TDI engine
(150kW) with PR no.
D7U, and with 2.9 ltr.
TFSI engine with PR
no. TV8
Audi A7 TFSI e From 07.2019 on‐ 570 ± 15 • Electrical air conditioner com‐
wards pressor

16 Rep. gr.00 - Technical data

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5.2 Approved refrigerant oils and refrigerant

oil capacities
⇒ “5.2.1 Approved refrigerant oils and refrigerant oil capacities for
refrigerant R134a”, page 17
⇒ “5.2.2 Approved refrigerant oils for refrigerant R1234yf”,
page 17
⇒ “5.2.3 Refrigerant oil capacities for refrigerant R1234yf”,
page 19
⇒ “5.2.4 Refrigerant oil capacities for refrigerant R134a”,
page 20

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 available on the refrigerant
oil market ⇒ Electronic parts catalogue .
♦ The refrigerant circuit must only be charged with approved re‐
frigerant oils ⇒ Electronic parts catalogue . The correct refrig‐
erant oil depends on the make and type of the air conditioner
compressor fitted.
♦ 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 lubrication
problems.
♦ 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 in‐
formation 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.
♦ 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
♦ The refrigerant circuit must only be charged with approved re‐
frigerant oils ⇒ Electronic parts catalogue . The correct refrig‐
erant oil depends on the make and type of the air conditioner
compressor fitted.
♦ 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 lubrication
problems.
♦ 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 - General informa‐

5. Technical data 17
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tion; Rep. gr. 00 ; Repair instructions; Refrigerant and refrig‐

erant 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.
♦ 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.

18 Rep. gr.00 - Technical data

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♦ 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.
♦ 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 .
♦ 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 ⇒ “2.6 Exploded view - refrigerant lines”, page 46 .

5.2.3 Refrigerant oil capacities for refrigerant

R1234yf
♦ The compressor version may differ depending on the produc‐
tion period and engine ⇒ Electronic parts catalogue .

5. Technical data 19
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♦ There may be different refrigerant oil capacities for the refrig‐

erant circuit depending on the type of air conditioner compres‐
sor ⇒ Electronic parts catalogue .
♦ Depending on the manufacturer of the air conditioner com‐
pressor, different refrigerant oils must be used ⇒ Electronic
parts catalogue .
♦ ⇒ “5.2.2 Approved refrigerant oils for refrigerant R1234yf”,
page 17
Vehicle Production Total quantity of oil in re‐ Quantity of refrigerant oil Differing characteristics of
model period frigerant circuit in cm3 in replacement compres‐ this refrigerant circuit
sor in cm3
A6, A7 From 10/2017 110 +/- 10 110 +/- 10 • “Denso” air conditioner
onwards compressor

100 +/- 10 100 +/- 10 • “Sanden” air condition‐

er compressor

Audi A7 From 07.19 220+/- 10 220+/- 10 • Electrically driven air

TFSI e onwards conditioner compres‐
sor manufactured by
“Sanden” (refrigerant
oil SP-A2
⇒ “5.2.2 Approved re‐
frigerant oils for refrig‐
erant R1234yf”,
page 17 )
• Ensure correct refriger‐
ant oil ⇒ Electronic
parts catalogue

♦ The replacement compressor contains a certain amount of re‐

frigerant oil (depending on the air conditioner compressor).
This quantity of refrigerant oil corresponds to the quantity of
oil specified for this refrigerant circuit. If the air conditioner
compressor is renewed without having to clean the refrigerant
circuit, the quantity of refrigerant oil in the new compressor to
be fitted should be adjusted in line with the quantity of oil pour‐
ed out of the old compressor ⇒ Air conditioners with refrigerant
R1234yf - General information; Rep. gr. 87 ; Refrigerant cir‐
cuit; Renewing components .
♦ 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.

5.2.4 Refrigerant oil capacities for refrigerant

R134a
♦ 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 .
♦ Depending on the manufacturer of the air conditioner com‐
pressor, different refrigerant oils must be used ⇒ Electronic
parts catalogue .
♦ ⇒ “5.2.1 Approved refrigerant oils and refrigerant oil capacities
for refrigerant R134a”, page 17

20 Rep. gr.00 - Technical data

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Vehicle Production Total quantity of oil in re‐ Quantity of refrigerant oil Differing characteristics of
model period frigerant circuit in cm3 in replacement compres‐ this refrigerant circuit
sor in cm3
A6, A7 From 10/2017 110 +/- 10 110 +/- 10 • “Denso” air conditioner
onwards compressor

100 +/- 10 100 +/- 10 • “Sanden” air condition‐

er compressor

Audi A7 From 07.19 220+/- 10 220+/- 10 • Electrically driven air

TFSI e onwards conditioner compres‐
sor manufactured by
“Sanden” (refrigerant
oil SP-A2
⇒ “5.2.2 Approved re‐
frigerant oils for refrig‐
erant R1234yf”,
page 17 )
• Ensure correct refriger‐
ant oil ⇒ Electronic
parts catalogue

♦ The replacement compressor contains a certain amount of re‐

frigerant oil (depending on the air conditioner compressor).
This quantity of refrigerant oil corresponds to the quantity of
oil specified for this refrigerant circuit. If the air conditioner
compressor is renewed without having to clean the refrigerant
circuit, the quantity of refrigerant oil in the new compressor to
be fitted should be adjusted in line with the quantity of oil pour‐
ed out of the old compressor ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Renewing components of refrigerant cir‐
cuit .
♦ 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 , or ⇒ Air conditioners with refrigerant
R1234yf - General information; Rep. gr. 87 ; Refrigerant cir‐
cuit; Renewing components .

5. Technical data 21
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80 – Heating
1 Overview of fitting locations - heater
Only one type of air conditioner is available for the Audi A6/Audi
A7. There is currently no provision for a heater separate from the
air conditioner.
All the information required for servicing the heating and air con‐
ditioning system can be found in
⇒ “1 Overview of fitting locations - air conditioner”, page 23 .

22 Rep. gr.80 - Heating

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87 – Air conditioning system

1 Overview of fitting locations - air con‐
ditioner
⇒ “1.1 Overview of fitting locations - components not located in
passenger compartment”, page 23
⇒ “1.2 Overview of fitting locations - components in passenger
compartment (front)”, page 27
⇒ “1.3 Overview of fitting locations - components in passenger
compartment (rear)”, page 29

1.1 Overview of fitting locations - compo‐

nents not located in passenger compart‐
ment
⇒ “1.1.1 Overview of fitting locations - components not located in
passenger compartment, vehicles without high-voltage system”,
page 23
⇒ “1.1.2 Overview of fitting locations - components not located in
passenger compartment, vehicles with high-voltage system”,
page 25

1.1.1 Overview of fitting locations - components not located in passenger com‐

partment, vehicles without high-voltage system

1. Overview of fitting locations - air conditioner 23

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1 - High-pressure sender -
G65-
❑ Removing and installing
⇒ “2.3 Removing and in‐
stalling high-pressure
sender G65 ”,
page 39
2 - Condenser
❑ Removing and installing
⇒ “2.18.1 Removing and
installing condenser -
vehicles without high-
voltage system”,
page 94
❑ Exploded view
⇒ “2.2 Exploded view -
condenser”, page 38
3 - Ambient temperature sen‐
sor - G17-
❑ Removing and installing
⇒ “10.2 Removing and
installing ambient tem‐
perature sensor G17 ”,
page 317
4 - Desiccant cartridge
❑ Removing and installing
⇒ “2.20 Removing and
installing desiccant bag/
desiccant cartridge”,
page 103
❑ Exploded view
⇒ “2.2 Exploded view -
condenser”, page 38
5 - Air conditioner compressor
regulating valve - N280-
❑ Removing and installing
⇒ Air conditioner with refrigerant R134a; Rep. gr. 87 ; Renewing components of refrigerant circuit , or
⇒ Air conditioners with refrigerant R1234yf - General information; Rep. gr. 87 ; Refrigerant circuit;
Renewing components
6 - Air quality sensor - G238- / external air quality and air humidity sensor - G935-
❑ Removing and installing
⇒ “10.1 Removing and installing air quality sensor G238 / external air quality and air humidity sensor
G935 ”, page 316
❑ Fitted depending on equipment
7 - Fresh air intake
❑ Removing and installing ⇒ “7.11.4 Removing and installing fresh air intake”, page 300
8 - Expansion valve (front)
❑ Removing and installing ⇒ “2.15 Removing and installing expansion valve”, page 81
9 - Service connection (low-pressure side)
10 - Forced ventilation vent in passenger compartment (right-side)
❑ Removing and installing
⇒ “7.9 Removing and installing forced ventilation vents in passenger compartment”, page 297
11 - Forced ventilation vent in passenger compartment (left-side)
❑ Removing and installing
⇒ “7.9 Removing and installing forced ventilation vents in passenger compartment”, page 297

24 Rep. gr.87 - Air conditioning system

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12 - Service connection (high-pressure side)

13 - Refrigerant line with internal heat exchanger
❑ Removing and installing
⇒ “2.12.1 Removing and installing refrigerant lines with internal heat exchanger - vehicles without high-
voltage system”, page 70
14 - Air conditioner compressor
❑ Removing and installing ⇒ “4.5 Removing and installing air conditioner compressor”, page 170
❑ Exploded view ⇒ “4.1 Exploded view - air conditioner compressor”, page 141

1.1.2 Overview of fitting locations - components not located in passenger com‐

partment, vehicles with high-voltage system

1 - Service connection (low-

pressure side)
2 - Refrigerant pressure and
temperature sender 2 - G826-
❑ Removing and installing
⇒ “2.5 Removing and in‐
stalling refrigerant pres‐
sure and temperature
sender 2 G826 ”,
page 42
3 - Refrigerant pressure and
temperature sender 1 - G395-
❑ Removing and installing
⇒ “2.4 Removing and in‐
stalling refrigerant pres‐
sure and temperature
sender G395 ”,
page 40
4 - Service connection (high-
pressure side)
5 - External air quality and air
humidity sensor - G935-
❑ Fitted depending on
equipment
❑ Removing and installing
⇒ “10.1 Removing and
installing air quality sen‐
sor G238 / external air
quality and air humidity
sensor G935 ”,
page 316
6 - Fresh air intake
❑ Removing and installing
⇒ “7.11 Removing and
installing fresh air in‐
take”, page 298
7 - High-voltage heater (PTC) - Z115-
❑ Exploded view ⇒ “8.1 Exploded view - high-voltage heater (PTC) Z115 ”, page 302
❑ Removing and installing
⇒ “8.3 Removing and installing high-voltage heater (PTC) Z115 (with high-voltage heater (PTC) control
unit J848 )”, page 308
8 - Expansion valve
❑ Removing and installing ⇒ “2.15 Removing and installing expansion valve”, page 81

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9 - Refrigerant shut-off valve - V424-

❑ Removing and installing ⇒ “2.14 Removing and installing refrigerant shut-off valve V424 ”, page 79
10 - Forced ventilation vent in passenger compartment (right-side)
❑ Checking ⇒ “7.10 Checking forced ventilation vents in passenger compartment”, page 297
❑ Removing and installing
⇒ “7.9 Removing and installing forced ventilation vents in passenger compartment”, page 297
11 - Thermal management control unit - J1024-
❑ Removing and installing
⇒ “10.11 Removing and installing thermal management control unit J1024 ”, page 321
12 - Forced ventilation vent in passenger compartment (left-side)
❑ Checking ⇒ “7.10 Checking forced ventilation vents in passenger compartment”, page 297
❑ Removing and installing
⇒ “7.9 Removing and installing forced ventilation vents in passenger compartment”, page 297
13 - Heat exchanger for heat pump operation with refrigerant receiver
❑ Exploded view ⇒ “2.7 Exploded view - heat exchanger for heat pump operation”, page 57
❑ Removing and installing
⇒ “2.9 Removing and installing heat exchanger for heat pump operation with refrigerant receiver”, page
60
14 - Heat exchanger for high-voltage battery with refrigerant expansion valve 2 - N637-
❑ Exploded view ⇒ “2.8 Exploded view - heat exchanger for high-voltage battery”, page 59
❑ Removing and installing
⇒ “2.11 Removing and installing heat exchanger for high-voltage battery”, page 67
❑ Removing and installing refrigerant expansion valve 2 - N637-
⇒ “3.5 Removing and installing refrigerant expansion valve 2 N637 ”, page 139
15 - Heat pump valve unit
❑ with
♦ Refrigerant shut-off valve 2 - N640-
♦ Refrigerant shut-off valve 3 - N641-
♦ Refrigerant shut-off valve 4 - N642-
♦ Refrigerant shut-off valve 5 - N643-
❑ Exploded view ⇒ “3.1 Exploded view - heat pump valve unit”, page 130
16 - Air conditioner compressor
❑ Exploded view ⇒ “4.1.3 Exploded view - electrically driven air conditioner compressor”, page 146
❑ Removing and installing
⇒ “4.5.8 Removing and installing electrically driven air conditioner compressor”, page 182
17 - Condenser
❑ Exploded view ⇒ “2.2 Exploded view - condenser”, page 38
❑ Removing and installing ⇒ “2.18 Removing and installing condenser”, page 94
18 - Ambient temperature sensor - G17-
❑ Removing and installing
⇒ “10.2 Removing and installing ambient temperature sensor G17 ”, page 317
19 - Desiccant cartridge
❑ Exploded view ⇒ “2.2 Exploded view - condenser”, page 38
❑ Removing and installing
⇒ “2.20 Removing and installing desiccant bag/desiccant cartridge”, page 103

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1.2 Overview of fitting locations - components in passenger compartment (front)

1 - Display unit 2 for front infor‐

mation display and operating
unit control unit - J1060-
❑ Removing and installing
⇒ Communication;
Rep. gr. 91 ; Infotain‐
ment system; Removing
and installing infotain‐
ment system display
2 - Display unit for front infor‐
mation display and operating
unit control unit - J685-
❑ Removing and installing
⇒ Communication;
Rep. gr. 91 ; Infotain‐
ment system; Removing
and installing infotain‐
ment system display
3 - Rain and light sensor -
G397- with humidity sender -
G355-
❑ Removing and installing
⇒ “10.10 Removing and
installing humidity send‐
er G355 ”, page 321
4 - Left footwell vent tempera‐
ture sender - G261-
❑ Removing and installing
⇒ “10.4 Removing and
installing left footwell
vent temperature send‐
er G261 ”, page 318
5 - Dash panel temperature
sensor - G56-
❑ Removing and installing
⇒ “10.9 Removing and
installing dash panel
temperature sensor G56 ”, page 321
6 - Front left chest vent temperature sensor - G385-
❑ Removing and installing
⇒ “10.3.1 Removing and installing front left chest vent temperature sensor G385 ”, page 317
7 - Condensation drain hose (left-side)
❑ Removing and installing ⇒ “6.13 Removing and installing condensation drain hose”, page 284
❑ Checking ⇒ “6.14 Checking condensation drain hose”, page 285
8 - Control motor
❑ Shown as an example; all other control motors are similar
❑ Overview of fitting locations - control motors
⇒ “5.1 Overview of fitting locations - control motors (front)”, page 198
9 - Evaporator
❑ Removing and installing ⇒ “6.5 Removing and installing evaporator”, page 260
10 - Evaporator output temperature sender - G263-
❑ Removing and installing
⇒ “10.6 Removing and installing evaporator output temperature sender G263 ”, page 319

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❑ On right-hand drive vehicles, the evaporator output temperature sender - G263- is installed from the left
of the evaporator housing of the heater and air conditioning unit (in the area behind the coolant pipes to
the heat exchanger)
11 - Fresh air blower - V2- with fresh air blower control unit - J126-
❑ Removing and installing
⇒ “6.11 Removing and installing fresh air blower V2 with fresh air blower control unit J126 ”, page 276
12 - Dust and pollen filter
❑ Removing and installing ⇒ “6.10 Removing and installing dust and pollen filter”, page 275
13 - Front right chest vent temperature sensor - G386-
❑ Removing and installing
⇒ “10.3.2 Removing and installing front right chest vent temperature sensor G386 ”, page 318
14 - Condensation drain hose (right-side)
❑ Removing and installing ⇒ “6.13 Removing and installing condensation drain hose”, page 284
❑ Checking ⇒ “6.14 Checking condensation drain hose”, page 285
15 - Right footwell vent temperature sender - G262-
❑ Removing and installing
⇒ “10.5 Removing and installing right footwell vent temperature sender G262 ”, page 319
16 - Auxiliary air heater element - Z35-
❑ Removing and installing ⇒ “6.7 Removing and installing auxiliary air heater element Z35 ”, page 268
17 - Heat exchanger
❑ Removing and installing ⇒ “6.12 Removing and installing heat exchanger”, page 277

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1.3 Overview of fitting locations - components in passenger compartment (rear)

1 - Operating and display unit

for rear air conditioning system
- E265-
❑ Removing and installing
⇒ “9.2 Removing and in‐
stalling operating and
display unit”, page 314
2 - Vent temperature sender
for rear left footwell - G637-
❑ Fitted depending on
equipment
❑ Removing and installing
⇒ “10.8 Removing and
installing vent tempera‐
ture sender for rear left
footwell G637 / vent
temperature sender for
rear right footwell G638
”, page 320
3 - Rear left chest vent temper‐
ature sender - G635-
❑ Fitted depending on
equipment
❑ Removing and installing
⇒ “10.7 Removing and
installing rear left chest
vent temperature send‐
er G635 / rear right
chest vent temperature
sender G636 ”,
page 320
4 - Rear right chest vent tem‐
perature sender - G636-
❑ Fitted depending on
equipment
❑ Removing and installing
⇒ “10.7 Removing and
installing rear left chest vent temperature sender G635 / rear right chest vent temperature sender G636
”, page 320
5 - Vent temperature sender for rear right footwell - G638-
❑ Fitted depending on equipment
❑ Removing and installing
⇒ “10.8 Removing and installing vent temperature sender for rear left footwell G637 / vent temperature
sender for rear right footwell G638 ”, page 320

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30 Rep. gr.87 - Air conditioning system

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2 Refrigerant circuit
⇒ “2.1 System overview - refrigerant circuit”, page 31
⇒ “2.2 Exploded view - condenser”, page 38
⇒ “2.3 Removing and installing high-pressure sender G65 ”, page
39
⇒ “2.4 Removing and installing refrigerant pressure and temper‐
ature sender G395 ”, page 40
⇒ “2.5 Removing and installing refrigerant pressure and temper‐
ature sender 2 G826 ”, page 42
⇒ “2.6 Exploded view - refrigerant lines”, page 46
⇒ “2.7 Exploded view - heat exchanger for heat pump operation”,
page 57
⇒ “2.8 Exploded view - heat exchanger for high-voltage battery”,
page 59
⇒ “2.9 Removing and installing heat exchanger for heat pump
operation with refrigerant receiver”, page 60
⇒ “2.10 Removing and installing refrigerant receiver”, page 63
⇒ “2.11 Removing and installing heat exchanger for high-voltage
battery”, page 67
⇒ “2.12 Removing and installing refrigerant lines with internal heat
exchanger”, page 70
⇒ “2.13 Removing and installing refrigerant lines in plenum cham‐
ber”, page 74
⇒ “2.14 Removing and installing refrigerant shut-off valve V424 ”,
page 79
⇒ “2.15 Removing and installing expansion valve”, page 81
⇒ “2.16 Removing and installing non-return valves in refrigerant
circuit”, page 84
⇒ “2.17 Unfastening and assembling connection points in refrig‐
erant lines”, page 91
⇒ “2.18 Removing and installing condenser”, page 94
⇒ “2.19 Detaching and attaching refrigerant lines at condenser”,
page 98
⇒ “2.20 Removing and installing desiccant bag/desiccant car‐
tridge”, page 103
⇒ “2.21 Removing and installing evacuating and charging valve
(low-pressure and high-pressure sides)”, page 105
⇒ “2.22 Starting up air conditioner after charging refrigerant cir‐
cuit”, page 108
⇒ “2.23 Cleaning air conditioner refrigerant circuit - vehicles with
high-voltage system”, page 110

2.1 System overview - refrigerant circuit

⇒ “2.1.1 System overview - refrigerant circuit, vehicles without
high-voltage system”, page 31
⇒ “2.1.2 System overview - refrigerant circuit, vehicles with high-
voltage system”, page 35

2.1.1 System overview - refrigerant circuit, ve‐

hicles without high-voltage system

2. Refrigerant circuit 31
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Air conditioner (air conditioner compressor, condenser and inter‐

nal heat exchanger) ⇒ page 32
Air conditioner (internal heat exchanger, expansion valve, evap‐
orator, service connections) ⇒ page 33

Air conditioner (air conditioner compressor, condenser and inter‐

nal heat exchanger)
The arrows indicate the direction of refrigerant flow.
HD = High-pressure side
ND = Low-pressure side

1 - Air conditioner compressor

regulating valve - N280-
❑ Installed in air condition‐
er compressor
❑ Checking ⇒ Vehicle di‐
agnostic tester and
⇒ Current flow dia‐
grams, Electrical fault
finding and Fitting loca‐
tions
2 - Air conditioner compressor
❑ Exploded view
⇒ “4.1 Exploded view -
air conditioner compres‐
sor”, page 141
❑ Different versions de‐
pending on refrigerant
(R134a or R1234yf) ⇒
Electronic parts cata‐
logue
3 - Air conditioner compressor
pulley
❑ Renewing pulley
⇒ “4.2 Exploded view -
pulley”, page 147
❑ Depending on engine
version and air condi‐
tioner compressor with
or without air condition‐
ing system magnetic
clutch - N25-
4 - Oil drain plug
5 - High-pressure safety valve
6 - Connection in refrigerant
line
❑ Depending on vehicle version and engine, these connection points may be at different locations on re‐
frigerant lines
7 - High-pressure sender - G65-
❑ Removing and installing ⇒ “2.3 Removing and installing high-pressure sender G65 ”, page 39
8 - Connection with valve
9 - Condenser
❑ Exploded view ⇒ “2.2 Exploded view - condenser”, page 38
10 - Receiver (for condenser with desiccant cartridge)
❑ Receiver is integrated in condenser

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❑ Exploded view ⇒ “2.2 Exploded view - condenser”, page 38

11 - Connection of refrigerant line (low-pressure side)
❑ Fitted in area around headlight (left-side) underneath wing
12 - Refrigerant line with internal heat exchanger
❑ Fitted in area underneath wing (left-side)
❑ In this refrigerant line, 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
13 - Connection of refrigerant line (high-pressure side)
❑ Fitted in area around headlight (left-side) underneath wing

Air conditioner (internal heat exchanger, expansion valve, evap‐

orator, service connections)
HD = High-pressure side
ND = Low-pressure side

1 - Refrigerant line with internal

heat exchanger
❑ Fitted in area under‐
neath wing (left-side)
❑ In this refrigerant line,
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 en‐
hancing the efficiency of
the air conditioner
2 - Leadthrough for refrigerant
lines
❑ From area underneath
wing (left-side) into ple‐
num chamber
❑ Version without outputs
to second evaporator
3 - Service connection (high-
pressure side)
❑ For measuring, dis‐
charging and charging
❑ Depending on vehicle
version, installed in ple‐
num chamber (left-side,
next to brake fluid reser‐
voir) underneath ple‐
num chamber cover
❑ Different versions de‐
pending on refrigerant
(R134a or R1234yf) ⇒
Electronic parts cata‐
logue
4 - Cap
❑ With seal
❑ Always screw on
❑ Different versions depending on refrigerant (R134a or R1234yf) ⇒ Electronic parts catalogue

2. Refrigerant circuit 33
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5 - Refrigerant line to expansion valve (high-pressure side)

6 - Expansion valve (front)
❑ Exploded view ⇒ “6.4 Exploded view - evaporator housing”, page 258
❑ Different versions depending on refrigerant (R134a or R1234yf) ⇒ Electronic parts catalogue
7 - Evaporator
❑ In front heater and air conditioning unit (fitted beneath dash panel)
8 - Refrigerant line to expansion valve (low-pressure side)
9 - Service connection (low-pressure side)
❑ For measuring, discharging and charging
❑ Depending on vehicle version, installed in plenum chamber (left-side, next to brake fluid reservoir) un‐
derneath plenum chamber cover or in engine compartment (left-side)
❑ Different versions depending on refrigerant (R134a or R1234yf) ⇒ Electronic parts catalogue
10 - Cap
❑ With seal
❑ Always screw on
❑ Different versions depending on refrigerant (R134a or R1234yf) ⇒ Electronic parts catalogue

34 Rep. gr.87 - Air conditioning system

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

♦ The valves are actuated and the individual circuits are inter‐
connected depending on the operating mode of and request
issued by the thermal management control unit - J1024- .

1 - Refrigerant shut-off valve 4

- N642-
❑ Removing and installing
valve block
⇒ “3.3 Removing and in‐
stalling heat pump valve
unit”, page 136
❑ Layout of valves in valve
block
⇒ “3.4 Dismantling and
assembling heat pump
valve unit”, page 137
❑ Removing and installing
valves in valve block
⇒ “3.4 Dismantling and
assembling heat pump
valve unit”, page 137
2 - Refrigerant shut-off valve 5
- N643-
❑ Removing and installing
valve block
⇒ “3.3 Removing and in‐
stalling heat pump valve
unit”, page 136
❑ Layout of valves in valve
block
⇒ “3.4 Dismantling and
assembling heat pump
valve unit”, page 137
❑ Removing and installing
valves in valve block
⇒ “3.4 Dismantling and
assembling heat pump
valve unit”, page 137
3 - Refrigerant shut-off valve 2
- N640-
❑ Removing and installing
valve block ⇒ “3.3 Removing and installing heat pump valve unit”, page 136
❑ Layout of valves in valve block ⇒ “3.4 Dismantling and assembling heat pump valve unit”, page 137
❑ Removing and installing valves in valve block
⇒ “3.4 Dismantling and assembling heat pump valve unit”, page 137
4 - Refrigerant shut-off valve 3 - N641-
❑ Removing and installing valve block ⇒ “3.3 Removing and installing heat pump valve unit”, page 136
❑ Layout of valves in valve block ⇒ “3.4 Dismantling and assembling heat pump valve unit”, page 137
❑ Removing and installing valves in valve block
⇒ “3.4 Dismantling and assembling heat pump valve unit”, page 137
5 - Valve block in refrigerant circuit
❑ With valves -N640- , -N641- -N642- and -N643-
❑ Removing and installing valve block ⇒ “3.3 Removing and installing heat pump valve unit”, page 136
❑ Removing and installing valves in valve block
⇒ “3.4 Dismantling and assembling heat pump valve unit”, page 137

2. Refrigerant circuit 35
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6 - Condenser
❑ Exploded view ⇒ “2.2 Exploded view - condenser”, page 38
7 - Receiver (for condenser with desiccant cartridge)
❑ Receiver is integrated in condenser
❑ Exploded view ⇒ “2.2 Exploded view - condenser”, page 38
8 - Refrigerant pressure and temperature sender - G395-
❑ Removing and installing
⇒ “2.4 Removing and installing refrigerant pressure and temperature sender G395 ”, page 40
9 - Electrically driven air conditioner compressor
❑ Exploded view ⇒ “4.1.3 Exploded view - electrically driven air conditioner compressor”, page 146
❑ With control unit for air conditioning compressor - J842- and electrical air conditioner compressor - V470-
❑ Removing and installing
⇒ “4.5.8 Removing and installing electrically driven air conditioner compressor”, page 182
❑ Different versions ⇒ Electronic parts catalogue
10 - Refrigerant pressure and temperature sender 2 - G826-
❑ Removing and installing
⇒ “2.5 Removing and installing refrigerant pressure and temperature sender 2 G826 ”, page 42
11 - Non-return valve in refrigerant line from condenser
❑ Different versions ⇒ Electronic parts catalogue
❑ Removing and installing
⇒ “2.16.3 Removing and installing non-return valve in refrigerant line from condenser”, page 88
12 - Service connection (low-pressure side)
❑ For measuring, discharging and charging
❑ Exploded view
⇒ “2.6.3 Exploded view - refrigerant lines, vehicles with high-voltage system”, page 50
❑ Installed in motor compartment (left-side)
❑ Different versions ⇒ Electronic parts catalogue
13 - Non-return valve in refrigerant line from internal heat exchanger
❑ Different versions ⇒ Electronic parts catalogue
❑ Removing and installing
⇒ “2.16.1 Removing and installing non-return valve in refrigerant line from internal heat exchanger”, page
84
14 - Refrigerant line with internal heat exchanger
❑ Exploded view ⇒ “2.6 Exploded view - refrigerant lines”, page 46
❑ Removing and installing
⇒ “2.12.2 Removing and installing refrigerant lines with internal heat exchanger - vehicles with high-
voltage system”, page 72
15 - Refrigerant expansion valve 2 - N637-
❑ Removing and installing
⇒ “3.5 Removing and installing refrigerant expansion valve 2 N637 ”, page 139
16 - Refrigerant shut-off valve - V424-
❑ Removing and installing ⇒ “2.14 Removing and installing refrigerant shut-off valve V424 ”, page 79
17 - Incorporation into battery cooling circuit
❑ Incorporation into coolant circuit ⇒ Rep. gr. 19 ; Cooling system/coolant; Connection diagram - coolant
hoses
18 - Expansion valve (front)
❑ Removing and installing ⇒ “2.15 Removing and installing expansion valve”, page 81
❑ Different versions ⇒ Electronic parts catalogue

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19 - High-voltage battery heat exchanger

❑ Incorporation into coolant circuit for high-voltage system ⇒ Engine, mechanics; Rep. gr. 19 ; Cooling
system/coolant; Connection diagram - coolant hoses
❑ Removing and installing
⇒ “2.11 Removing and installing heat exchanger for high-voltage battery”, page 67
20 - Evaporator
❑ Exploded view ⇒ “6.4 Exploded view - evaporator housing”, page 258
21 - Heat exchanger for heat pump operation with refrigerant receiver
❑ Removing and installing
⇒ “2.9 Removing and installing heat exchanger for heat pump operation with refrigerant receiver”, page
60
22 - Refrigerant receiver at heat exchanger for heat pump operation
❑ Removing and installing ⇒ “2.10 Removing and installing refrigerant receiver”, page 63
23 - Non-return valve in refrigerant line from refrigerant receiver
❑ Different versions ⇒ Electronic parts catalogue
❑ Removing and installing
⇒ “2.16.2 Removing and installing non-return valve in refrigerant line from refrigerant receiver”,
page 86
24 - Incorporation into heating circuit (vehicle interior)
❑ Incorporation into coolant circuit ⇒ Rep. gr. 19 ; Cooling system/coolant; Connection diagram - coolant
hoses
25 - Service connection (high-pressure side)
❑ For measuring, discharging and charging
❑ Exploded view
⇒ “2.6.3 Exploded view - refrigerant lines, vehicles with high-voltage system”, page 50
❑ Different versions ⇒ Electronic parts catalogue
❑ As the service connection is located in the refrigerant circuit, high pressure is only available at this con‐
nection during operation of the refrigerant circuit in heat pump mode. When operating the air conditioner,
the same pressure is available here as at the service connection on the low-pressure side.
❑ To measure pressure in refrigerant circuit in air conditioner mode, read out measured value for refrigerant
pressure and temperature sender - G395- from -J1024- ⇒ Vehicle diagnostic tester
26 - Non-return valve in refrigerant line from valve block in refrigerant circuit
❑ Different versions ⇒ Electronic parts catalogue
❑ Removing and installing
⇒ “2.16.4 Removing and installing non-return valve in refrigerant line from valve block”, page 90

2. Refrigerant circuit 37
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2.2 Exploded view - condenser

1 - Receiver insert
❑ Different versions
❑ Fit into mounting in re‐
ceiver as far as stop;
make sure it is in correct
position
❑ With strainer
❑ Check receiver; if it is
dirty, clean refrigerant
circuit or renew con‐
denser if necessary ⇒
Air conditioner with re‐
frigerant R134a; Rep.
gr. 87 ; General infor‐
mation on air condition‐
ing systems , or ⇒ Air
conditioners with refrig‐
erant R1234yf - General
information; Rep. gr.
87 ; Working with the air
conditioner service sta‐
tion; Cleaning refriger‐
ant circuit
❑ Illustration shows an in‐
sert as fitted in a “Den‐
so” condenser. An insert
with a different contour
is fitted in “Keihin” con‐
densers; however, the
operation and removal
and installation proce‐
dures are the same.
2 - Desiccant bag
❑ Different versions ⇒
Electronic parts cata‐
logue
❑ Removing and installing
⇒ “2.20 Removing and
installing desiccant bag/desiccant cartridge”, page 103
3 - O-ring
❑ Renew if removed; for correct version refer to ⇒ Electronic parts catalogue
❑ Before installing, lubricate with refrigerant oil ⇒ “4.12 Refrigerant circuit seals”, page 14
4 - O-ring
❑ Renew if removed; for correct version refer to ⇒ Electronic parts catalogue
❑ Before installing, lubricate with refrigerant oil ⇒ “4.12 Refrigerant circuit seals”, page 14
5 - Plug
❑ Different versions
❑ Renew after removing
❑ Keihin: 5 Nm
❑ Denso: 2 Nm
❑ Removing and installing
⇒ “2.20 Removing and installing desiccant bag/desiccant cartridge”, page 103
6 - Condenser
❑ Different versions ⇒ Electronic parts catalogue

38 Rep. gr.87 - Air conditioning system

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❑ Detaching and attaching refrigerant lines

⇒ “2.19 Detaching and attaching refrigerant lines at condenser”, page 98
❑ Removing and installing ⇒ “2.18 Removing and installing condenser”, page 94
7 - High-pressure sender - G65-
❑ Only vehicles without high-voltage system
❑ Removing and installing ⇒ “2.3 Removing and installing high-pressure sender G65 ”, page 39
❑ Depending on version of condenser, high-pressure sender - G65- is fitted further down.
❑ 5 Nm
8 - O-ring
❑ Only vehicles without high-voltage system
❑ Renew if removed; for correct version refer to ⇒ Electronic parts catalogue
❑ Before installing, lubricate with refrigerant oil ⇒ “4.12 Refrigerant circuit seals”, page 14
9 - Connection with valve
❑ Only vehicles without high-voltage system
10 - Receiver
❑ Receiver is part of condenser
❑ Check receiver; if it is dirty, clean refrigerant circuit or renew condenser if necessary ⇒ Air conditioner
with refrigerant R134a; Rep. gr. 87 ; General information on air conditioning systems , or ⇒ Air condi‐
tioners with refrigerant R1234yf - General information; Rep. gr. 87 ; Working with the air conditioner
service station; Cleaning refrigerant circuit

2.3 Removing and installing high-pressure

sender - G65-
Removing
– Switch off ignition.
– Remove lock carrier cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Bumper (front) .
Version 1
– Unplug electrical connector -D-.

CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– If refrigerant escapes from the refrigerant line for more than
1 sec. when the pressure sender is unfastened, tighten the
pressure sender and renew the defective non-return valve.
– Extract/drain refrigerant and then immediately open up re‐
frigerant 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 pres‐
sure in the refrigerant circuit.

– Unscrew high-pressure sender - G65- -A- from connection on

condenser -C-.

2. Refrigerant circuit 39
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Version 2
– Unplug electrical connector -D-.

CAUTION
Risk of frostbite from escaping pressurised refrigerant
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– If refrigerant escapes from the refrigerant line for more than
1 sec. when the pressure sender is unfastened, tighten the
pressure sender and renew the defective non-return valve.
– Extract/drain refrigerant and then immediately open up re‐
frigerant 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 pres‐
sure in the refrigerant circuit.

– Unscrew high-pressure sender - G65- -A- from connection on

condenser -C-.
All vehicles (continued)
Installing
Installation is carried out in reverse order; note the following:
– Renew O-ring -B-; lubricate it lightly with refrigerant oil before
fitting ⇒ “4.12 Refrigerant circuit seals”, page 14 .
– Tighten high-pressure sender - G65- -A-.
Tightening torques
♦ ⇒ “2.6.1 Exploded view - refrigerant lines, air conditioner com‐
pressor and condenser”, page 46
♦ ⇒ General body repairs, exterior; Rep. gr. 63 ; Bumper (front)

2.4 Removing and installing refrigerant

pressure and temperature sender -
G395-
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

Removing
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .

40 Rep. gr.87 - Air conditioning system

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♦ The refrigerant pressure and temperature sender - G395- and

the refrigerant pressure and temperature sender 2 - G826- are
identical ⇒ Electronic parts catalogue . Their functions and
fitting locations are only matched (addressing of senders) via
the Basic setting function, based on their positions in the
wiring ⇒ Vehicle diagnostic tester.
♦ If connectors have been interchanged at the senders, these
will be matched (addressed) incorrectly in the basic setting
function; this means they will be assigned incorrectly and their
measured values will be used incorrectly in the thermal man‐
agement control unit - J1024- . Check wiring connections to
these senders if you suspect that connectors have been in‐
terchanged ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations.
♦ If senders have been removed from the lines and installed in
a different line, these senders will retain their old assignment
(address) until the next time the basic setting function is per‐
formed.
Working with ignition switched on or high-voltage system active
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
– Switch on ignition.
– Initiate basic setting of air conditioner via thermal manage‐
ment control unit - J1024- ; use the Extract, evacuate and
charge refrigerant circuit routine stored there to open
electrically actuated valves ⇒ Vehicle diagnostic tester.
– Switch off ignition.
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station .
– Mark electrical connector -A- and sender -B- to prevent inter‐
change with other connectors or senders.
– Unplug electrical connector -A-.
– Check refrigerant line and connection -D- for dirt; clean if nec‐
essary.

CAUTION
Risk of frostbite from escaping pressurised refrigerant
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 re‐
frigerant 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 pres‐
sure in the refrigerant circuit.

– Loosen and remove sender -B-.

– Seal off open connection -D- with a clean plug from engine
bung set - VAS 6122- .

2. Refrigerant circuit 41
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Installing
Installation is carried out in reverse order; note the following:
– Check connection -D- for dirt or damage; clean or renew if
necessary.
– Renew O-ring -C-; lubricate it lightly with refrigerant oil before
fitting ⇒ “4.12 Refrigerant circuit seals”, page 14 .
– Insert and tighten sender -B-.
– 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 .
– Switch on ignition.
– Initiate air conditioner basic setting via thermal management
control unit - J1024- and use a routine stored there to open
electrically actuated valves ( Stop routine: Charging/
flushing refrigerant circuit ) ⇒ Vehicle diagnostic test‐
er.
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22.2 Starting up air conditioner after charging refrigerant
circuit - vehicles with high-voltage system”, page 109 .
– If refrigerant pressure and temperature sender - G395- is be‐
ing renewed, perform addressing.
Procedure
– Connect ⇒ Vehicle diagnostic tester.
– Select Diagnosis mode and begin diagnosis.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 00C5 - Thermal management control unit J1024
♦ 00C5 - Basic setting
♦ ⇒ Automatic addressing of pressure and temperature senders
Tightening torques
♦ ⇒ “1.1 Overview of fitting locations - components not located
in passenger compartment”, page 23
♦ ⇒ “2.6.3 Exploded view - refrigerant lines, vehicles with high-
voltage system”, page 50

2.5 Removing and installing refrigerant

pressure and temperature sender 2 -
G826-
Special tools and workshop equipment required

42 Rep. gr.87 - Air conditioning system

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♦ Engine bung set - VAS 6122-

Removing
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
♦ The refrigerant pressure and temperature sender - G395- and
the refrigerant pressure and temperature sender 2 - G826- are
identical ⇒ Electronic parts catalogue . Their functions and
fitting locations are only matched (addressing of senders) via
the Basic setting function, based on their positions in the
wiring ⇒ Vehicle diagnostic tester.
♦ If connectors have been interchanged at the senders, these
will be matched (addressed) incorrectly in the basic setting
function; this means they will be assigned incorrectly and their
measured values will be used incorrectly in the thermal man‐
agement control unit - J1024- . Check wiring connections to
these senders if you suspect that connectors have been in‐
terchanged ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations.
♦ If senders have been removed from the lines and installed in
a different line, these senders will retain their old assignment
(address) until the next time the basic setting function is per‐
formed.
Working with ignition switched on or high-voltage system active
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
– Switch on ignition.
– Initiate basic setting of air conditioner via thermal manage‐
ment control unit - J1024- ; use the Extract, evacuate and
charge refrigerant circuit routine stored there to open
electrically actuated valves ⇒ Vehicle diagnostic tester.
– Switch off ignition.
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station .
– Remove coolant expansion tank for high-voltage coolant cir‐
cuit ⇒ 4-cylinder direct injection engine (2.0 ltr. 4-valve TFSI,
EA 888 Gen. III); Rep. gr. 19 ; Cooling system/coolant; Ex‐
ploded view - coolant expansion tank .

2. Refrigerant circuit 43
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– Mark electrical connector -A- and sender -B- to prevent inter‐

change with other connectors or senders.
– Unplug electrical connector -A-.
– Check refrigerant line and connection -D- for dirt; clean if nec‐
essary.

CAUTION
Risk of frostbite from escaping pressurised refrigerant
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 re‐
frigerant 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 pres‐
sure in the refrigerant circuit.

– Loosen and remove sender -B-.

– Seal off open connection -D- with a clean plug from engine
bung set - VAS 6122- .

44 Rep. gr.87 - Air conditioning system

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

Installing
Installation is carried out in reverse order; note the following:
– Check connection -D- for dirt or damage; clean or renew if
necessary.
– Renew O-ring -C-; lubricate it lightly with refrigerant oil before
fitting ⇒ “4.12 Refrigerant circuit seals”, page 14 .
– Insert and tighten sender -B-.
– Re-install remaining components removed previously in re‐
verse order and/or re-attach detached components.
– 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 .
– Switch on ignition.
– Initiate air conditioner basic setting via thermal management
control unit - J1024- and use a routine stored there to open
electrically actuated valves ( Stop routine: Charging/
flushing refrigerant circuit ) ⇒ Vehicle diagnostic test‐
er.
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22.2 Starting up air conditioner after charging refrigerant
circuit - vehicles with high-voltage system”, page 109 .
– If refrigerant pressure and temperature sender 2 - G826- is
being renewed, perform addressing.
Procedure
– Connect ⇒ Vehicle diagnostic tester.
– Select Diagnosis mode and begin diagnosis.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 00C5 - Thermal management control unit J1024
♦ 00C5 - Basic setting
♦ ⇒ Automatic addressing of pressure and temperature senders
Tightening torques
♦ ⇒ “1.1.2 Overview of fitting locations - components not located
in passenger compartment, vehicles with high-voltage sys‐
tem”, page 25
♦ ⇒ “2.6.3 Exploded view - refrigerant lines, vehicles with high-
voltage system”, page 50
♦ ⇒ 4-cylinder direct injection engine (2.0 ltr. 4-valve TFSI, EA
888 Gen. III); Rep. gr. 19 ; Cooling system/coolant; Exploded
view - coolant expansion tank

2. Refrigerant circuit 45
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

2.6 Exploded view - refrigerant lines

⇒ “2.6.1 Exploded view - refrigerant lines, air conditioner com‐
pressor and condenser”, page 46
⇒ “2.6.2 Exploded view - internal heat exchanger refrigerant lines
in plenum chamber and expansion valve”, page 48
⇒ “2.6.3 Exploded view - refrigerant lines, vehicles with high-volt‐
age system”, page 50

2.6.1 Exploded view - refrigerant lines, air conditioner compressor and condenser

1 - Condenser (with receiver)

❑ Detaching and attach‐
ing refrigerant lines
⇒ “2.19 Detaching and
attaching refrigerant
lines at condenser”,
page 98
❑ Removing and installing
⇒ “2.18 Removing and
installing condenser”,
page 94
❑ Receiver is part of con‐
denser
⇒ “2.2 Exploded view -
condenser”, page 38
❑ Removing and installing
dryer from receiver
⇒ “2.20 Removing and
installing desiccant bag/
desiccant cartridge”,
page 103
2 - High-pressure sender -
G65-
❑ 5 Nm
❑ Removing and installing
⇒ “2.3 Removing and in‐
stalling high-pressure
sender G65 ”, page 39
3 - Air conditioner compressor
❑ Exploded view
⇒ “4.1 Exploded view -
air conditioner compres‐
sor”, page 141
4 - O-ring
❑ Renewing
⇒ “4.12 Refrigerant cir‐
cuit seals”, page 14
❑ Before installing, lubricate lightly with refrigerant oil
5 - O-ring
❑ Renewing ⇒ “4.12 Refrigerant circuit seals”, page 14
❑ Before installing, lubricate lightly with refrigerant oil
6 - Bolt
❑ 25 Nm
7 - Bolt
❑ 25 Nm

46 Rep. gr.87 - Air conditioning system

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

8 - Refrigerant line with internal heat exchanger

❑ Exploded view
⇒ “2.6.2 Exploded view - internal heat exchanger refrigerant lines in plenum chamber and expansion
valve”, page 48
❑ In this refrigerant line, 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
❑ Removing and installing
⇒ “2.12 Removing and installing refrigerant lines with internal heat exchanger”, page 70
9 - O-ring
❑ Renewing ⇒ “4.12 Refrigerant circuit seals”, page 14
❑ Before installing, lubricate lightly with refrigerant oil
10 - Refrigerant line (low-pressure side)
❑ From internal heat exchanger to air conditioner compressor
❑ Detaching and attaching at air conditioner compressor
⇒ “4.4 Detaching and attaching refrigerant lines at air conditioner compressor”, page 163
❑ Detaching and attaching at internal heat exchanger
⇒ “2.12 Removing and installing refrigerant lines with internal heat exchanger”, page 70
11 - O-ring
❑ Renewing ⇒ “4.12 Refrigerant circuit seals”, page 14
❑ Before installing, lubricate lightly with refrigerant oil
12 - Nut
❑ 8 Nm
13 - Refrigerant line (high-pressure side)
❑ From condenser to internal heat exchanger
❑ Detaching and attaching at condenser
⇒ “2.19 Detaching and attaching refrigerant lines at condenser”, page 98
❑ Detaching and attaching at internal heat exchanger
⇒ “2.12 Removing and installing refrigerant lines with internal heat exchanger”, page 70
14 - Bracket
15 - Refrigerant line (high-pressure side)
❑ From air conditioner compressor to condenser
❑ Detaching and attaching at air conditioner compressor
⇒ “4.4 Detaching and attaching refrigerant lines at air conditioner compressor”, page 163
❑ Detaching and attaching at condenser
⇒ “2.19 Detaching and attaching refrigerant lines at condenser”, page 98
16 - Bolt
❑ 8 Nm
❑ Depending on version of condenser, this bolt may not be fitted; in this case refrigerant lines
⇒ Item 13 (page 47) and ⇒ Item 15 (page 47) are secured with bolt ⇒ Item 17 (page 47)
17 - Bolt
❑ 8 Nm
18 - O-ring
❑ Renewing ⇒ “4.12 Refrigerant circuit seals”, page 14
❑ Before installing, lubricate lightly with refrigerant oil
19 - O-ring
❑ Renewing ⇒ “4.12 Refrigerant circuit seals”, page 14
❑ Before installing, lubricate lightly with refrigerant oil

2. Refrigerant circuit 47
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

2.6.2 Exploded view - internal heat exchanger refrigerant lines in plenum cham‐
ber and expansion valve

1 - Refrigerant line (low-pres‐

sure side)
❑ With service connection
(low-pressure side)
❑ From expansion valve
to refrigerant line with in‐
ternal heat exchanger
❑ Removing and installing
⇒ “2.13 Removing and
installing refrigerant
lines in plenum cham‐
ber”, page 74
2 - Nut
❑ 8 Nm
❑ 2x
3 - Grommet
4 - Retainer for refrigerant lines
❑ Different versions ⇒
Electronic parts cata‐
logue
5 - Bracket for internal heat ex‐
changer
❑ Different versions ⇒
Electronic parts cata‐
logue
6 - Flexible mounting
7 - Bolt
❑ 8 Nm
8 - O-ring
❑ Renewing
⇒ “4.12 Refrigerant cir‐
cuit seals”, page 14
❑ Before installing, lubricate lightly with refrigerant oil
9 - Bolt
❑ 8 Nm
10 - Refrigerant line with internal heat exchanger
❑ In this refrigerant line, 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
❑ Removing and installing
⇒ “2.12 Removing and installing refrigerant lines with internal heat exchanger”, page 70
11 - Nut
❑ 8 Nm
12 - O-ring
❑ Renewing ⇒ “4.12 Refrigerant circuit seals”, page 14
❑ Before installing, lubricate lightly with refrigerant oil
13 - Extracting and charging valve (high-pressure side)
❑ 1.5 Nm

48 Rep. gr.87 - Air conditioning system

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

❑ Removing and installing

⇒ “2.21 Removing and installing evacuating and charging valve (low-pressure and high-pressure sides)”,
page 105
❑ Different versions depending on refrigerant ⇒ Electronic parts catalogue
14 - Retainer for filler lines
15 - Bolts
❑ 8 Nm
❑ 2x
16 - Retainer for high-pressure line
17 - Refrigerant line (high-pressure side)
❑ With service connection (high-pressure side)
❑ From refrigerant line with internal heat exchanger to expansion valve
❑ Removing and installing
⇒ “2.13 Removing and installing refrigerant lines in plenum chamber”, page 74
18 - Nut
❑ 8 Nm
19 - Cap for service connection (high-pressure side)
❑ Cap with seal, always screw on
20 - Extracting and charging valve (low-pressure side)
❑ 1.5 Nm
❑ Removing and installing
⇒ “2.21 Removing and installing evacuating and charging valve (low-pressure and high-pressure sides)”,
page 105
❑ Different versions depending on refrigerant ⇒ Electronic parts catalogue
21 - Cap for service connection (low-pressure side)
❑ Cap with seal, always screw on
22 - O-ring
❑ Renewing ⇒ “4.12 Refrigerant circuit seals”, page 14
❑ Before installing, lubricate lightly with refrigerant oil
23 - Expansion valve (front)
❑ Removing and installing ⇒ “2.15 Removing and installing expansion valve”, page 81

2. Refrigerant circuit 49
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

2.6.3 Exploded view - refrigerant lines, vehicles with high-voltage system

1 - Exploded view - refrigerant

lines from air conditioner com‐
pressor and condenser
⇒ page 50
2 - Exploded view - refrigerant
lines at heat pump valve unit
⇒ page 52
3 - Exploded view - internal
heat exchanger and refrigerant
lines in plenum chamber
⇒ page 54
4 - Exploded view - refrigerant
lines at non-return valves
⇒ page 55

Exploded view - refrigerant lines from air conditioner compressor

and condenser

50 Rep. gr.87 - Air conditioning system

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

1 - O-ring
❑ Renew after removing
⇒ “4.12 Refrigerant cir‐
cuit seals”, page 14
❑ Different versions ⇒
Electronic parts cata‐
logue
❑ Before installing, lubri‐
cate lightly with refriger‐
ant oil
2 - Refrigerant line (high-pres‐
sure side)
❑ From condenser to heat
pump valve unit
❑ Detaching and attach‐
ing at condenser
⇒ “2.19.3 Detaching and
attaching refrigerant
lines at condenser - ve‐
hicles with high-voltage
system”, page 101
3 - Bolt
❑ 8 Nm
4 - Bolt
❑ 25 Nm
5 - Refrigerant pressure and
temperature sender - G395-
❑ Removing and installing
⇒ “2.4 Removing and in‐
stalling refrigerant pres‐
sure and temperature
sender G395 ”, page 40
❑ 10 Nm
6 - Refrigerant line (high-pres‐
sure side)
❑ From air conditioner compressor to heat pump valve unit
❑ Detaching and attaching at electrical air conditioner compressor - V470-
⇒ “4.4.3 Detaching and attaching refrigerant lines at electrical air conditioner compressor V470 ”,
page 166
7 - Bolt
❑ 25 Nm
8 - Refrigerant pressure and temperature sender 2 - G826-
❑ Removing and installing
⇒ “2.5 Removing and installing refrigerant pressure and temperature sender 2 G826 ”, page 42
❑ 10 Nm
9 - Heat pump valve unit
❑ Exploded view ⇒ “3.1 Exploded view - heat pump valve unit”, page 130
❑ Removing and installing ⇒ “3.3 Removing and installing heat pump valve unit”, page 136
❑ Dismantling and assembling ⇒ “3.4 Dismantling and assembling heat pump valve unit”, page 137
10 - Refrigerant line (low-pressure side)
❑ Refrigerant lines to base plate connection ⇒ page 55
11 - Non-return valve
❑ Exploded view ⇒ page 55

2. Refrigerant circuit 51
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

12 - Refrigerant line (high-pressure side)

❑ From condenser to non-return valve
❑ Detaching and attaching
⇒ “2.19.3 Detaching and attaching refrigerant lines at condenser - vehicles with high-voltage system”,
page 101
13 - Condenser (with receiver)
❑ Detaching and attaching refrigerant lines
⇒ “2.19.3 Detaching and attaching refrigerant lines at condenser - vehicles with high-voltage system”,
page 101
❑ Removing and installing ⇒ “2.18 Removing and installing condenser”, page 94
❑ Receiver is part of condenser ⇒ “2.2 Exploded view - condenser”, page 38
❑ Removing and installing dryer from receiver
⇒ “2.20 Removing and installing desiccant bag/desiccant cartridge”, page 103
14 - Electrical air conditioner compressor - V470-
❑ Exploded view ⇒ “4.1.3 Exploded view - electrically driven air conditioner compressor”, page 146
❑ Removing and installing
⇒ “4.5.8 Removing and installing electrically driven air conditioner compressor”, page 182
15 - Refrigerant line (low-pressure side)
❑ With service connection (low-pressure side)
❑ To air conditioner compressor
❑ Detaching and attaching at electrical air conditioner compressor - V470-
⇒ “4.4.3 Detaching and attaching refrigerant lines at electrical air conditioner compressor V470 ”,
page 166
16 - Bolt
❑ 25 Nm
17 - Retainer for service connection
18 - Extracting and charging valve (low-pressure side)
❑ 2.4 Nm
❑ Removing and installing
⇒ “2.21 Removing and installing evacuating and charging valve (low-pressure and high-pressure sides)”,
page 105
❑ Different versions depending on refrigerant ⇒ Electronic parts catalogue
19 - Cap for service connection (low-pressure side)
❑ Cap with seal, always screw on

Exploded view - refrigerant lines at heat pump valve unit

52 Rep. gr.87 - Air conditioning system

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

1 - Refrigerant line (high-pres‐

sure side)
❑ With service connection
❑ At heat exchanger for
heat pump operation
and heat pump valve
unit
2 - Extracting and charging
valve (high-pressure side)
❑ 2.4 Nm
❑ Removing and installing
⇒ “2.21 Removing and
installing evacuating
and charging valve (low-
pressure and high-pres‐
sure sides)”, page 105
❑ Different versions de‐
pending on refrigerant
⇒ Electronic parts cata‐
logue
3 - Cap for service connection
(high-pressure side)
❑ Cap with seal, always
screw on
4 - Bolt
❑ 8 Nm
5 - Refrigerant line (high-pres‐
sure side)
❑ Exploded view
⇒ page 55
6 - Refrigerant line with internal
heat exchanger
❑ Exploded view
⇒ page 54
7 - O-ring
❑ Renew after removing ⇒ “4.12 Refrigerant circuit seals”, page 14
❑ Different versions ⇒ Electronic parts catalogue
❑ Before installing, lubricate lightly with refrigerant oil
8 - Nut
❑ 8 Nm
9 - Refrigerant line (low-pressure side)
❑ From non-return valve to connection at refrigerant line with internal heat exchanger
10 - Bolt
❑ 20 Nm
11 - Non-return valve
❑ Non-return valve in refrigerant line from internal heat exchanger
❑ Exploded view ⇒ page 55
12 - Heat exchanger for heat pump operation with refrigerant receiver
❑ Exploded view ⇒ “2.7 Exploded view - heat exchanger for heat pump operation”, page 57
❑ Removing and installing
⇒ “2.9 Removing and installing heat exchanger for heat pump operation with refrigerant receiver”, page
60

2. Refrigerant circuit 53
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

13 - Heat pump valve unit

❑ Exploded view ⇒ “3.1 Exploded view - heat pump valve unit”, page 130
❑ Removing and installing ⇒ “3.3 Removing and installing heat pump valve unit”, page 136
❑ Dismantling and assembling ⇒ “3.4 Dismantling and assembling heat pump valve unit”, page 137

Exploded view - internal heat exchanger and refrigerant lines in

plenum chamber

1 - O-ring
❑ Renew after removing
⇒ “4.12 Refrigerant cir‐
cuit seals”, page 14
❑ Different versions ⇒
Electronic parts cata‐
logue
❑ Before installing, lubri‐
cate lightly with refriger‐
ant oil
2 - Refrigerant line (low-pres‐
sure side)
❑ Different versions ⇒
Electronic parts cata‐
logue
❑ From expansion valve
to refrigerant line with in‐
ternal heat exchanger
❑ Removing and installing
⇒ “2.13.2 Removing and
installing refrigerant
lines in plenum chamber
- vehicles with high-volt‐
age system”, page 76
3 - Expansion valve (front)
❑ Removing and installing
⇒ “2.15 Removing and
installing expansion
valve”, page 81
4 - Bolt
❑ 8 Nm
5 - Flexible mounting
6 - Nut
❑ 8 Nm
❑ 2x
7 - Retainer for refrigerant lines
❑ Different versions ⇒ Electronic parts catalogue
8 - Grommet
9 - Refrigerant line with internal heat exchanger
❑ In this refrigerant line, 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
❑ Removing and installing
⇒ “2.12.2 Removing and installing refrigerant lines with internal heat exchanger - vehicles with high-
voltage system”, page 72

54 Rep. gr.87 - Air conditioning system

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

10 - Bracket for internal heat exchanger

❑ Different versions ⇒ Electronic parts catalogue
11 - Nut
❑ 8 Nm
12 - Refrigerant shut-off valve - V424-
❑ Removing and installing ⇒ “2.14 Removing and installing refrigerant shut-off valve V424 ”, page 79
13 - Refrigerant line (high-pressure side)
❑ From refrigerant line with internal heat exchanger to refrigerant shut-off valve - V424-
❑ Removing and installing
⇒ “2.13.2 Removing and installing refrigerant lines in plenum chamber - vehicles with high-voltage sys‐
tem”, page 76
14 - Union nut
❑ Unfastening and tightening
⇒ “2.14 Removing and installing refrigerant shut-off valve V424 ”, page 79
❑ 16.5 Nm
15 - Refrigerant line (high-pressure side)
❑ From refrigerant shut-off valve - V424- to expansion valve
❑ Removing and installing
⇒ “2.13.2 Removing and installing refrigerant lines in plenum chamber - vehicles with high-voltage sys‐
tem”, page 76
16 - Nut
❑ 8 Nm

Exploded view - refrigerant lines at non-return valves

2. Refrigerant circuit 55
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

1 - Bolt
❑ 8 Nm
2 - Bolt
❑ 8 Nm
3 - Heat pump valve unit
❑ Exploded view
⇒ “3.1 Exploded view -
heat pump valve unit”,
page 130
❑ Removing and installing
⇒ “3.3 Removing and in‐
stalling heat pump valve
unit”, page 136
❑ Dismantling and assem‐
bling
⇒ “3.4 Dismantling and
assembling heat pump
valve unit”, page 137
4 - Heat exchanger for high-
voltage battery with refrigerant
expansion valve 2 - N637-
❑ Exploded view
⇒ “2.8 Exploded view -
heat exchanger for high-
voltage battery”,
page 59
❑ Removing and installing
⇒ “2.11 Removing and
installing heat exchang‐
er for high-voltage bat‐
tery”, page 67
❑ Removing and installing
refrigerant expansion
valve 2 - N637-
⇒ “3.5 Removing and in‐
stalling refrigerant ex‐
pansion valve 2 N637 ”, page 139
5 - Heat exchanger for heat pump operation with refrigerant receiver
❑ Exploded view ⇒ “2.7 Exploded view - heat exchanger for heat pump operation”, page 57
❑ Removing and installing
⇒ “2.9 Removing and installing heat exchanger for heat pump operation with refrigerant receiver”, page
60
6 - Refrigerant line with internal heat exchanger
❑ Exploded view ⇒ page 54
7 - O-ring
❑ Renew after removing ⇒ “4.12 Refrigerant circuit seals”, page 14
❑ Different versions ⇒ Electronic parts catalogue
❑ Before installing, lubricate lightly with refrigerant oil
8 - Bolt
❑ Tightening torque ⇒ Item 16 (page 131)
9 - Base plate
❑ Exploded view ⇒ “2.8 Exploded view - heat exchanger for high-voltage battery”, page 59
10 - Refrigerant line (high-pressure side)
❑ From base plate to refrigerant line with internal heat exchanger

56 Rep. gr.87 - Air conditioning system

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

11 - Bolt
❑ 8 Nm
12 - Bolt
❑ 8 Nm
13 - Non-return valve
❑ Removing and installing
⇒ “2.16.2 Removing and installing non-return valve in refrigerant line from refrigerant receiver”,
page 86
14 - Refrigerant line (high-pressure side)
❑ From refrigerant receiver to non-return valve
15 - Refrigerant line (high-pressure side)
❑ From condenser to non-return valve
❑ Exploded view ⇒ page 50
16 - Non-return valve
❑ Removing and installing
⇒ “2.16.3 Removing and installing non-return valve in refrigerant line from condenser”, page 88
17 - Non-return valve
❑ Removing and installing
⇒ “2.16.1 Removing and installing non-return valve in refrigerant line from internal heat exchanger”, page
84
18 - Bolt
❑ Tightening torque ⇒ Item 8 (page 131)
19 - Bracket
❑ Exploded view ⇒ page 131
20 - Refrigerant line (low-pressure side)
❑ From base plate to non-return valve and refrigerant line to air conditioner compressor
21 - Refrigerant line (low-pressure side)
❑ From non-return valve to heat pump valve unit
22 - Non-return valve
❑ Removing and installing
⇒ “2.16.4 Removing and installing non-return valve in refrigerant line from valve block”, page 90
23 - Base plate
❑ Exploded view ⇒ “2.8 Exploded view - heat exchanger for high-voltage battery”, page 59

2.7 Exploded view - heat exchanger for heat

pump operation
Heat exchanger for heat pump operation with refrigerant receiver

2. Refrigerant circuit 57
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

1 - Bolts
❑ Tightening torque
⇒ Item 18 (page 131)
2 - Bracket
❑ Exploded view
⇒ “3.1 Exploded view -
heat pump valve unit”,
page 130
3 - Bracket
❑ Exploded view
⇒ “3.1 Exploded view -
heat pump valve unit”,
page 130
4 - Refrigerant receiver
❑ Removing and installing
⇒ “2.10 Removing and
installing refrigerant re‐
ceiver”, page 63
5 - O-ring
❑ Renew after removing
⇒ “4.12 Refrigerant cir‐
cuit seals”, page 14
❑ Before installing, lubri‐
cate lightly with refriger‐
ant oil
6 - Bolt
❑ 8 Nm
7 - Heat exchanger for heat
pump operation
❑ Removing and installing
⇒ “2.9 Removing and in‐
stalling heat exchanger
for heat pump operation
with refrigerant receiv‐
er”, page 60
8 - Bolts
❑ 8 Nm

58 Rep. gr.87 - Air conditioning system

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

2.8 Exploded view - heat exchanger for high-voltage battery

1 - O-ring
❑ Renew if removed
⇒ “4.12 Refrigerant cir‐
cuit seals”, page 14 ; for
correct version refer to
⇒ Electronic parts cata‐
logue
❑ Before installing, lubri‐
cate lightly with refriger‐
ant oil
2 - Base plate
❑ Removing and installing
⇒ “3.5 Removing and in‐
stalling refrigerant ex‐
pansion valve 2 N637 ”,
page 139
3 - Bolts
❑ 8 Nm
4 - Bolt
❑ Tightening torque
⇒ Item 2 (page 56)
5 - Base plate
6 - High-voltage battery heat
exchanger
❑ Removing and installing
⇒ “2.11 Removing and
installing heat exchang‐
er for high-voltage bat‐
tery”, page 67
7 - Bracket
❑ Exploded view
⇒ “3.1 Exploded view -
heat pump valve unit”,
page 130
8 - Bracket
❑ Exploded view ⇒ “3.1 Exploded view - heat pump valve unit”, page 130
9 - Bolts
❑ 3x
❑ 8 Nm
10 - Base plate
11 - Bolt
❑ Tightening torque ⇒ Item 12 (page 57)
12 - Bolts
❑ Tightening torque ⇒ Item 16 (page 131)
13 - Refrigerant expansion valve 2 - N637-
❑ Do not dismantle any further
❑ Removing and installing
⇒ “3.5 Removing and installing refrigerant expansion valve 2 N637 ”, page 139
14 - Bolts
❑ Tightening torque ⇒ Item 18 (page 131)

2. Refrigerant circuit 59
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

2.9 Removing and installing heat exchanger

for heat pump operation with refrigerant
receiver
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

Removing
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
Working with ignition switched on or high-voltage system active
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
– Switch on ignition.
– Initiate basic setting of air conditioner via thermal manage‐
ment control unit - J1024- ; use the Extract, evacuate and
charge refrigerant circuit routine stored there to open
electrically actuated valves ⇒ Vehicle diagnostic tester.
– Switch off ignition.
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station .
– Drain coolant for engine coolant circuit ⇒ 4-cylinder direct in‐
jection engine (2.0 ltr. 4-valve TFSI, EA 888 Gen. III); Rep. gr.
19 ; Cooling system/coolant; Draining and filling cooling sys‐
tem .
– Remove wheel housing liner (front left) ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Exploded
view - wheel housing liner (front) .
– Remove closure plate at bumper cover ⇒ General body re‐
pairs, exterior; Rep. gr. 63 ; Bumper (front); Exploded view -
bumper cover .

60 Rep. gr.87 - Air conditioning system

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

– Move clear all lines and connectors at bracket -A-.

CAUTION
Risk of frostbite from escaping pressurised refrigerant
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 re‐
frigerant 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 pres‐
sure in the refrigerant circuit.

– Unscrew bolt -B- and detach refrigerant line -D-.

– Remove bolts -arrows-.
– Remove bolts -C- and detach bracket -A- downwards.

– Mark arrangement of coolant hoses on connections to heat

exchanger.
– Open clips -B- and disconnect coolant hoses -A, D- from con‐
nections to heat exchanger -C-.
– Seal off open pipes and connections immediately with clean
plugs from engine bung set - VAS 6122- .

– Remove bolts -B, F- and detach refrigerant lines -C, E-.

– Remove bolts -arrows-.
– Remove heat exchanger -A- with refrigerant receiver -D-
downwards.

2. Refrigerant circuit 61
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

Installing
Installation is carried out in reverse order; note the following:
• When removed, the heat exchanger and refrigerant receiver
contain refrigerant oil which must be returned to the refrigerant
circuit if any of these components are renewed ⇒ Air condi‐
tioner with refrigerant R134a; Rep. gr. 87 ; Renewing com‐
ponents of refrigerant circuit , or ⇒ Air conditioners with
refrigerant R1234yf - General information; Rep. gr. 87 ; Re‐
frigerant circuit; Renewing components .
– Renew O-rings -3-
⇒ “4.12 Refrigerant circuit seals”, page 14 .
– If fitted, check that dowel pins -4- at refrigerant lines are not
damaged and are seated correctly.

– Fit refrigerant lines -C, E-, ensuring they are routed correctly.
– Screw in bolts -B, F-.
– After attaching, check routing of refrigerant lines. They must
be inserted in brackets provided and should not make contact
with other components.

62 Rep. gr.87 - Air conditioning system

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
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– Attach coolant hoses -D, A- to connections going to heat ex‐

changer -C- (observe marking) and secure with a clip -B-.
– Re-install remaining components removed previously in re‐
verse order and/or re-attach detached components.
– 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 .
– Switch on ignition.
– Initiate air conditioner basic setting via thermal management
control unit - J1024- and use a routine stored there to open
electrically actuated valves ( Stop routine: Charging/
flushing refrigerant circuit ) ⇒ Vehicle diagnostic test‐
er.
– Fill up coolant for engine coolant circuit and bleed coolant cir‐
cuit ⇒ 4-cylinder direct injection engine (2.0 ltr. 4-valve TFSI,
EA 888 Gen. III); Rep. gr. 19 ; Cooling system/coolant; Drain‐
ing and filling cooling system .
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22.2 Starting up air conditioner after charging refrigerant
circuit - vehicles with high-voltage system”, page 109 .
Tightening torques
♦ ⇒ “2.7 Exploded view - heat exchanger for heat pump opera‐
tion”, page 57
♦ ⇒ “2.6.3 Exploded view - refrigerant lines, vehicles with high-
voltage system”, page 50
♦ ⇒ “3.1 Exploded view - heat pump valve unit”, page 130
♦ Exploded view - wheel actuator ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Lock carrier .
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front)
♦ ⇒ General body repairs, exterior; Rep. gr. 63 ; Bumper (front);
Exploded view - bumper cover

2.10 Removing and installing refrigerant re‐

ceiver
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

2. Refrigerant circuit 63
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

Removing
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
Working with ignition switched on or high-voltage system active
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
– Switch on ignition.
– Initiate basic setting of air conditioner via thermal manage‐
ment control unit - J1024- ; use the Extract, evacuate and
charge refrigerant circuit routine stored there to open
electrically actuated valves ⇒ Vehicle diagnostic tester.
– Switch off ignition.
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station .

CAUTION
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.

– Drain coolant for engine coolant circuit ⇒ 4-cylinder direct in‐

jection engine (2.0 ltr. 4-valve TFSI, EA 888 Gen. III); Rep. gr.
19 ; Cooling system/coolant; Draining and filling cooling sys‐
tem .
– Remove wheel housing liner (front left) ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Exploded
view - wheel housing liner (front) .
– Remove closure plate at bumper cover ⇒ General body re‐
pairs, exterior; Rep. gr. 63 ; Bumper (front); Exploded view -
bumper cover .

64 Rep. gr.87 - Air conditioning system

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

– Move clear all lines and connectors at bracket -A-.

CAUTION
Risk of frostbite from escaping pressurised refrigerant
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 re‐
frigerant 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 pres‐
sure in the refrigerant circuit.

– Unscrew bolt -B- and detach refrigerant line -D-.

– Remove bolts -arrows-.
– Remove bolts -C- and detach bracket -A- downwards.

– Mark arrangement of coolant hoses on connections to heat

exchanger.
– Open clips -B- and disconnect coolant hoses -A, D- from con‐
nections to heat exchanger -C-.
– Seal off open pipes and connections immediately with clean
plugs from engine bung set - VAS 6122- .

– Remove bolts -B, F- and detach refrigerant lines -C, E-.

– Remove bolts -arrows- and detach heat exchanger with re‐
frigerant receiver -A-.

2. Refrigerant circuit 65
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

– Remove bolt -A-.

– Detach refrigerant receiver -B- from heat exchanger -C- and
guide it out downwards.

Installing
Installation is carried out in reverse order; note the following:
• When removed, the heat exchanger and refrigerant receiver
contain refrigerant oil which must be returned to the refrigerant
circuit if any of these components are renewed ⇒ Air condi‐
tioner with refrigerant R134a; Rep. gr. 87 ; Renewing com‐
ponents of refrigerant circuit , or ⇒ Air conditioners with
refrigerant R1234yf - General information; Rep. gr. 87 ; Re‐
frigerant circuit; Renewing components .
– Renew O-rings -E-
⇒ “4.12 Refrigerant circuit seals”, page 14 .
– If fitted, check that dowel pin on heat exchanger -D- is not
damaged and is seated correctly.
– Attach refrigerant receiver -B- to heat exchanger -C-.
– Screw in bolt -A-.

– Renew O-rings -3-

⇒ “4.12 Refrigerant circuit seals”, page 14 .
– If fitted, check that dowel pins -4- at refrigerant lines are not
damaged and are seated correctly.

66 Rep. gr.87 - Air conditioning system

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Heating, air conditioning - Edition 12.2018

– Insert refrigerant lines -C, E-, ensuring they are routed cor‐
rectly.
– Screw in bolts -B, F-.
– After attaching, check routing of refrigerant lines. They must
be inserted in brackets provided and should not make contact
with other components.

– Attach coolant hoses -D, A- to connections going to heat ex‐

changer -C- (observe marking) and secure with a clip -B-.
– Re-install remaining components removed previously in re‐
verse order and/or re-attach detached components.
– 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 .
– Switch on ignition.
– Initiate air conditioner basic setting via thermal management
control unit - J1024- and use a routine stored there to open
electrically actuated valves ( Stop routine: Charging/
flushing refrigerant circuit ) ⇒ Vehicle diagnostic test‐
er.
– Fill up and bleed engine coolant circuit ⇒ 4-cylinder direct in‐
jection engine (2.0 ltr. 4-valve TFSI, EA 888 Gen. III); Rep. gr.
19 ; Cooling system/coolant; Draining and filling cooling sys‐
tem .
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22.2 Starting up air conditioner after charging refrigerant
circuit - vehicles with high-voltage system”, page 109 .
Tightening torques
♦ ⇒ “2.7 Exploded view - heat exchanger for heat pump opera‐
tion”, page 57
♦ ⇒ “2.6.3 Exploded view - refrigerant lines, vehicles with high-
voltage system”, page 50
♦ ⇒ “3.1 Exploded view - heat pump valve unit”, page 130
♦ Exploded view - wheel actuator ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Lock carrier .
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front)
♦ ⇒ General body repairs, exterior; Rep. gr. 63 ; Bumper (front);
Exploded view - bumper cover

2.11 Removing and installing heat exchanger

for high-voltage battery
Special tools and workshop equipment required

2. Refrigerant circuit 67
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

♦ Engine bung set - VAS 6122-

Removing
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
Heat exchanger for high-voltage battery is removed together with
refrigerant expansion valve 2 - N637- .
– Remove bracket with heat pump valve unit
⇒ “3.2 Removing and installing bracket with heat pump valve
unit”, page 131 .
– Remove bolts -B, F- and detach refrigerant lines -C, E-.
– Remove bolts -arrows- and detach heat exchanger with re‐
frigerant receiver -A-.

NOTICE
Escaping coolant may result in dirt entering refrigerant circuit.
– Seal off open pipes and connections immediately with clean
plugs from engine bung set - VAS 6122- .
– Use absorbent paper to clean up any coolant which has es‐
caped.

– Release and unplug electrical connector -C-.

– Remove bolts -A, D- and detach base plate -G-.
– Remove bolts -F-.
– Detach heat exchanger for high-voltage battery -E- from
bracket and base plate -B- together with refrigerant expansion
valve 2 - N637- .

68 Rep. gr.87 - Air conditioning system

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Heating, air conditioning - Edition 12.2018

– Remove bolt -B-.

– Unfasten base plate -E- from connection at heat exchanger
-A-.
Installing
Installation is carried out in reverse order; note the following:
– Renew O-rings on refrigerant lines
⇒ “4.12 Refrigerant circuit seals”, page 14 .
• When removed, the heat exchanger contains refrigerant oil
which must be returned to the refrigerant circuit if this compo‐
nent is renewed ⇒ Air conditioner with refrigerant R134a; Rep.
gr. 87 ; Renewing components of refrigerant circuit , or ⇒ Air
conditioners with refrigerant R1234yf - General information;
Rep. gr. 87 ; Refrigerant circuit; Renewing components .

– If fitted, check that dowel pins at base plates are not damaged
and are seated correctly.
– Fit refrigerant expansion valve 2 - N637- on base plates -B-,
making sure they are seated correctly.
– Fit base plate -G-, making sure refrigerant lines are routed
correctly.
– Screw bolts -A, D- into base plates.
– After attaching, check routing of refrigerant lines. They must
be inserted in brackets provided and should not make contact
with other components.
– Re-install remaining components removed previously in re‐
verse order and/or re-attach detached components.
– 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 .
– Switch on ignition.
– Initiate air conditioner basic setting via thermal management
control unit - J1024- and use a routine stored there to open
electrically actuated valves ( Stop routine: Charging/
flushing refrigerant circuit ) ⇒ Vehicle diagnostic test‐
er.
– Fill up and bleed high-voltage coolant circuit ⇒ 4-cylinder di‐
rect injection engine (2.0 ltr. 4-valve TFSI, EA 888 Gen. III);
Rep. gr. 19 ; Cooling system/coolant; Draining and filling cool‐
ing system .
– Fill up coolant for engine coolant circuit and bleed coolant cir‐
cuit ⇒ 4-cylinder direct injection engine (2.0 ltr. 4-valve TFSI,
EA 888 Gen. III); Rep. gr. 19 ; Cooling system/coolant; Drain‐
ing and filling cooling system .
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22.2 Starting up air conditioner after charging refrigerant
circuit - vehicles with high-voltage system”, page 109 .
Tightening torques
♦ ⇒ “2.8 Exploded view - heat exchanger for high-voltage bat‐
tery”, page 59
♦ ⇒ “2.6.3 Exploded view - refrigerant lines, vehicles with high-
voltage system”, page 50
♦ ⇒ “3.1 Exploded view - heat pump valve unit”, page 130

2. Refrigerant circuit 69
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

2.12 Removing and installing refrigerant lines

with internal heat exchanger
⇒ “2.12.1 Removing and installing refrigerant lines with internal
heat exchanger - vehicles without high-voltage system”,
page 70
⇒ “2.12.2 Removing and installing refrigerant lines with internal
heat exchanger - vehicles with high-voltage system”, page 72

2.12.1 Removing and installing refrigerant lines

with internal heat exchanger - vehicles
without high-voltage system
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

Removing
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
– Switch off ignition.
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station .
– Remove wheel housing liner and wheel spoiler (front left) ⇒
General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front) .

70 Rep. gr.87 - Air conditioning system

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

CAUTION
Risk of frostbite from escaping pressurised refrigerant
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 re‐
frigerant 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 pres‐
sure in the refrigerant circuit.

– Unscrew nut -E- and detach refrigerant lines -A and D-.

– Unscrew nut -C- and move retaining clip -B- clear.

– Move refrigerant lines -B- clear at retaining clip -C-.

– Release catches -arrows-, and press out and detach lead‐
through -A- to wheel housing.

– Open retainer -E- and move service connections for refriger‐

ant lines clear.
– Unscrew bolts -C- and detach refrigerant lines -D-.
– Detach refrigerant lines with internal heat exchanger -B- from
rubber mounting -A- and guide it out towards wheel housing.
Installing
Installation is carried out in reverse order; note the following:
– Renew O-rings ⇒ “4.12 Refrigerant circuit seals”, page 14 .
– Thoroughly clean internal heat exchanger, leadthrough and
refrigerant lines in connection area and check for damage.
• Install refrigerant lines so that they are free of tension.
– After attaching, check routing of refrigerant lines: they must be
fitted tension-free in appropriate brackets and must not make
contact with any other components.
– Evacuate and charge refrigerant circuit ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air
conditioners with refrigerant R1234yf - General information;
Rep. gr. 87 ; Working with the air conditioner service station .
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22 Starting up air conditioner after charging refrigerant
circuit”, page 108 .
Tightening torques
♦ ⇒ “2.6.2 Exploded view - internal heat exchanger refrigerant
lines in plenum chamber and expansion valve”, page 48

2. Refrigerant circuit 71
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

2.12.2 Removing and installing refrigerant lines

with internal heat exchanger - vehicles
with high-voltage system
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

Removing
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
Working with ignition switched on or high-voltage system active
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
– Switch on ignition.
– Initiate basic setting of air conditioner via thermal manage‐
ment control unit - J1024- ; use the Extract, evacuate and
charge refrigerant circuit routine stored there to open
electrically actuated valves ⇒ Vehicle diagnostic tester.
– Switch off ignition.
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station .
– Remove brake system pressure accumulator - VX70- ⇒ Brake
system; Rep. gr. 47 ; Brake servo/brake master cylinder; Ex‐
ploded view - brake servo/brake master cylinder .
– Remove wheel housing liner (front left) ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Exploded
view - wheel housing liner (front) .

72 Rep. gr.87 - Air conditioning system

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

CAUTION
Risk of frostbite from escaping pressurised refrigerant
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 re‐
frigerant 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 pres‐
sure in the refrigerant circuit.

– Unscrew nut -E- and detach refrigerant lines -A and D-.

– Unscrew nut -C- and move retaining clip -B- clear.

– Move refrigerant lines -B- clear at retaining clip -C-.

– Release catches -arrows-, and press out and detach lead‐
through -A- to wheel housing.

2. Refrigerant circuit 73
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

– Remove bolts -D- and detach refrigerant lines -C-.

– Detach refrigerant lines with internal heat exchanger -B- from
rubber mounting -A- and guide it out towards wheel housing.

Installing
Installation is carried out in reverse order; note the following:
– Renew O-rings ⇒ “4.12 Refrigerant circuit seals”, page 14 .
– Thoroughly clean internal heat exchanger, leadthrough and
refrigerant lines in connection area and check for damage.
• Install refrigerant lines so that they are free of tension.
– After attaching, check routing of refrigerant lines: they must be
fitted tension-free in appropriate brackets and must not make
contact with any other components.
– 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 .
– Switch on ignition.
– Initiate air conditioner basic setting via thermal management
control unit - J1024- and use a routine stored there to open
electrically actuated valves ( Stop routine: Charging/
flushing refrigerant circuit ) ⇒ Vehicle diagnostic test‐
er.
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22.2 Starting up air conditioner after charging refrigerant
circuit - vehicles with high-voltage system”, page 109 .
Tightening torques
♦ ⇒ “2.6.3 Exploded view - refrigerant lines, vehicles with high-
voltage system”, page 50

2.13 Removing and installing refrigerant lines

in plenum chamber
⇒ “2.13.1 Removing and installing refrigerant lines in plenum
chamber - vehicles without high-voltage system”, page 74
⇒ “2.13.2 Removing and installing refrigerant lines in plenum
chamber - vehicles with high-voltage system”, page 76

2.13.1 Removing and installing refrigerant lines

in plenum chamber - vehicles without
high-voltage system
Special tools and workshop equipment required

74 Rep. gr.87 - Air conditioning system

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

♦ Engine bung set - VAS 6122-

Removing
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
– Switch off ignition.
– Remove plenum chamber partition panel ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Bulkhead; Removing and instal‐
ling plenum chamber partition panel .
– To remove the low-pressure refrigerant line, remove wind‐
screen wiper motor ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing windscreen
wiper motor - V- .
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station .

CAUTION
Risk of frostbite from escaping pressurised refrigerant
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 re‐
frigerant 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 pres‐
sure in the refrigerant circuit.

– Remove nut -A-.

– Disconnect refrigerant lines -B, C- from expansion valve (front)
-E-.
– Move refrigerant lines clear.

2. Refrigerant circuit 75
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

– Move service connections for refrigerant lines clear at retainer.

– Unscrew bolts -C- and disconnect refrigerant lines -A and B-
from refrigerant line with internal heat exchanger -D-.
– Detach refrigerant lines -A, B-.
Installing
Installation is carried out in reverse order; note the following:
– Renew O-rings ⇒ “4.12 Refrigerant circuit seals”, page 14 .
– Thoroughly clean expansion valve and refrigerant lines in con‐
nection area and check for damage.
• Install refrigerant lines so that they are free of tension.
– After attaching, check routing of refrigerant lines: they must be
fitted tension-free in appropriate brackets and must not make
contact with any other components.
– Evacuate and charge refrigerant circuit ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air
conditioners with refrigerant R1234yf - General information;
Rep. gr. 87 ; Working with the air conditioner service station .
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22 Starting up air conditioner after charging refrigerant
circuit”, page 108 .
Tightening torques
♦ ⇒ “2.6.2 Exploded view - internal heat exchanger refrigerant
lines in plenum chamber and expansion valve”, page 48

2.13.2 Removing and installing refrigerant lines

in plenum chamber - vehicles with high-
voltage system
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

Removing
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
Working with ignition switched on or high-voltage system active
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
– Switch on ignition.
– Initiate basic setting of air conditioner via thermal manage‐
ment control unit - J1024- ; use the Extract, evacuate and

76 Rep. gr.87 - Air conditioning system

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

charge refrigerant circuit routine stored there to open

electrically actuated valves ⇒ Vehicle diagnostic tester.
– Switch off ignition.
– Remove plenum chamber partition panel ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Bulkhead; Removing and instal‐
ling plenum chamber partition panel .
– Remove brake system pressure accumulator - VX70- ⇒ Brake
system; Rep. gr. 47 ; Brake servo/brake master cylinder; Ex‐
ploded view - brake servo/brake master cylinder .
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
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 .

CAUTION
Risk of frostbite from escaping pressurised refrigerant
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 re‐
frigerant 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 pres‐
sure in the refrigerant circuit.

– Remove nut -A-.

– Disconnect refrigerant lines -B, C- from expansion valve (front)
-E-.

– Before loosening union nuts -E- on refrigerant lines -A, D-,

mark positions of lines in relation to refrigerant shut-off valve
- V424- -B-.
– Unplug electrical connector -C-.
– Loosen union nuts -E- (counterhold at refrigerant shut-off
valve - V424- -B-).
– Remove refrigerant shut-off valve - V424- -B- with refrigerant
line -A-.

2. Refrigerant circuit 77
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

– Unscrew bolts -D- and disconnect refrigerant lines -C- from

refrigerant line with internal heat exchanger -B-.
– Detach refrigerant lines -C-.

Installing
Installation is carried out in reverse order; note the following:
– Screw in union nuts -A, C- by hand until they make contact.
– Check positions of refrigerant lines in relation to refrigerant
shut-off valve - V424- -D- based on marks made during re‐
moval, and correct positions if necessary.
– Counterhold at refrigerant shut-off valve - V424- -D- and tight‐
en union nuts -A, C-; make sure refrigerant lines are routed
without tension.
– Renew O-rings ⇒ “4.12 Refrigerant circuit seals”, page 14 .
– Thoroughly clean expansion valve and refrigerant lines in con‐
nection area and check for damage.
– After attaching, check routing of refrigerant lines. They must
be inserted in brackets provided and should not make contact
with other components.
– 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 .
– Switch on ignition.
– Initiate air conditioner basic setting via thermal management
control unit - J1024- and use a routine stored there to open
electrically actuated valves ( Stop routine: Charging/
flushing refrigerant circuit ) ⇒ Vehicle diagnostic test‐
er.
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22.2 Starting up air conditioner after charging refrigerant
circuit - vehicles with high-voltage system”, page 109 .
Tightening torques
♦ ⇒ “2.6.3 Exploded view - refrigerant lines, vehicles with high-
voltage system”, page 50

78 Rep. gr.87 - Air conditioning system

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

2.14 Removing and installing refrigerant

shut-off valve - V424-
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

Removing
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
Working with ignition switched on or high-voltage system active
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
– Switch on ignition.
– Initiate basic setting of air conditioner via thermal manage‐
ment control unit - J1024- ; use the Extract, evacuate and
charge refrigerant circuit routine stored there to open
electrically actuated valves ⇒ Vehicle diagnostic tester.
– Switch off ignition.
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station .
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .

2. Refrigerant circuit 79
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

– Unplug electrical connector -C-.

– Before loosening union nuts -E- on refrigerant lines -A, D-,
mark positions of lines in relation to refrigerant shut-off valve
- V424- -B-.

CAUTION
Risk of frostbite from escaping pressurised refrigerant
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 re‐
frigerant 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 pres‐
sure in the refrigerant circuit.

– Loosen union nuts -E- (counterhold at refrigerant shut-off

valve - V424- -B-).
– Remove refrigerant shut-off valve - V424- -B-.

Installing
Installation is carried out in reverse order; note the following:
– Renew O-rings -B-; lubricate them lightly with refrigerant oil
before fitting ⇒ “4.12 Refrigerant circuit seals”, page 14 .
– Screw in union nuts -A, C- by hand until they make contact.
– Check positions of refrigerant lines in relation to refrigerant
shut-off valve - V424- -D- based on marks made during re‐
moval, and correct positions if necessary.
– Counterhold at refrigerant shut-off valve - V424- -D- and tight‐
en union nuts -A, C-; make sure refrigerant lines are routed
without tension.
• When tightening the union nuts, make sure not to strain the
refrigerant lines.
– After attaching, check routing of refrigerant lines. They must
be inserted in brackets provided and should not make contact
with other components.
– 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 .
– Switch on ignition.
– Initiate air conditioner basic setting via thermal management
control unit - J1024- and use a routine stored there to open
electrically actuated valves ( Stop routine: Charging/
flushing refrigerant circuit ) ⇒ Vehicle diagnostic test‐
er.
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22.2 Starting up air conditioner after charging refrigerant
circuit - vehicles with high-voltage system”, page 109 .
Tightening torques
♦ ⇒ “2.6.3 Exploded view - refrigerant lines, vehicles with high-
voltage system”, page 50

80 Rep. gr.87 - Air conditioning system

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

2.15 Removing and installing expansion

valve
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

Removing
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
– Switch on ignition.
– Initiate basic setting of air conditioner via thermal manage‐
ment control unit - J1024- ; use the Extract, evacuate and
charge refrigerant circuit routine stored there to open
electrically actuated valves ⇒ Vehicle diagnostic tester.
– Switch off ignition.
All vehicles (continued)
– Remove plenum chamber partition panel ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Bulkhead; Removing and instal‐
ling plenum chamber partition panel .
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station .

2. Refrigerant circuit 81
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

CAUTION
Risk of frostbite from escaping pressurised refrigerant
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 re‐
frigerant 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 pres‐
sure in the refrigerant circuit.

– Remove nut -A-.

– Disconnect refrigerant lines -B, C- from expansion valve (front)
-E-.

– Unscrew bolts -A-.

– Detach expansion valve -B- from refrigerant lines to evapora‐
tor.

Installing
Installation is carried out in reverse order; note the following:
– Make sure that support ring -D- is correctly positioned and that
grommet in plenum chamber back wall is not damaged and is
fitted properly.
– Clean connecting pipes -B- and -C- leading to evaporator and
check for damage.

82 Rep. gr.87 - Air conditioning system

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

– Check that retainer -A- is seated correctly on evaporator con‐

necting pipes -B- and -C-.
– Renew O-rings -D- and -E- and lubricate lightly with refrigerant
oil before fitting ⇒ “4.12 Refrigerant circuit seals”, page 14 .
– Insert O-rings -D- and -E- in grooves on connecting pipes
-B- and -C- -arrows-.
– Renew O-rings ⇒ “4.12 Refrigerant circuit seals”, page 14 .
– Thoroughly clean expansion valve and refrigerant lines in con‐
nection area and check for damage.
– Make sure that O-rings are correctly positioned in grooves of
refrigerant line connections at refrigerant lines -B, C-.
• Install refrigerant lines so that they are free of tension.
– After attaching, check routing of refrigerant lines: they must be
fitted tension-free in appropriate brackets and must not make
contact with any other components.
– 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 .
Vehicles with high-voltage system
– Switch on ignition.
– Initiate basic setting of air conditioner via thermal manage‐
ment control unit - J1024- ; use the Stop routine: Charg-
ing/flushing refrigerant circuit stored there to open
electrically actuated valves ⇒ Vehicle diagnostic tester.
All vehicles (continued)
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22 Starting up air conditioner after charging refrigerant
circuit”, page 108 .
Tightening torques
♦ ⇒ “6.4 Exploded view - evaporator housing”, page 258
♦ ⇒ “2.6.2 Exploded view - internal heat exchanger refrigerant
lines in plenum chamber and expansion valve”, page 48
♦ ⇒ “2.6.3 Exploded view - refrigerant lines, vehicles with high-
voltage system”, page 50

2. Refrigerant circuit 83
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

2.16 Removing and installing non-return

valves in refrigerant circuit
⇒ “2.16.1 Removing and installing non-return valve in refrigerant
line from internal heat exchanger”, page 84
⇒ “2.16.2 Removing and installing non-return valve in refrigerant
line from refrigerant receiver”, page 86
⇒ “2.16.3 Removing and installing non-return valve in refrigerant
line from condenser”, page 88
⇒ “2.16.4 Removing and installing non-return valve in refrigerant
line from valve block”, page 90

2.16.1 Removing and installing non-return

valve in refrigerant line from internal
heat exchanger
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

Removing
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
♦ There are different versions of the non-return valves (different
connections and internal diameters for flow rate); ensure cor‐
rect allocation ⇒ Electronic parts catalogue .
Working with ignition switched on or high-voltage system active
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
– Switch on ignition.
– Initiate basic setting of air conditioner via thermal manage‐
ment control unit - J1024- ; use the Extract, evacuate and
charge refrigerant circuit routine stored there to open
electrically actuated valves ⇒ Vehicle diagnostic tester.
– Switch off ignition.
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station .
– Remove wheel spoiler (front left) ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Wheel housing liners; Exploded view -
wheel housing liner (front) .

84 Rep. gr.87 - Air conditioning system

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

CAUTION
Risk of frostbite from escaping pressurised refrigerant
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 re‐
frigerant 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 pres‐
sure in the refrigerant circuit.

– Unscrew bolt -B- and detach refrigerant line -C-.

– Remove bolt -A- and detach non-return valve -D- from refrig‐
erant line -E-.
Installing
Installation is carried out in reverse order; note the following:
• Pay attention to direction of flow of non-return valve -D- (stick‐
er).

– Renew O-rings -2-

⇒ “4.12 Refrigerant circuit seals”, page 14 .
– If fitted, check that dowel pins -6- at connections are not dam‐
aged and are seated correctly.

2. Refrigerant circuit 85
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

– Fit non-return valve -D- on refrigerant line -E- and screw in bolt
-A-.
– Attach refrigerant line -C- to non-return valve -D- and screw in
bolt -B- by hand until it makes contact.
– Check that refrigerant line -C- is routed correctly.
– Screw in bolts -B-.
– After attaching, check routing of refrigerant lines. They must
be inserted in brackets provided and should not make contact
with other components.
– Re-install components removed previously in reverse order
and/or re-attach detached components.
– 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 .
– Switch on ignition.
– Initiate air conditioner basic setting via thermal management
control unit - J1024- and use a routine stored there to open
electrically actuated valves ( Stop routine: Charging/
flushing refrigerant circuit ) ⇒ Vehicle diagnostic test‐
er.
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22.2 Starting up air conditioner after charging refrigerant
circuit - vehicles with high-voltage system”, page 109 .
Tightening torques
♦ ⇒ “2.6.3 Exploded view - refrigerant lines, vehicles with high-
voltage system”, page 50
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front)

2.16.2 Removing and installing non-return

valve in refrigerant line from refrigerant
receiver
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

Removing
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .

86 Rep. gr.87 - Air conditioning system

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

♦ There are different versions of the non-return valves (different

connections and internal diameters for flow rate); ensure cor‐
rect allocation ⇒ Electronic parts catalogue .
– Remove heat pump valve unit with bracket
⇒ “3.2 Removing and installing bracket with heat pump valve
unit”, page 131 .
– Remove bolts -A and C-.
– Remove non-return valve -B-.
Installing
Installation is carried out in reverse order; note the following:
• Pay attention to direction of flow of non-return valve -B- (stick‐
er).

– Renew O-rings -2-

⇒ “4.12 Refrigerant circuit seals”, page 14 .
– If fitted, check that dowel pins -6- at connections are not dam‐
aged and are seated correctly.

2. Refrigerant circuit 87
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

– Install non-return valve -B-.

– Screw in bolts -A, C-.
– After attaching, check routing of refrigerant lines. They must
be inserted in brackets provided and should not make contact
with other components.
– Install heat pump valve unit with bracket
⇒ “3.2 Removing and installing bracket with heat pump valve
unit”, page 131 .
– Re-install components removed previously in reverse order
and/or re-attach detached components.
– 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 .
– Switch on ignition.
– Initiate air conditioner basic setting via thermal management
control unit - J1024- and use a routine stored there to open
electrically actuated valves ( Stop routine: Charging/
flushing refrigerant circuit ) ⇒ Vehicle diagnostic test‐
er.
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22.2 Starting up air conditioner after charging refrigerant
circuit - vehicles with high-voltage system”, page 109 .
Tightening torques
♦ ⇒ “2.6.3 Exploded view - refrigerant lines, vehicles with high-
voltage system”, page 50

2.16.3 Removing and installing non-return

valve in refrigerant line from condenser
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

Removing
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
♦ There are different versions of the non-return valves (different
connections and internal diameters for flow rate); ensure cor‐
rect allocation ⇒ Electronic parts catalogue .
– Remove heat pump valve unit with bracket
⇒ “3.2 Removing and installing bracket with heat pump valve
unit”, page 131 .

88 Rep. gr.87 - Air conditioning system

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

– Remove bolt -B-.

– Remove non-return valve -C-.
Installing
Installation is carried out in reverse order; note the following:
• Pay attention to direction of flow of non-return valve -C- (stick‐
er).

– Renew O-rings -2-

⇒ “4.12 Refrigerant circuit seals”, page 14 .
– If fitted, check that dowel pins -6- at connections are not dam‐
aged and are seated correctly.

– Install non-return valve -C-.

– Screw in bolt -B-.
– Seal off connection on non-return valve -C- with a clean plug
from engine bung set - VAS 6122- .
– Install heat pump valve unit with bracket
⇒ “3.2 Removing and installing bracket with heat pump valve
unit”, page 131 .
– After attaching, check routing of refrigerant lines. They must
be inserted in brackets provided and should not make contact
with other components.
– Re-install components removed previously in reverse order
and/or re-attach detached components.
– 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 .
– Switch on ignition.
– Initiate air conditioner basic setting via thermal management
control unit - J1024- and use a routine stored there to open
electrically actuated valves ( Stop routine: Charging/
flushing refrigerant circuit ) ⇒ Vehicle diagnostic test‐
er.
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22.2 Starting up air conditioner after charging refrigerant
circuit - vehicles with high-voltage system”, page 109 .
Tightening torques
♦ ⇒ “2.6.3 Exploded view - refrigerant lines, vehicles with high-
voltage system”, page 50

2. Refrigerant circuit 89
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

2.16.4 Removing and installing non-return

valve in refrigerant line from valve block
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

Removing
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
♦ There are different versions of the non-return valves (different
connections and internal diameters for flow rate); ensure cor‐
rect allocation ⇒ Electronic parts catalogue .
– Remove heat pump valve unit with bracket
⇒ “3.2 Removing and installing bracket with heat pump valve
unit”, page 131 .
– Remove bolts -A, D-.
– Remove non-return valve -E-.
Installing
Installation is carried out in reverse order; note the following:
• Pay attention to direction of flow of non-return valve -E- (stick‐
er).

– Renew O-rings -2-

⇒ “4.12 Refrigerant circuit seals”, page 14 .
– If fitted, check that dowel pins -6- at connections are not dam‐
aged and are seated correctly.

90 Rep. gr.87 - Air conditioning system

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

– Install non-return valve -E-.

– Screw in bolts -A, D-.
– After attaching, check routing of refrigerant lines. They must
be inserted in brackets provided and should not make contact
with other components.
– Install heat pump valve unit with bracket
⇒ “3.2 Removing and installing bracket with heat pump valve
unit”, page 131 .
– Re-install components removed previously in reverse order
and/or re-attach detached components.
– 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 .
– Switch on ignition.
– Initiate air conditioner basic setting via thermal management
control unit - J1024- and use a routine stored there to open
electrically actuated valves ( Stop routine: Charging/
flushing refrigerant circuit ) ⇒ Vehicle diagnostic test‐
er.
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22.2 Starting up air conditioner after charging refrigerant
circuit - vehicles with high-voltage system”, page 109 .
Tightening torques
♦ ⇒ “2.6.3 Exploded view - refrigerant lines, vehicles with high-
voltage system”, page 50

2.17 Unfastening and assembling connection

points in refrigerant lines
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

Unfastening
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
– Switch on ignition.
– Initiate basic setting of air conditioner via thermal manage‐
ment control unit - J1024- ; use the Extract, evacuate and

2. Refrigerant circuit 91
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

charge refrigerant circuit routine stored there to open

electrically actuated valves ⇒ Vehicle diagnostic tester.
– Switch off ignition.
All vehicles (continued)
– Remove components which prevent access (depending on
joint).
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station .

92 Rep. gr.87 - Air conditioning system

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

CAUTION
Risk of frostbite from escaping pressurised refrigerant
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 re‐
frigerant 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 pres‐
sure in the refrigerant circuit.

– Remove bolt -A-.

– Disconnect connection points of refrigerant lines -B, C-.
Assembling
Installation is carried out in reverse order; note the following:
– Clean refrigerant lines thoroughly in connection area of con‐
nection points and check for damage.
– Renew O-rings -D-, for different versions refer to ⇒ Electronic
parts catalogue .
– Lubricate O-rings -D- lightly with refrigerant oil before installing
⇒ “4.12 Refrigerant circuit seals”, page 14 .
– If fitted, check that dowel pins are not damaged and are seated
correctly.
– Observe different tightening torques of bolt -A-.
– After attaching, check routing of refrigerant lines: they must be
fitted tension-free in appropriate brackets and must not make
contact with any other components.
– Re-install components removed previously in reverse order
and/or re-attach detached components.
– 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 .
Vehicles with high-voltage system
– Switch on ignition.
– Initiate basic setting of air conditioner via thermal manage‐
ment control unit - J1024- ; use the Stop routine: Charg-
ing/flushing refrigerant circuit stored there to open
electrically actuated valves ⇒ Vehicle diagnostic tester.
All vehicles (continued)
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22 Starting up air conditioner after charging refrigerant
circuit”, page 108 .

2. Refrigerant circuit 93
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Heating, air conditioning - Edition 12.2018

2.18 Removing and installing condenser

⇒ “2.18.1 Removing and installing condenser - vehicles without
high-voltage system”, page 94
⇒ “2.18.2 Removing and installing condenser - vehicles with high-
voltage system”, page 96

2.18.1 Removing and installing condenser - ve‐

hicles without high-voltage system
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

Removing
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
♦ 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 remedied
by bending the lugs back into position, provided that the con‐
denser (refrigerant circuit) is still functioning properly and that
there is no leakage. If the lugs are slightly deformed, the con‐
denser need not 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 (refrigerant cir‐
cuit) is still functioning properly and there is no leakage.
– Remove lock carrier cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Bumper (front); Exploded view - bumper cover .
– Remove bolts -arrows- and detach air ducts -1, 2-.
– Separate refrigerant lines from condenser
⇒ “2.19 Detaching and attaching refrigerant lines at condens‐
er”, page 98 .

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All vehicles (except S6/S7 with TDI, V6 2.9 ltr. TFSI engine)
– Remove mounting bracket with Bowden cable and move to
rear ⇒ General body repairs, exterior; Rep. gr. 55 ; Bonnet;
Exploded view - Bowden cable .
– Release air duct (left-side) and catches -arrow-, swivel air duct
-3- inwards and detach it.
– Unclip air duct (right-side) -1- at top only -arrow- and pull it as
far forwards as possible.

– Unplug electrical connector -2-.

– Release fasteners -arrows- and detach condenser -1- slightly
from radiator.
– Detach condenser -1- upwards from mountings on radiator,
keeping an eye on air duct (right-side).
S6/S7 with TDI, V6 2.9 ltr. TFSI engine

– Vehicles with V6 TDI engine: Remove charge air cooler ⇒ 6-

cylinder TDI engine, 3.0 ltr. 4-valve common rail; Rep. gr. 21 ;
Charge air system; Removing and installing charge air cooler .
– Release catches -arrow-, swivel air ducts -1, 3- inwards and
detach.

2. Refrigerant circuit 95
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– Unplug electrical connector -2-.

– Release fasteners -arrows- and detach condenser -1- slightly
from radiator.
– Pull condenser -1- upwards out of its mountings on radiator
and take it out downwards.
Installing
Installation is carried out in reverse order; note the following:
– When it has been removed, the condenser contains refrigerant
oil which must be returned to the refrigerant circuit (together
with the new condenser) ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Renewing components of refrigerant cir‐
cuit , or ⇒ Air conditioners with refrigerant R1234yf - General
information; Rep. gr. 87 ; Refrigerant circuit; Renewing com‐
ponents .
– Evacuate and charge refrigerant circuit ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air
conditioners with refrigerant R1234yf - General information;
Rep. gr. 87 ; Working with the air conditioner service station .
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22 Starting up air conditioner after charging refrigerant
circuit”, page 108 .
Tightening torques
♦ ⇒ Engine; Rep. gr. 23 ; Air cleaner; Exploded view - air clean‐
er housing , or ⇒ Engine; Rep. gr. 24 ; Air cleaner; Exploded
view - air cleaner housing

2.18.2 Removing and installing condenser - ve‐

hicles with high-voltage system
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

Removing
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
♦ 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 remedied
by bending the lugs back into position, provided that the con‐
denser (refrigerant circuit) is still functioning properly and that

96 Rep. gr.87 - Air conditioning system

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there is no leakage. If the lugs are slightly deformed, the con‐

denser need not 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 (refrigerant cir‐
cuit) is still functioning properly and there is no leakage.
– Separate refrigerant lines from condenser
⇒ “2.19.3 Detaching and attaching refrigerant lines at con‐
denser - vehicles with high-voltage system”, page 101 .
– Remove mounting bracket with Bowden cable and move to
rear ⇒ General body repairs, exterior; Rep. gr. 55 ; Bonnet;
Exploded view - Bowden cable .
– Release catch -5-, detach auxiliary radiator -1- and place it
down to one side.
– Remove bolts -4- and remove bracket -2- for auxiliary radiator
upwards in direction of -arrows-.

– Release fasteners on bracket -1- -arrows- and detach con‐

denser -3- slightly from radiator.
– Detach condenser -3- upwards from mountings -2-, keeping
an eye on air duct (right-side).
Installing
Installation is carried out in reverse order; note the following:
– 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 .
– Switch on ignition.
– Initiate air conditioner basic setting via thermal management
control unit - J1024- and use a routine stored there to open
electrically actuated valves ( Stop routine: Charging/
flushing refrigerant circuit ) ⇒ Vehicle diagnostic test‐
er.
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22.2 Starting up air conditioner after charging refrigerant
circuit - vehicles with high-voltage system”, page 109 .
Tightening torques
♦ ⇒ Engine; Rep. gr. 23 ; Air cleaner; Exploded view - air clean‐
er housing , or ⇒ Engine; Rep. gr. 24 ; Air cleaner; Exploded
view - air cleaner housing
♦ ⇒ General body repairs, exterior; Rep. gr. 55 ; Bonnet; Ex‐
ploded view - Bowden cable
♦ ⇒ 4-cylinder direct injection engine (2.0 ltr. 4-valve TFSI, EA
888 Gen. III); Rep. gr. 19 ; Radiators/radiator fans; Exploded
view - radiators/radiator fans

2. Refrigerant circuit 97
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2.19 Detaching and attaching refrigerant

lines at condenser
⇒ “2.19.1 Detaching and attaching refrigerant lines at condenser
- vehicles with 4-cyl. TDI engine, S6/S7 models with TFSI engine”,
page 98
⇒ “2.19.2 Detaching and attaching refrigerant lines at condenser
- vehicles with 4-cyl. TFSI engine (without high-voltage system),
all vehicles with V6 engine except S6/S7 models with TFSI en‐
gine”, page 99
⇒ “2.19.3 Detaching and attaching refrigerant lines at condenser
- vehicles with high-voltage system”, page 101

2.19.1 Detaching and attaching refrigerant

lines at condenser - vehicles with 4-cyl.
TDI engine, S6/S7 models with TFSI en‐
gine
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

Detaching
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
– Switch off ignition.
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station .
Vehicles with 4-cyl. TDI engine
– Remove air intake grille (left-side) ⇒ General body repairs,
exterior; Rep. gr. 63 ; Bumper (front); Exploded view - bumper
cover .
S6/S7 with TFSI engine
– Remove closure plate at bumper cover ⇒ General body re‐
pairs, exterior; Rep. gr. 63 ; Bumper (front); Exploded view -
bumper cover .

98 Rep. gr.87 - Air conditioning system

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All vehicles (continued)

CAUTION
Risk of frostbite from escaping pressurised refrigerant
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 re‐
frigerant 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 pres‐
sure in the refrigerant circuit.

– Remove bolt -C-.

– Detach refrigerant lines -B, D- from condenser.
– Seal open lines and connections with clean plugs from engine
bung set - VAS 6122- .

Attaching
Attaching is carried out in the reverse order; note the following:
– Clean refrigerant line connections on condenser -C- and re‐
frigerant lines -A, E-, and check for damage.
– Renew O-rings -D-
⇒ “4.12 Refrigerant circuit seals”, page 14 .
– Insert refrigerant lines in connections on condenser.
– After attaching, check routing of refrigerant lines: they must be
fitted tension-free in appropriate brackets and must not make
contact with any other components.
– Evacuate and charge refrigerant circuit ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air
conditioners with refrigerant R1234yf - General information;
Rep. gr. 87 ; Working with the air conditioner service station .
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22 Starting up air conditioner after charging refrigerant
circuit”, page 108 .
Tightening torques
♦ ⇒ “2.6.1 Exploded view - refrigerant lines, air conditioner com‐
pressor and condenser”, page 46

2.19.2 Detaching and attaching refrigerant

lines at condenser - vehicles with 4-cyl.
TFSI engine (without high-voltage sys‐
tem), all vehicles with V6 engine except
S6/S7 models with TFSI engine
Special tools and workshop equipment required

2. Refrigerant circuit 99
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♦ Engine bung set - VAS 6122-

Detaching
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
– Switch off ignition.
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station .
– Remove lock carrier cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Bumper (front); Exploded view - bumper cover .
Vehicles with 4-cyl. TFSI engine (without high-voltage system)
– Remove air intake grille (left-side) ⇒ General body repairs,
exterior; Rep. gr. 63 ; Bumper (front); Exploded view - bumper
cover .
All vehicles with V6 (except S6/S7 models with TFSI engine)
– Remove closure plate at bumper cover ⇒ General body re‐
pairs, exterior; Rep. gr. 63 ; Bumper (front); Exploded view -
bumper cover .
Vehicles with V6 TDI engine with charge air cooler
Remove air hose (left-side) from charge air cooler ⇒ 6-cylinder
TDI engine, 3.0 ltr. 4-valve common rail; Rep. gr. 21 ; Charge air
system; Removing and installing charge air cooler .
– Release air duct (left-side) and catches -arrow-, swivel air duct
-3- inwards and detach it.

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All vehicles

CAUTION
Risk of frostbite from escaping pressurised refrigerant
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 re‐
frigerant 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 pres‐
sure in the refrigerant circuit.

– Unscrew bolts -A-.

– Detach refrigerant lines -B, C- from condenser.
Attaching
Attaching is carried out in the reverse order; note the following:
– Clean refrigerant line connections at condenser and refriger‐
ant lines and check for damage.
– Renew O-rings ⇒ “4.12 Refrigerant circuit seals”, page 14 .
– Insert refrigerant lines in connections on condenser.
– After attaching, check routing of refrigerant lines: they must be
fitted tension-free in appropriate brackets and must not make
contact with any other components.
– Evacuate and charge refrigerant circuit ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air
conditioners with refrigerant R1234yf - General information;
Rep. gr. 87 ; Working with the air conditioner service station .
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22 Starting up air conditioner after charging refrigerant
circuit”, page 108 .
Tightening torques
♦ ⇒ “2.6.1 Exploded view - refrigerant lines, air conditioner com‐
pressor and condenser”, page 46

2.19.3 Detaching and attaching refrigerant

lines at condenser - vehicles with high-
voltage system
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

2. Refrigerant circuit 101

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Detaching
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
Working with ignition switched on or high-voltage system active
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
– Switch on ignition.
– Initiate basic setting of air conditioner via thermal manage‐
ment control unit - J1024- ; use the Extract, evacuate and
charge refrigerant circuit routine stored there to open
electrically actuated valves ⇒ Vehicle diagnostic tester.
– Switch off ignition.
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station .
– Remove charge air cooler ⇒ 4-cylinder direct injection engine
(2.0 ltr. 4-valve TFSI, EA 888 Gen. III); Rep. gr. 21 ; Charge
air system; Removing and installing charge air cooler .

102 Rep. gr.87 - Air conditioning system

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CAUTION
Risk of frostbite from escaping pressurised refrigerant
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 re‐
frigerant 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 pres‐
sure in the refrigerant circuit.

– Unscrew bolts -A-.

– Detach refrigerant lines -B, C- from condenser.
Attaching
Attaching is carried out in the reverse order; note the following:
– Clean refrigerant line connections at condenser and refriger‐
ant lines and check for damage.
– Renew O-rings ⇒ “4.12 Refrigerant circuit seals”, page 14 .
– Insert refrigerant lines in connections on condenser.
– After attaching, check routing of refrigerant lines: they must be
fitted tension-free in appropriate brackets and must not make
contact with any other components.
– 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 .
– Switch on ignition.
– Initiate air conditioner basic setting via thermal management
control unit - J1024- and use a routine stored there to open
electrically actuated valves ( Stop routine: Charging/
flushing refrigerant circuit ) ⇒ Vehicle diagnostic test‐
er.
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22.2 Starting up air conditioner after charging refrigerant
circuit - vehicles with high-voltage system”, page 109 .
Tightening torques
♦ ⇒ “2.6.3 Exploded view - refrigerant lines, vehicles with high-
voltage system”, page 50

2.20 Removing and installing desiccant bag/

desiccant cartridge
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
– Switch on ignition.
– Initiate basic setting of air conditioner via thermal manage‐
ment control unit - J1024- ; use the Extract, evacuate and

2. Refrigerant circuit 103

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charge refrigerant circuit routine stored there to open

electrically actuated valves ⇒ Vehicle diagnostic tester.
– Switch off ignition.
All vehicles (continued)
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station .
All vehicles (except those with 4-cyl. TDI engine and S6/S7 mod‐
els with TFSI engine)
– Remove lock carrier cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Bumper (front); Exploded view - bumper cover .
– Remove bolts -arrows- and detach air duct -1-.
Vehicles with 4-cyl. TDI engine, S6/S7 models with TFSI engine
– Remove closure plate at bumper cover ⇒ General body re‐
pairs, exterior; Rep. gr. 63 ; Bumper (front); Exploded view -
bumper cover .

All vehicles

CAUTION
Risk of frostbite from escaping pressurised refrigerant
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 re‐
frigerant 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 pres‐
sure in the refrigerant circuit.

– Unscrew plug -A-.

– Remove desiccant bag from condenser -B-.
– Seal off open connection on receiver for condenser using
screw plug -A- to prevent dirt and moisture from entering.

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Installing
Installation is carried out in reverse order; note the following:
♦ Make sure that receiver -E- and thread on condenser are not
dirty or damaged by checking through opening -arrow-.
♦ Renew screw plug -A- together with filter element and the two
O-rings -B, C- (supplied together with dryer ⇒ Electronic parts
catalogue ).
♦ Lubricate O-rings -B, C- lightly with refrigerant oil before fitting
⇒ “4.12 Refrigerant circuit seals”, page 14 .
♦ Make sure that O-rings are correctly seated in grooves of cor‐
responding components.
♦ Keep bag with air-tight seal containing desiccant bag -D-
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.
– Take desiccant bag -D- out of its bag and insert it in receiver.
– Fit plug -A- together with O-rings -B, C-.
– 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 .
Vehicles with high-voltage system
– Switch on ignition.
– Initiate air conditioner basic setting via thermal management
control unit - J1024- and use a routine stored there to open
electrically actuated valves ( Stop routine: Charging/
flushing refrigerant circuit ) ⇒ Vehicle diagnostic test‐
er.
All vehicles (continued)
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22 Starting up air conditioner after charging refrigerant
circuit”, page 108 .
Tightening torques
♦ ⇒ “2.2 Exploded view - condenser”, page 38
♦ ⇒ Engine; Rep. gr. 24 ; Air cleaner; Exploded view - air clean‐
er housing
♦ ⇒ Engine; Rep. gr. 23 ; Air cleaner; Exploded view - air clean‐
er housing
♦ ⇒ General body repairs, exterior; Rep. gr. 63 ; Bumper (front);
Exploded view - bumper cover

2.21 Removing and installing evacuating and

charging valve (low-pressure and high-
pressure sides)
Special tools and workshop equipment required

2. Refrigerant circuit 105

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♦ Torque screwdriver - VAS 6494-

♦ Engine bung set - VAS 6122-

♦ Adapter set for service connections - T10364-

♦ For further information on the service connection, refer to ⇒

Air conditioner with refrigerant R134a; Rep. gr. 87 ; General
information on air conditioning systems , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Refrigerant circuit; General description of refrigerant circuit
components .
Note
♦ Different fitting locations for service connections
⇒ “1.1 Overview of fitting locations - components not located
in passenger compartment”, page 23
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
– Switch on ignition.
– Initiate basic setting of air conditioner via thermal manage‐
ment control unit - J1024- ; use the Extract, evacuate and

106 Rep. gr.87 - Air conditioning system

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charge refrigerant circuit routine stored there to open

electrically actuated valves ⇒ Vehicle diagnostic tester.
– Switch off ignition.
All vehicles (continued)
– Unscrew cap (with seal) -A- or -B-.
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station .

CAUTION
Risk of frostbite from escaping pressurised refrigerant
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 re‐
frigerant 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 pres‐
sure in the refrigerant circuit.

– Unscrew valve -C- with suitable socket from adapter set for
service connections - T10364- .
Installing
Installation is carried out in reverse order; note the following:
♦ The evacuating and charging valves vary depending on the
refrigerant type ⇒ Electronic parts catalogue .
– Evacuate and charge refrigerant circuit ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air
conditioners with refrigerant R1234yf - General information;
Rep. gr. 87 ; Working with the air conditioner service station .
Vehicles with high-voltage system
– Switch on ignition.
– Initiate basic setting of air conditioner via thermal manage‐
ment control unit - J1024- ; use the Stop routine: Charg-
ing/flushing refrigerant circuit stored there to open
electrically actuated valves ⇒ Vehicle diagnostic tester.
All vehicles (continued)
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22 Starting up air conditioner after charging refrigerant
circuit”, page 108 .
Tightening torques
♦ ⇒ “2.6.2 Exploded view - internal heat exchanger refrigerant
lines in plenum chamber and expansion valve”, page 48

2. Refrigerant circuit 107

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2.22 Starting up air conditioner after charging

refrigerant circuit
⇒ “2.22.1 Starting up air conditioner after charging refrigerant cir‐
cuit - vehicles without high-voltage system”, page 108
⇒ “2.22.2 Starting up air conditioner after charging refrigerant cir‐
cuit - vehicles with high-voltage system”, page 109

2.22.1 Starting up air conditioner after charging

refrigerant circuit - vehicles without high-
voltage system
♦ 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 , or ⇒ Air conditioners with refrigerant
R1234yf - General information; Rep. gr. 87 ; Working with the
air conditioner service station; Starting up air conditioner after
charging .
♦ Also observe notes on starting up air conditioner after charging
⇒ Air conditioner with refrigerant R134a; Rep. gr. 87 ; General
information on air conditioning systems , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. 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).
Should it be necessary to start the engine with an empty refrig‐
erant circuit, please observe the following:
♦ The refrigerant circuit must have been assembled completely.
♦ There must not be any vacuum in the refrigerant circuit.
♦ There must be at least a quarter of the amount of refrigerant
oil specified for this refrigerant circuit in the air conditioner
compressor.
♦ Engine speed must not exceed 2500 rpm.
• If it has been removed, give the mechanically driven air con‐
ditioner compressor approx. 10 turns by hand prior to initial
start-up (on or after installation, e.g. before fitting the belt) to
prevent damage caused by fluid lock when first switched on
(any refrigerant oil in the air conditioner compressor cylinder
is forced out by the cranking action)
⇒ “4.5 Removing and installing air conditioner compressor”,
page 170 .
If the air conditioner compressor has been renewed:
– Additionally perform test plan for automatic compressor run-in
⇒ Vehicle diagnostic tester.
– Connect ⇒ Vehicle diagnostic tester.
– Select Diagnosis mode and begin diagnosis.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 0009 - Electronic central electrics - J519
♦ 0009 - Electronic central electrics, functions
♦ 0009 - Basic setting for AC functions

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♦ 0009 - Automatic compressor run-in (basic setting 3)

All vehicles (continued)
Proceed as follows when starting the engine for the first time after
charging the refrigerant circuit:
– Switch on ignition.
– Set display unit 2 for front information display and operating
unit control unit - J1060- to “OFF”; red bar on A/C button will
not light up. Air conditioner and activation of air conditioner
compressor via air conditioner compressor regulating valve -
N280- are switched off.
– Start engine with air conditioner compressor switched off (set
to “OFF”) and run at idling speed for at least 5 minutes.
– Open all vents in dash panel, rear centre console and B-pillars.
– Switch on air conditioner and activation of the air conditioner
compressor by pressing Auto button on -E87- (“Auto” mode
selected and lamps in AUTO buttons and A/C button of display
unit 2 for front information display and operating unit control
unit - J1060- on).
– Activate SYNC and Rear functions on display unit 2 for front
information display and operating unit control unit - J1060- if
possible.
– On display unit 2 for front information display and operating
unit control unit - J1060- (and on -E265- if fitted), check lamps
in AUTO buttons; if these are off, press AUTO buttons.
– Set temperature for all zones to “cold”.
– Allow engine to idle for at least 5 minutes with air conditioner
compressor switched on.

2.22.2 Starting up air conditioner after charging

refrigerant circuit - vehicles with high-
voltage system
For all work on vehicles with high-voltage system, note additional
warnings for working on such vehicles
⇒ “1 Safety precautions”, page 1 .
For the following steps, work in the vicinity of high-voltage system
components is necessary. Therefore, perform a visual inspection
of the high-voltage components and wiring to check for damage
⇒ “1 Safety precautions”, page 1 .
Working with ignition switched on or high-voltage system active
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
• All components removed have been re-installed.
• The refrigerant circuit is charged ⇒ Air conditioner with refrig‐
erant R134a; Rep. gr. 87 ; Refrigerant circuit (Working with
the air conditioner service station), or ⇒ Air conditioners with
refrigerant R1234yf - General information; Rep. gr. 87 ; Work‐
ing with the air conditioner service station; Starting up air
conditioner after charging .
• Switch on ignition.
• Initiate air conditioner basic setting via thermal management
control unit - J1024- and use a routine stored there to open
electrically actuated valves ( Stop routine: Charging/
flushing refrigerant circuit ) ⇒ Vehicle diagnostic test‐
er.

2. Refrigerant circuit 109

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NOTICE
Risk of damage to electrically driven air conditioner compressor
if air conditioner is started up when the refrigerant circuit is
empty
– An electrically driven air conditioner compressor may only
be started up when the refrigerant circuit is charged.

– Start up the electrical air conditioner compressor - V470- via

the Compressor run-in function; proceed as follows to do
so.
Procedure
– Connect ⇒ Vehicle diagnostic tester.
– Select Diagnosis mode and begin diagnosis.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Body
♦ Heating, ventilation, air conditioning system
♦ Self-diagnosis compatible systems
♦ C5 - Thermal management control unit J1024
♦ C5 - Basic setting
♦ ⇒ Compressor run-in, automatic start

2.23 Cleaning air conditioner refrigerant cir‐

cuit - vehicles with high-voltage system
⇒ “2.23.1 Notes on cleaning (flushing) refrigerant circuit”,
page 110
⇒ “2.23.2 Tools required for cleaning refrigerant circuit”,
page 111
⇒ “2.23.3 Preparations for cleaning refrigerant circuit”,
page 112
⇒ “2.23.4 Cleaning refrigerant circuit (routine 1)”, page 115
⇒ “2.23.5 Cleaning refrigerant circuit (routine 2)”, page 118
⇒ “2.23.6 Cleaning refrigerant circuit (routine 3) ”, page 121
⇒ “2.23.7 Cleaning refrigerant circuit (routine 4) ”, page 124

2.23.1 Notes on cleaning (flushing) refrigerant

circuit
♦ Before cleaning the refrigerant circuit of vehicles with a high-
voltage system, various electrically operated valves must be
in a certain position ⇒ Vehicle diagnostic tester. In addition,
various components (non-return and shut-off valves) must be
removed and replaced with manually activated shut-off valves
⇒ “2.23.4 Cleaning refrigerant circuit (routine 1)”, page 115 .
♦ To make sure that the entire refrigerant circuit is cleaned
(flushed), the circuit must be flushed four times, with the re‐
frigerant flowing in a different direction each time (see flushing
routines “1” to “4”).
♦ Flush refrigerant circuit if particular problems occur which
make it necessary to do so ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit (Cleaning refrigerant

110 Rep. gr.87 - Air conditioning system

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circuit with refrigerant R134a), or ⇒ Air conditioners with re‐

frigerant R1234yf - General information; Rep. gr. 87 ; Working
with the air conditioner service station; Cleaning refrigerant
circuit .
♦ The cleanest, most environmentally responsible method of re‐
moving moisture, contaminants (e.g. abraded material from a
defective air conditioner compressor) and old refrigerant oil is
to clean (flush) the refrigerant circuit with refrigerant R134a or
R1234yf as well. This conserves refrigerant and does not re‐
quire extensive repair work.
♦ If only the air conditioner compressor needs to be renewed
(e.g. due to an electrical fault), it is not always necessary to
flush the entire refrigerant circuit. In this case, it may be suffi‐
cient to flush just the air conditioner compressor (e.g. to de‐
termine the amount of refrigerant oil in the air conditioner
compressor after it has been removed) ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit (Cleaning
refrigerant circuit with refrigerant R134a), or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station; Cleaning elec‐
trically driven air conditioner compressor .
♦ For additional information, refer to ⇒ Air conditioner with re‐
frigerant R134a; Rep. gr. 87 ; Refrigerant circuit (Cleaning
refrigerant circuit with refrigerant R134a), or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station; Cleaning re‐
frigerant circuit .
♦ After cleaning of the refrigerant circuit is complete, specific
components must be renewed ⇒ page 127 .

2.23.2 Tools required for cleaning refrigerant

circuit
Special tools and workshop equipment required
♦ Air conditioner service station with flushing attachment (⇒
Electronic parts catalogue ) and with sufficient refrigerant
R134a or R1234yf ⇒ Air conditioner with refrigerant R134a;
Rep. gr. 87 ; Refrigerant circuit (Cleaning refrigerant circuit
with refrigerant R134a), or ⇒ Air conditioners with refrigerant
R1234yf - General information; Rep. gr. 87 ; Working with the
air conditioner service station; Cleaning refrigerant circuit .
♦ Adapters -VAS 6338/3- and -VAS 6338/12- from adapter set
for refrigerant circuit - VAS 6338/1-

2. Refrigerant circuit 111

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♦ Shut-off valve - VAS 6338/42-

♦ Set of adapter valves - VAS 6338/47- (with 3x shut-off valve -

VAS 6338/47-1- -items A, B, C- and 1x shut-off valve - VAS
6338/47-2- -item D-).

2.23.3 Preparations for cleaning refrigerant cir‐

cuit
For all work on vehicles with high-voltage system, note additional
warnings for working on such vehicles
⇒ “1 Safety precautions”, page 1 .
For the following steps, work in the vicinity of high-voltage system
components is necessary. Therefore, perform a visual inspection
of the high-voltage components and wiring to check for damage
⇒ “1 Safety precautions”, page 1 .
Working with ignition switched on or high-voltage system active

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or electric
arcs.
– Have an Audi high-voltage technician (HVT) or an Audi high-
voltage expert (HVE) de-energise the high-voltage system.

– De-energise high-voltage system ⇒ Rep. gr. 93 ; De-ener‐

gising high-voltage system .
– Switch on ignition.
– Initiate basic setting of air conditioner via thermal manage‐
ment control unit - J1024- ; use the “Extract, evacuate and

112 Rep. gr.87 - Air conditioning system

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charge refrigerant circuit” routine stored there to open electri‐

cally actuated valves ⇒ Vehicle diagnostic tester.
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station .
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
– Switch off ignition.

CAUTION
Risk of frostbite from escaping pressurised refrigerant
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 re‐
frigerant 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 pres‐
sure in the refrigerant circuit.

– Remove electrically driven air conditioner compressor and at‐

tach adapters -VAS 6338/12- and -VAS 6338/3- to connection
lines in vehicle
⇒ “4.5.8 Removing and installing electrically driven air condi‐
tioner compressor”, page 182 .
– Remove non-return valves -A, B, C, D- from refrigerant lines
and install shut-off valves from adapter valve set - VAS
6338/47- in their place.
♦ Non-return valve -A- should be exchanged for shut-off valve -
VAS 6338/47-2-
⇒ “2.16.1 Removing and installing non-return valve in
refrigerant line from internal heat exchanger”, page 84 .
♦ Non-return valve -B- should be exchanged for shut-off valve -
VAS 6338/47-1-
⇒ “2.16.4 Removing and installing non-return valve in
refrigerant line from valve block”, page 90 .
♦ Non-return valve -C- should be exchanged for shut-off valve -
VAS 6338/47-1-
⇒ “2.16.3 Removing and installing non-return valve in
refrigerant line from condenser”, page 88 .
♦ Non-return valve -D- should be exchanged for shut-off valve -
VAS 6338/47-1-
⇒ “2.16.2 Removing and installing non-return valve in
refrigerant line from refrigerant receiver”, page 86 .
• It must be possible to move operating lever for shut-off valves
from adapter valve set - VAS 6338/47- through its entire ad‐
justment range after installation.
Note
♦ Mark allocation of shut-off valves -A, B, C, D- installed in ve‐
hicle to prevent mixing them up when opening/closing them
before the different routines
⇒ “2.23.4 Cleaning refrigerant circuit (routine 1)”, page 115 .
– Remove expansion valve (front) and install adapter -VAS
6338/44- in its place
⇒ “2.15 Removing and installing expansion valve”, page 81 .

2. Refrigerant circuit 113

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– Remove refrigerant shut-off valve - V424- and install shut-off

valve - VAS 6338/42- in its place
⇒ “2.14 Removing and installing refrigerant shut-off valve
V424 ”, page 79 .
• It must be possible to move operating lever -arrow- through its
entire adjustment range after installation.
– Remove desiccant bag from condenser receiver and then re-
seal receiver
⇒ “2.20 Removing and installing desiccant bag/desiccant car‐
tridge”, page 103 .
– If necessary, clean filter element on cap before re-installing.
– Screw caps with seals onto both service connections of re‐
frigerant circuit
⇒ “2.1 System overview - refrigerant circuit”, page 31 .
Note
♦ The refrigerant circuit cannot be evacuated properly if caps
are not fitted, as air will enter when the vacuum in the refrig‐
erant circuit causes the valves in the service connections to
open.

114 Rep. gr.87 - Air conditioning system

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– Connect air conditioner service station -1- to refrigerant circuit

for flushing
⇒ “2.23.4 Cleaning refrigerant circuit (routine 1)”, page 115 .
♦ The -arrows- indicate the direction of refrigerant flow during
the flushing procedure.
Connection diagram
1- Air conditioner service station (with sufficient quantity of re‐
frigerant)
2- Refrigerant hose of air conditioner service station (low pres‐
sure side)
3- Flushing device
4- Refrigerant hose
5- Adapter - VAS 6338/3-
6- Vehicle refrigerant line with connection to air conditioner
compressor (high-pressure side)
7- Vehicle refrigerant line with connection to air conditioner
compressor (low-pressure side)
8- Adapter - VAS 6338/12-
9- Refrigerant hose of air conditioner service station (high-
pressure side)
– Open all manual shut-off valves fitted in flushing circuit
⇒ “2.23.4 Cleaning refrigerant circuit (routine 1)”, page 115 .
– Evacuate flushing circuit using air conditioner service station.
♦ If the various electrically operated valves in the valve block ( -
N640- , -N641- , -N642- and -N643- ) are not open or closed
as specified, it will not be possible to clean all the components
installed in the refrigerant circuit. The same applies to the
electrically operated refrigerant expansion valve 2 - N637- .
♦ If the various manual shut-off valves installed are not in the
correct position during the flushing procedure, it will not be
possible to clean all the components installed in the refrigerant
circuit.
♦ If one of the valves in the refrigerant circuit does not open or
close correctly, the flushing procedure and subsequent evac‐
uation of the refrigerant circuit may take considerably longer
or, depending on the flow rate of the valve in question, may
not be possible in the intended manner.
– Clean (flush out) first section of refrigerant circuit with refrig‐
erant R134a or R1234yf
⇒ “2.23.4 Cleaning refrigerant circuit (routine 1)”, page 115 .

2.23.4 Cleaning refrigerant circuit (routine “1”)

In this flushing procedure, the following components are cleaned:
evaporator in heater and air conditioning unit, condenser with re‐
ceiver, part of valve block and corresponding refrigerant lines.
Requirements:
♦ The preparations for cleaning the refrigerant circuit must have
been carried out
⇒ “2.23.3 Preparations for cleaning refrigerant circuit”,
page 112 .
Cleaning refrigerant circuit
– Initiate air conditioner basic setting via thermal management
control unit - J1024- and use a routine stored there to open or

2. Refrigerant circuit 115

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close the electrically activated valves for the first flushing pro‐
cedure (flushing routine “1”) ⇒ Vehicle diagnostic tester.

1 - -A-
Shut-off valve - VAS
6338/47-2-
2 - -B-
Shut-off valve - VAS
6338/47-1-
3 - -C-
Shut-off valve - VAS
6338/47-1-
4 - -D-
Shut-off valve - VAS
6338/47-1-

– Close or open shut-off valves fitted in flushing circuit as shown

in the following illustrations.
♦ The following illustrations only apply to components that are
directly affected by the flushing procedure; for all components
not described refer to
⇒ “2.1 System overview - refrigerant circuit”, page 31 .
♦ The colours of the lines in the following illustrations indicate
which components are flushed (red lines) due to the different
valve positions, which are only filled with refrigerant (green
lines) and which are not affected (blue lines).

116 Rep. gr.87 - Air conditioning system

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1 - Refrigerant shut-off valve 4

- N642- (closed via Basic set‐
ting function)
2 - Refrigerant shut-off valve 5
- N643- (closed via Basic set‐
ting function)
3 - Refrigerant shut-off valve 2
- N640- (closed via Basic set‐
ting function)
4 - Refrigerant shut-off valve 3
- N641- (opened via Basic set‐
ting function)
5 - Receiver on condenser
(desiccant bag removed and
re-sealed)
6 - Adapter - VAS 6338/3-
(connected to refrigerant hose
to flushing device)
7 - Adapter - VAS 6338/12-
(connected to refrigerant hose
of air conditioner service sta‐
tion on high-pressure side)
8 - Shut-off valve - VAS
6338/47-1- (installed in refrig‐
erant line from condenser,
opened manually)
⇒ Item 3 (page 116)
9 - Shut-off valve - VAS
6338/47-2- (installed in refrig‐
erant line from internal heat ex‐
changer, opened manually)
⇒ Item 1 (page 116)
10 - Refrigerant expansion
valve 2 - N637- (closed via Ba‐
sic setting function)
11 - Shut-off valves - VAS 6338/42- (installed in refrigerant line to expansion valve, opened manually)
12 - Adapter - VAS 6338/44- (installed in place of expansion valve to evaporator in front heater and air condi‐
tioning unit)
13 - Shut-off valve - VAS 6338/47-1- (installed in refrigerant line from refrigerant receiver, closed manually)
⇒ Item 4 (page 116)
14 - Shut-off valve - VAS 6338/47-1- (installed in refrigerant line from valve block, closed manually)
⇒ Item 2 (page 116)

– Select “Flush air conditioner” routine on connected air condi‐

tioner service station and start routine.
• Observe operating instructions supplied with air conditioner
service station .
• For notes on flushing procedure, refer to ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit (Cleaning
refrigerant circuit with refrigerant R134a), or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station; Cleaning re‐
frigerant circuit .
Wait until entire flushing procedure has been completed by air
conditioner service station.

2. Refrigerant circuit 117

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♦ The air conditioner service station displays when the flushing

procedure has been completed.
♦ The flushing procedure is complete when the air conditioner
service station has extracted the refrigerant from the flushing
circuit after the final flushing cycle.
♦ If refrigerant reaches areas it is not actually intended to reach
(areas indicated by blue lines) in this flushing routine because
a valve has not closed correctly, it can take a very long time
to extract all the refrigerant from the flushing circuit. You can
recognise a valve that does not close correctly e.g. by the fact
that this valve cools down due to refrigerant slowly evaporat‐
ing. The valve then constricts the flow. In this case, open all
manually operated shut-off valves and, if necessary, switch on
the air conditioner service station again, extract the remaining
refrigerant from the flushing circuit and evacuate the circuit
again.

CAUTION
If the flushing procedure is interrupted or the cleaning proce‐
dure is not continued when this routine has been completed,
there is a danger of frostbite from escaping pressurised refrig‐
erant.
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Before removing components of the flushing circuit or de‐
taching refrigerant lines, open all shut-off valves installed in
the flushing circuit.
– Initiate air conditioner basic setting via the thermal manage‐
ment control unit - J1024- and use a routine stored there to
open the various electrically activated valves ⇒ Vehicle di‐
agnostic tester.
– Check pressure in flushing circuit using air conditioner serv‐
ice station. If necessary, extract any remaining refrigerant
and open flushing circuit immediately afterwards.

When routine “1” has been completed, initiate and run routine “2”
⇒ “2.23.5 Cleaning refrigerant circuit (routine 2)”, page 118 .

2.23.5 Cleaning refrigerant circuit (routine “2”)

In this flushing procedure, the following components are cleaned:
heat exchanger for high-voltage battery and, again, condenser
with receiver, part of valve block and corresponding refrigerant
lines.
Requirements:
♦ Flushing routine “1” has been performed and completed suc‐
cessfully
⇒ “2.23.4 Cleaning refrigerant circuit (routine 1)”, page 115 .
Cleaning refrigerant circuit
– Initiate air conditioner basic setting via thermal management
control unit - J1024- and use a routine stored there to open or
close the electrically activated valves for the second flushing
procedure (flushing routine “2”) ⇒ Vehicle diagnostic tester.

118 Rep. gr.87 - Air conditioning system

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1 - -A- Shut-off valve - VAS

6338/47-2-
2 - -B- Shut-off valve - VAS
6338/47-1-
3 - -C- Shut-off valve - VAS
6338/47-1-
4 - -D- Shut-off valve - VAS
6338/47-1-

– Close or open shut-off valves fitted in flushing circuit as shown

in the following illustrations.
♦ The following illustrations only apply to components that are
directly affected by the flushing procedure; for all components
not described refer to
⇒ “2.1 System overview - refrigerant circuit”, page 31 .
♦ The colours of the lines in the following illustrations indicate
which components are flushed (red lines) due to the different
valve positions, which are only filled with refrigerant (green
lines) and which are not affected (blue lines).

2. Refrigerant circuit 119

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1 - Refrigerant shut-off valve 4

- N642- (closed via Basic set‐
ting function)
2 - Refrigerant shut-off valve 5
- N643- (closed via Basic set‐
ting function)
3 - Refrigerant shut-off valve 2
- N640- (closed via Basic set‐
ting function)
4 - Refrigerant shut-off valve 3
- N641- (opened via Basic set‐
ting function)
5 - Receiver on condenser
(desiccant bag removed and
re-sealed)
6 - Adapter - VAS 6338/3-
(connected to refrigerant hose
to flushing device)
7 - Adapter - VAS 6338/12-
(connected to refrigerant hose
of air conditioner service sta‐
tion on high-pressure side)
8 - Shut-off valve - VAS
6338/47-1- (installed in refrig‐
erant line from condenser,
opened manually)
⇒ Item 3 (page 119)
9 - Shut-off valve - VAS
6338/47-2- (installed in refrig‐
erant line from internal heat ex‐
changer, closed manually)
⇒ Item 1 (page 119)
10 - Refrigerant expansion
valve 2 - N637- (opened via
Basic setting function)
11 - Shut-off valves - VAS 6338/42- (installed in refrigerant line to expansion valve, closed manually)
12 - Adapter - VAS 6338/44- (installed in place of expansion valve to evaporator in front heater and air condi‐
tioning unit)
13 - Shut-off valve - VAS 6338/47-1- (installed in refrigerant line from refrigerant receiver, closed manually)
⇒ Item 4 (page 119)
14 - Shut-off valve - VAS 6338/47-1- (installed in refrigerant line from valve block, closed manually)
⇒ Item 2 (page 119)

– Select “Flush air conditioner” routine on connected air condi‐

tioner service station and start routine.
• Observe operating instructions supplied with air conditioner
service station .
• For notes on flushing procedure, refer to ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit (Cleaning
refrigerant circuit with refrigerant R134a), or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station; Cleaning re‐
frigerant circuit .
Wait until entire flushing procedure has been completed by air
conditioner service station.

120 Rep. gr.87 - Air conditioning system

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♦ The air conditioner service station displays when the flushing

procedure has been completed.
♦ The flushing procedure is complete when the air conditioner
service station has extracted the refrigerant from the flushing
circuit after the final flushing cycle.
♦ If refrigerant reaches areas it is not actually intended to reach
(areas indicated by blue lines) in this flushing routine because
a valve has not closed correctly, it can take a very long time
to extract all the refrigerant from the flushing circuit. You can
recognise a valve that does not close correctly e.g. by the fact
that this valve cools down due to refrigerant slowly evaporat‐
ing. The valve then constricts the flow. In this case, open all
manually operated shut-off valves and, if necessary, switch on
the air conditioner service station again, extract the remaining
refrigerant from the flushing circuit and evacuate the circuit
again.

CAUTION
If the flushing procedure is interrupted or the cleaning proce‐
dure is not continued when this routine has been completed,
there is a danger of frostbite from escaping pressurised refrig‐
erant.
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Before removing components of the flushing circuit or de‐
taching refrigerant lines, open all shut-off valves installed in
the flushing circuit.
– Initiate air conditioner basic setting via the thermal manage‐
ment control unit - J1024- and use a routine stored there to
open the various electrically activated valves ⇒ Vehicle di‐
agnostic tester.
– Check pressure in flushing circuit using air conditioner serv‐
ice station. If necessary, extract any remaining refrigerant
and open flushing circuit immediately afterwards.

When routine “2” has been completed, initiate and run routine “3”.

2.23.6 Cleaning refrigerant circuit (routine “3”)

In this flushing process, the following components are cleaned:
heat exchanger for heat pump operation, refrigerant receiver, part
of valve block and corresponding refrigerant lines. To achieve the
highest possible flow rate, the refrigerant is conveyed through the
heat exchanger for high-voltage battery and the evaporator.
Requirements:
♦ Flushing routine “2” has been performed and completed suc‐
cessfully
⇒ “2.23.5 Cleaning refrigerant circuit (routine 2)”, page 118 .
Cleaning refrigerant circuit
– Initiate air conditioner basic setting via thermal management
control unit - J1024- and use a routine stored there to open or
close the electrically activated valves for the third flushing pro‐
cedure (flushing routine “3”) ⇒ Vehicle diagnostic tester.

2. Refrigerant circuit 121

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1 - -A- Shut-off valve - VAS

6338/47-2-
2 - -B- Shut-off valve - VAS
6338/47-1-
3 - -C- Shut-off valve - VAS
6338/47-1-
4 - -D- Shut-off valve - VAS
6338/47-1-

– Close or open shut-off valves fitted in flushing circuit as shown

in the following illustrations.
♦ The following illustrations only apply to components that are
directly affected by the flushing procedure; for all components
not described refer to
⇒ “2.1 System overview - refrigerant circuit”, page 31 .
♦ The colours of the lines in the following illustrations indicate
which components are flushed (red lines) due to the different
valve positions, which are only filled with refrigerant (green
lines) and which are not affected (blue lines).

122 Rep. gr.87 - Air conditioning system

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1 - Refrigerant shut-off valve 4

- N642- (closed via Basic set‐
ting function)
2 - Refrigerant shut-off valve 5
- N643- (closed via Basic set‐
ting function)
3 - Refrigerant shut-off valve 2
- N640- (opened via Basic set‐
ting function)
4 - Refrigerant shut-off valve 3
- N641- (closed via Basic set‐
ting function)
5 - Receiver on condenser
(desiccant bag removed and
re-sealed)
6 - Adapter - VAS 6338/3-
(connected to refrigerant hose
to flushing device)
7 - Adapter - VAS 6338/12-
(connected to refrigerant hose
of air conditioner service sta‐
tion on high-pressure side)
8 - Shut-off valve - VAS
6338/47-1- (installed in refrig‐
erant line from condenser,
closed manually)
⇒ Item 3 (page 122)
9 - Shut-off valve - VAS
6338/47-2- (installed in refrig‐
erant line from internal heat ex‐
changer, opened manually)
⇒ Item 1 (page 122)
10 - Refrigerant expansion
valve 2 - N637- (opened via
Basic setting function)
11 - Shut-off valves - VAS 6338/42- (installed in refrigerant line to expansion valve, opened manually)
12 - Adapter - VAS 6338/44- (installed in place of expansion valve to evaporator in front heater and air condi‐
tioning unit)
13 - Shut-off valve - VAS 6338/47-1- (installed in refrigerant line from refrigerant receiver, opened manually)
⇒ Item 4 (page 122)
14 - Shut-off valve - VAS 6338/47-1- (installed in refrigerant line from valve block, closed manually)
⇒ Item 2 (page 122)

– Select “Flush air conditioner” routine on connected air condi‐

tioner service station and start routine.
• Observe operating instructions supplied with air conditioner
service station .
• For notes on flushing procedure, refer to ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit (Cleaning
refrigerant circuit with refrigerant R134a), or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station; Cleaning re‐
frigerant circuit .
Wait until entire flushing procedure has been completed by air
conditioner service station.

2. Refrigerant circuit 123

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♦ The air conditioner service station displays when the flushing

procedure has been completed.
♦ The flushing procedure is complete when the air conditioner
service station has extracted the refrigerant from the flushing
circuit after the final flushing cycle.
♦ If refrigerant reaches areas it is not actually intended to reach
(areas indicated by blue lines) in this flushing routine because
a valve has not closed correctly, it can take a very long time
to extract all the refrigerant from the flushing circuit. You can
recognise a valve that does not close correctly e.g. by the fact
that this valve cools down due to refrigerant slowly evaporat‐
ing. The valve then constricts the flow. In this case, open all
manually operated shut-off valves and, if necessary, switch on
the air conditioner service station again, extract the remaining
refrigerant from the flushing circuit and evacuate the circuit
again.

CAUTION
If the flushing procedure is interrupted or the cleaning proce‐
dure is not continued when this routine has been completed,
there is a danger of frostbite from escaping pressurised refrig‐
erant.
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Before removing components of the flushing circuit or de‐
taching refrigerant lines, open all shut-off valves installed in
the flushing circuit.
– Initiate air conditioner basic setting via the thermal manage‐
ment control unit - J1024- and use a routine stored there to
open the various electrically activated valves ⇒ Vehicle di‐
agnostic tester.
– Check pressure in flushing circuit using air conditioner serv‐
ice station. If necessary, extract any remaining refrigerant
and open flushing circuit immediately afterwards.

When routine “3” has been completed, initiate and run routine “4”.

2.23.7 Cleaning refrigerant circuit (routine “4”)

In this flushing procedure, the following components are cleaned:
part of valve block and corresponding refrigerant lines.
Requirements:
♦ Flushing routine “3” has been performed and completed suc‐
cessfully
⇒ “2.23.6 Cleaning refrigerant circuit (routine 3) ”, page 121 .
Cleaning refrigerant circuit
– Initiate air conditioner basic setting via thermal management
control unit - J1024- and use a routine stored there to open or
close the electrically activated valves for the fourth flushing
procedure (flushing routine “4”) ⇒ Vehicle diagnostic tester.

124 Rep. gr.87 - Air conditioning system

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1 - -A- Shut-off valve - VAS

6338/47-2-
2 - -B- Shut-off valve - VAS
6338/47-1-
3 - -C- Shut-off valve - VAS
6338/47-1-
4 - -D- Shut-off valve - VAS
6338/47-1-

– Close or open shut-off valves fitted in flushing circuit as shown

in the following illustrations.
♦ The following illustrations only apply to components that are
directly affected by the flushing procedure; for all components
not described refer to
⇒ “2.1 System overview - refrigerant circuit”, page 31 .
♦ The colours of the lines in the following illustrations indicate
which components are flushed (red lines) due to the different
valve positions, which are only filled with refrigerant (green
lines) and which are not affected (blue lines).

2. Refrigerant circuit 125

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1 - Refrigerant shut-off valve 4

- N642- (opened via Basic set‐
ting function)
2 - Refrigerant shut-off valve 5
- N643- (closed via Basic set‐
ting function)
3 - Refrigerant shut-off valve 2
- N640- (opened via Basic set‐
ting function)
4 - Refrigerant shut-off valve 3
- N641- (closed via Basic set‐
ting function)
5 - Receiver on condenser
(desiccant bag removed and
re-sealed)
6 - Adapter - VAS 6338/3-
(connected to refrigerant hose
to flushing device)
7 - Adapter - VAS 6338/12-
(connected to refrigerant hose
of air conditioner service sta‐
tion on high-pressure side)
8 - Shut-off valve - VAS
6338/47-1- (installed in refrig‐
erant line from condenser,
closed manually)
⇒ Item 3 (page 125)
9 - Shut-off valve - VAS
6338/47-2- (installed in refrig‐
erant line from internal heat ex‐
changer, closed manually)
⇒ Item 1 (page 125)
10 - Refrigerant expansion
valve 2 - N637- (closed via Ba‐
sic setting function)
11 - Shut-off valves - VAS 6338/42- (installed in refrigerant line to expansion valve, closed manually)
12 - Adapter - VAS 6338/44- (installed in place of expansion valve to evaporator in front heater and air condi‐
tioning unit)
13 - Shut-off valve - VAS 6338/47-1- (installed in refrigerant line from refrigerant receiver, closed manually)
⇒ Item 4 (page 125)
14 - Shut-off valve - VAS 6338/47-1- (installed in refrigerant line from valve block, opened manually)
⇒ Item 2 (page 125)

– Select “Flush air conditioner” routine on connected air condi‐

tioner service station and start routine.
• Observe operating instructions supplied with air conditioner
service station .
• For notes on flushing procedure, refer to ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit (Cleaning
refrigerant circuit with refrigerant R134a), or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station; Cleaning re‐
frigerant circuit .
Wait until entire flushing procedure has been completed by air
conditioner service station.

126 Rep. gr.87 - Air conditioning system

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♦ The air conditioner service station displays when the flushing

procedure has been completed.
♦ The flushing procedure is complete when the air conditioner
service station has extracted the refrigerant from the flushing
circuit after the final flushing cycle.
♦ If refrigerant reaches areas it is not actually intended to reach
(areas indicated by blue lines) in this flushing routine because
a valve has not closed correctly, it can take a very long time
to extract all the refrigerant from the flushing circuit. You can
recognise a valve that does not close correctly e.g. by the fact
that this valve cools down due to refrigerant slowly evaporat‐
ing. The valve then constricts the flow. In this case, open all
manually operated shut-off valves and, if necessary, switch on
the air conditioner service station again, extract the remaining
refrigerant from the flushing circuit and evacuate the circuit
again.
– Open all manually operated shut-off valves in flushing circuit
(see above).
– Switch on ignition.
– Initiate basic setting of air conditioner via thermal manage‐
ment control unit - J1024- ; use the “Extract, evacuate and
charge refrigerant circuit” routine stored there to open electri‐
cally actuated valves ⇒ Vehicle diagnostic tester.
– Check pressure in flushing circuit; only detach refrigerant ho‐
ses from the two adapters -6, 7- if pressure is below or equal
to ambient pressure.

CAUTION
If the flushing procedure is interrupted or the cleaning proce‐
dure is not continued when this routine has been completed,
there is a danger of frostbite from escaping pressurised refrig‐
erant.
Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Before removing components of the flushing circuit or de‐
taching refrigerant lines, open all shut-off valves installed in
the flushing circuit.
– Initiate air conditioner basic setting via the thermal manage‐
ment control unit - J1024- and use a routine stored there to
open the various electrically activated valves ⇒ Vehicle di‐
agnostic tester.
– Check pressure in flushing circuit using air conditioner serv‐
ice station. If necessary, extract any remaining refrigerant
and open flushing circuit immediately afterwards.

– Switch off air conditioner service station.

The following components must be renewed after the refrigerant
circuit is cleaned:
♦ Desiccant bag in condenser receiver
⇒ “2.20 Removing and installing desiccant bag/desiccant car‐
tridge”, page 103
♦ Refrigerant shut-off valve - V424-
⇒ “2.14 Removing and installing refrigerant shut-off valve
V424 ”, page 79
♦ Refrigerant receiver at heat exchanger for heat pump opera‐
tion

2. Refrigerant circuit 127

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⇒ “2.10 Removing and installing refrigerant receiver”,

page 63
– Remove remaining flushing adapters and assemble refriger‐
ant circuit.
♦ Pay attention to the correct quantity of refrigerant oil when as‐
sembling the refrigerant circuit. If renewing the air conditioner
compressor, ensure that the replacement compressor con‐
tains the correct quantity of refrigerant oil. If the air conditioner
compressor is not being renewed, determine how much re‐
frigerant oil is in the compressor, and fill the correct quantity
into the refrigerant circuit or air conditioner compressor ⇒ Air
conditioner with refrigerant R134a; Rep. gr. 87 ; Refrigerant
circuit (Flushing electrically driven air conditioner compres‐
sor), or ⇒ Air conditioners with refrigerant R1234yf - General
information; Rep. gr. 87 ; Working with the air conditioner
service station; Cleaning refrigerant circuit , and
⇒ “5.2 Approved refrigerant oils and refrigerant oil capacities”,
page 17 .
♦ These air conditioner compressors are available as replace‐
ment parts with different refrigerant oil capacities; attention
must therefore be paid to the oil quantity in the air conditioner
compressor
⇒ “5.2 Approved refrigerant oils and refrigerant oil capacities”,
page 17 as well as the exact part number ⇒ Electronic parts
catalogue .
♦ There are different refrigerant oil capacities for the refrigerant
circuit depending on the layout of the refrigerant circuit and the
refrigerant used. 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
⇒ “5.2 Approved refrigerant oils and refrigerant oil capacities”,
page 17 .
– Evacuate and charge refrigerant circuit ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air
conditioners with refrigerant R1234yf - General information;
Rep. gr. 87 ; Working with the air conditioner service station .
– Initiate air conditioner basic setting via thermal management
control unit - J1024- and use a routine stored there to open
electrically actuated valves (“Stop routine: Charging/flushing
refrigerant circuit”) ⇒ Vehicle diagnostic tester.
– Re-install remaining components removed in reverse order.

WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or electric
arcs.
– Have an Audi high-voltage technician (HVT) or an Audi high-
voltage expert (HVE) re-energise the high-voltage system.

– Re-energise high-voltage system ⇒ Rep. gr. 93 ; Re-ener‐

gising high-voltage system .
• 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.

128 Rep. gr.87 - Air conditioning system

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• An electrically driven air conditioner compressor may only be

activated when the refrigerant circuit is charged. The air con‐
ditioner compressor may be damaged if it is allowed to run with
the refrigerant circuit empty.
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22.2 Starting up air conditioner after charging refrigerant
circuit - vehicles with high-voltage system”, page 109 .

2. Refrigerant circuit 129

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3 Heat pump valve unit

⇒ “3.1 Exploded view - heat pump valve unit”, page 130
⇒ “3.2 Removing and installing bracket with heat pump valve unit”,
page 131
⇒ “3.3 Removing and installing heat pump valve unit”,
page 136
⇒ “3.4 Dismantling and assembling heat pump valve unit”,
page 137
⇒ “3.5 Removing and installing refrigerant expansion valve 2
N637 ”, page 139

3.1 Exploded view - heat pump valve unit

♦ Exploded view - heat pump valve unit ⇒ page 130
♦ Exploded view - fastening elements for securing heat pump
valve unit to wheel actuator ⇒ page 131
Heat pump valve unit

1 - Bracket
2 - Rubber bush
3 - Spacer
4 - Bolts
❑ 8 Nm
5 - Bolt
❑ 25 Nm
6 - Guide sleeves
7 - Bolts
❑ Tightening torque
⇒ Item 3 (page 131)
8 - Valve block with wiring har‐
ness
❑ Removing and installing
⇒ “3.3 Removing and in‐
stalling heat pump valve
unit”, page 136
❑ Dismantling and assem‐
bling
⇒ “3.4 Dismantling and
assembling heat pump
valve unit”, page 137
9 - Bracket
10 - Bracket
11 - Bolts
❑ Tightening torque
⇒ Item 6 (page 131)
12 - Bracket
13 - Bolts
❑ Tightening torque
⇒ Item 5 (page 131)

130 Rep. gr.87 - Air conditioning system

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14 - Bracket
15 - Bolts
❑ Tightening torque ⇒ Item 8 (page 58)
16 - Bolts
❑ 8 Nm
17 - Bracket
18 - Bolts
❑ 8 Nm

Fastening elements for securing heat pump valve unit to wheel

actuator

1 - Heat pump valve unit

2 - Wheel actuator
3 - Bolts
❑ 8 Nm
4 - Bolts
❑ Tightening torque: Ex‐
ploded view - wheel ac‐
tuator ⇒ General body
repairs, exterior; Rep.
gr. 50 ; Lock carrier .
5 - Bolts
❑ 8 Nm
6 - Bolts
❑ 8 Nm
7 - Guide sleeves
8 - Bolts
❑ 8 Nm
9 - Bracket
10 - Rubber bush
11 - Spacer
12 - Bolts
❑ 8 Nm

3.2 Removing and installing bracket with

heat pump valve unit
Special tools and workshop equipment required

3. Heat pump valve unit 131

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♦ Hose clamps up to 25 mm - 3094-

♦ Engine bung set - VAS 6122-

♦ Spring-type clip pliers - VAS 5024A-

Removing
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
Working with ignition switched on or high-voltage system active
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
– Switch on ignition.
– Initiate basic setting of air conditioner via thermal manage‐
ment control unit - J1024- ; use the Extract, evacuate and
charge refrigerant circuit routine stored there to open
electrically actuated valves ⇒ Vehicle diagnostic tester.
– Switch off ignition.
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station .

132 Rep. gr.87 - Air conditioning system

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– Remove wheel housing liner (front left) ⇒ General body re‐

pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Exploded
view - wheel housing liner (front) .
– Remove closure plate for bumper cover (front) ⇒ General
body repairs, exterior; Rep. gr. 63 ; Bumper (front); Exploded
view - bumper cover .
– Unfasten bumper cover (left-side) on wing panel and push it
outwards ⇒ General body repairs, exterior; Rep. gr. 63 ;
Bumper (front); Exploded view - bumper cover .
– Drain coolant for high-voltage coolant circuit ⇒ 4-cylinder di‐
rect injection engine (2.0 ltr. 4-valve TFSI, EA 888 Gen. III);
Rep. gr. 19 ; Cooling system/coolant; Draining and filling cool‐
ing system .
– Drain coolant for engine coolant circuit ⇒ 4-cylinder direct in‐
jection engine (2.0 ltr. 4-valve TFSI, EA 888 Gen. III); Rep. gr.
19 ; Cooling system/coolant; Draining and filling cooling sys‐
tem .
– Remove coolant expansion tank for high-voltage coolant cir‐
cuit ⇒ 4-cylinder direct injection engine (2.0 ltr. 4-valve TFSI,
EA 888 Gen. III); Rep. gr. 19 ; Cooling system/coolant; Ex‐
ploded view - coolant expansion tank .
– Slacken bolt -arrow- three turns, but do not remove.

– Detach all lines and connectors at bracket -A-.

CAUTION
Risk of frostbite from escaping pressurised refrigerant
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 re‐
frigerant 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 pres‐
sure in the refrigerant circuit.

– Unscrew bolt -B- and detach refrigerant line -D-.

– Remove bolts -arrows-.
– Remove bolts -C- and detach bracket -A- downwards.

3. Heat pump valve unit 133

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– Unscrew bolt -D- and detach refrigerant line -E-.

– Unscrew bolt -G- and detach refrigerant line -F-.
– Unscrew nut -B- and detach refrigerant lines -A, C- going to
internal heat exchanger.

– Unplug connector -C- and move it clear.

– Mark arrangement of coolant hoses -A- on connections to heat
exchanger for high-voltage battery.
– Release hose clips -B- with pliers -VAS 5024A- and detach
coolant hoses -A- from connections on heat exchanger for
high-voltage battery.
– Seal off open pipes and connections immediately with clean
plugs from engine bung set - VAS 6122- .
– Remove bolt -E- and move coolant line -D- to auxiliary radiator
clear.

– Mark arrangement of coolant hoses on connections to heat

exchanger for heat pump operation.
– Release hose clips -B- with pliers -VAS 5024A- and detach
coolant hoses from connections on heat exchanger for hat
pump operation.
– Seal off open pipes and connections immediately with clean
plugs from engine bung set - VAS 6122- .
– Unscrew bolt -C- and detach refrigerant line -E-.
– Unscrew bolt -D- and detach refrigerant lines going to auxiliary
radiator.

134 Rep. gr.87 - Air conditioning system

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– Remove bolt -arrow- from bracket -A-.

– Lift bracket -A- and guide it out of guide in longitudinal mem‐
ber.
– Carefully remove heat pump valve unit downwards together
with bracket.
Installing
Installation is carried out in reverse order; note the following:
• When it has been removed, the valve block may contain re‐
frigerant oil which must be returned to the refrigerant circuit
(together with the new component) ⇒ Air conditioner with re‐
frigerant R134a; Rep. gr. 87 ; Renewing components of
refrigerant circuit , or ⇒ Air conditioners with refrigerant
R1234yf - General information; Rep. gr. 87 ; Refrigerant cir‐
cuit; Renewing components .
– Renew O-rings ⇒ “4.12 Refrigerant circuit seals”, page 14 .
– Fit refrigerant lines at expansion valve; make sure they are
routed correctly
⇒ “2.1.2 System overview - refrigerant circuit, vehicles with
high-voltage system”, page 35 .
– After attaching, check routing of refrigerant lines. They must
be inserted in brackets provided and should not make contact
with other components.
– Re-install remaining components removed previously in re‐
verse order and/or re-attach detached components.
– 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 .
– Switch on ignition.
– Initiate air conditioner basic setting via thermal management
control unit - J1024- and use a routine stored there to open
electrically actuated valves ( Stop routine: Charging/
flushing refrigerant circuit ) ⇒ Vehicle diagnostic test‐
er.
– Fill up and bleed high-voltage coolant circuit ⇒ 4-cylinder di‐
rect injection engine (2.0 ltr. 4-valve TFSI, EA 888 Gen. III);
Rep. gr. 19 ; Cooling system/coolant; Draining and filling cool‐
ing system .
– Fill up coolant for engine coolant circuit and bleed coolant cir‐
cuit ⇒ 4-cylinder direct injection engine (2.0 ltr. 4-valve TFSI,
EA 888 Gen. III); Rep. gr. 19 ; Cooling system/coolant; Drain‐
ing and filling cooling system .
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22.2 Starting up air conditioner after charging refrigerant
circuit - vehicles with high-voltage system”, page 109 .
Tightening torques
♦ ⇒ “3.1 Exploded view - heat pump valve unit”, page 130
♦ ⇒ “2.6.3 Exploded view - refrigerant lines, vehicles with high-
voltage system”, page 50
♦ ⇒ General body repairs, exterior; Rep. gr. 63 ; Bumper (front);
Exploded view - bumper cover
♦ Exploded view - wheel actuator ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Lock carrier .

3. Heat pump valve unit 135

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♦ ⇒ 4-cylinder direct injection engine (2.0 ltr. 4-valve TFSI, EA

888 Gen. III); Rep. gr. 19 ; Coolant pipes; Exploded view -
coolant pipes

3.3 Removing and installing heat pump

valve unit
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

Removing
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
– Remove bracket with heat pump valve unit
⇒ “3.2 Removing and installing bracket with heat pump valve
unit”, page 131 .
– Unscrew bolts -C, D- and detach refrigerant lines -B, F-.
– Unscrew bolts -A, E- and detach heat pump valve unit -G-.

Installing
– Insert heat pump valve unit -G- in bracket and screw in bolts
-A, E-.
– Fit refrigerant lines -B, F- at heat pump valve unit and screw
in bolts -C, D-.
Installation is carried out in reverse order; note the following:
• Renew O-rings ⇒ “4.12 Refrigerant circuit seals”, page 14 .
• When it has been removed, the valve block may contain re‐
frigerant oil which must be returned to the refrigerant circuit
(together with the new component) ⇒ Air conditioner with re‐
frigerant R134a; Rep. gr. 87 ; Renewing components of
refrigerant circuit , or ⇒ Air conditioners with refrigerant
R1234yf - General information; Rep. gr. 87 ; Refrigerant cir‐
cuit; Renewing components .
• After attaching, check routing of refrigerant lines. They must
be inserted in brackets provided and should not make contact
with other components.
Tightening torques
♦ ⇒ “3.1 Exploded view - heat pump valve unit”, page 130
♦ ⇒ “2.6.3 Exploded view - refrigerant lines, vehicles with high-
voltage system”, page 50

136 Rep. gr.87 - Air conditioning system

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3.4 Dismantling and assembling heat pump

valve unit
Dismantling and assembling heat pump valve unit ⇒ page 137
Connection diagram - wiring harness at valve block ⇒ page 138
Dismantling and assembling heat pump valve unit
♦ ⇒ “3.3 Removing and installing heat pump valve unit”,
page 136

1 - Bracket for wiring harness

2 - Valve block wiring harness
❑ Mark routing before re‐
moval
❑ Observe correct pin as‐
signment of connectors
to valves ⇒ page 138
❑ Valves of valve block
are currently identical;
they are assigned by
means of pin assign‐
ment of wiring harness
connectors, and activa‐
ted by thermal manage‐
ment control unit -
J1024- accordingly
⇒ Current flow dia‐
grams, Electrical fault
finding and Fitting loca‐
tions
3 - Refrigerant shut-off valve 2
- N640-
❑ Mark before removal to
ensure correct alloca‐
tion later on
❑ Valves of valve block
are currently identical;
they are assigned by
means of pin assign‐
ment of wiring harness
connectors, and activa‐
ted by thermal manage‐
ment control unit -
J1024- accordingly
⇒ Current flow dia‐
grams, Electrical fault
finding and Fitting loca‐
tions
4 - Bolt
❑ 9 Nm
5 - Outer connector block
6 - Seal
❑ Renew seal if it has been removed; for correct version refer to ⇒ Electronic parts catalogue
7 - Plug
❑ Renew after removal
❑ 20 Nm
8 - Dowel pin with thread
❑ Ensure correct fitting location

3. Heat pump valve unit 137

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❑ 4 Nm
9 - O-ring
❑ Renew if removed ⇒ “4.12 Refrigerant circuit seals”, page 14 ; for correct version refer to ⇒ Electronic
parts catalogue
❑ Before installing, lubricate lightly with refrigerant oil
10 - O-ring
❑ Renew if removed ⇒ “4.12 Refrigerant circuit seals”, page 14 ; for correct version refer to ⇒ Electronic
parts catalogue
❑ Before installing, lubricate lightly with refrigerant oil
11 - Bolt
❑ 9 Nm
12 - Refrigerant shut-off valve 4 - N642-
❑ Mark before removal to ensure correct allocation later on
❑ Valves of valve block are currently identical; they are assigned by means of pin assignment of wiring
harness connectors, and activated by thermal management control unit - J1024- accordingly ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations
13 - Inner connector block
14 - Refrigerant shut-off valve 5 - N643-
❑ Mark before removal to ensure correct allocation later on
❑ Valves of valve block are currently identical; they are assigned by means of pin assignment of wiring
harness connectors, and activated by thermal management control unit - J1024- accordingly ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations
15 - Refrigerant shut-off valve 3 - N641-
❑ Mark before removal to ensure correct allocation later on
❑ Valves of valve block are currently identical; they are assigned by means of pin assignment of wiring
harness connectors, and activated by thermal management control unit - J1024- accordingly ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations

Connection diagram - wiring harness at valve block

♦ The valves of the valve block -1- are currently identical. They
are assigned via the pin assignment of the wiring harness
connectors -6- and are activated by the thermal management
control unit - J1024- accordingly ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
♦ The valves ( -N640- , -N641- -N642- and -N643- ) in the valve
block -1- are assigned and activated solely based on the layout
of connectors -2, 4, 5 ,7- of wiring harness -6-. If the valve block
is rotated by 180° in the bracket and the wiring harness is
connected correctly as shown in the diagram, the function of
the individual valves changes (they are reversed), but the
valve block itself continues to operate properly.

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1 - Valve block
2 - Connector for refrigerant
shut-off valve 2 - N640-
3 - Bracket
4 - Connector for refrigerant
shut-off valve 4 - N642-
5 - Connector for refrigerant
shut-off valve 5 - N643-
6 - Wiring harness
7 - Connector for refrigerant
shut-off valve 3 - N641-

3.5 Removing and installing refrigerant ex‐

pansion valve 2 - N637-
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
Refrigerant expansion valve 2 - N637- -C- is removed together
with heat exchanger for high-voltage battery -A-.

3. Heat pump valve unit 139

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Removing
For all subsequent work, seal off any open lines and connections
immediately using clean plugs from engine bung set - VAS 6122- .
– Remove heat exchanger for high-voltage battery
⇒ “2.11 Removing and installing heat exchanger for high-volt‐
age battery”, page 67 .
– Remove bolt -D-.
– Unfasten base plate -E- at connection of refrigerant expansion
valve 2 - N637- -C-.
Installing
Installation is carried out in reverse order; note the following:
– If fitted, check that dowel pins at base plate connections are
not damaged and are seated correctly.
– Renew O-rings ⇒ “4.12 Refrigerant circuit seals”, page 14 .
– Install heat exchanger for high-voltage battery
⇒ “2.11 Removing and installing heat exchanger for high-volt‐
age battery”, page 67 .
Tightening torques
♦ ⇒ “2.8 Exploded view - heat exchanger for high-voltage bat‐
tery”, page 59
♦ ⇒ “2.6.3 Exploded view - refrigerant lines, vehicles with high-
voltage system”, page 50

140 Rep. gr.87 - Air conditioning system

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Heating, air conditioning - Edition 12.2018

4 Air conditioner compressor

⇒ “4.1 Exploded view - air conditioner compressor”, page 141
⇒ “4.2 Exploded view - pulley”, page 147
⇒ “4.3 Detaching and attaching air conditioner compressor at
bracket”, page 155
⇒ “4.4 Detaching and attaching refrigerant lines at air conditioner
compressor”, page 163
⇒ “4.5 Removing and installing air conditioner compressor”, page
170
⇒ “4.6 Preparations for renewing pulley”, page 187
⇒ “4.7 Removing and installing pulley (without magnetic clutch)”,
page 188
⇒ “4.8 Removing and installing pulley with air conditioning system
magnetic clutch N25 ”, page 192

4.1 Exploded view - air conditioner com‐

pressor
⇒ “4.1.1 Exploded view - air conditioner compressor, all vehicles
except those with V6 2.9 ltr. TFSI engine”, page 141
⇒ “4.1.2 Exploded view - air conditioner compressor, vehicles with
V6 2.9 ltr. TFSI engine”, page 144
⇒ “4.1.3 Exploded view - electrically driven air conditioner com‐
pressor”, page 146

4.1.1 Exploded view - air conditioner compressor, all vehicles except those with
V6 2.9 ltr. TFSI engine

4. Air conditioner compressor 141

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1 - Dowel sleeves
❑ 2x
2 - Oil drain plug with seal
❑ Denso: 30 Nm
❑ Denso: Seal can be
reused
❑ Sanden: 15 Nm
❑ Sanden: Seal can be
reused
❑ Seals, sealing surfaces
and threads must be
free from visible dam‐
age, dirt and particles
3 - Bracket for air conditioner
compressor
❑ Removing and installing
⇒ Engine; Rep. gr. 13 ;
Cylinder block (pulley
end); Removing and in‐
stalling bracket for ancil‐
laries
4 - 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 14
5 - Refrigerant line (high-pres‐
sure side)
❑ Detaching and attach‐
ing refrigerant line
⇒ “4.4 Detaching and at‐
taching refrigerant lines
at air conditioner compressor”, page 163
6 - Bolt
❑ Exploded view
⇒ “2.6.1 Exploded view - refrigerant lines, air conditioner compressor and condenser”, page 46
7 - Refrigerant line (low-pressure side)
❑ Detaching and attaching refrigerant line
⇒ “4.4 Detaching and attaching refrigerant lines at air conditioner compressor”, page 163
8 - Bolt
❑ Exploded view
⇒ “2.6.1 Exploded view - refrigerant lines, air conditioner compressor and condenser”, page 46
9 - O-ring
❑ Renew; for correct version refer to ⇒ Electronic parts catalogue
❑ Before installing, lubricate with refrigerant oil ⇒ “4.12 Refrigerant circuit seals”, page 14
10 - Bolt
❑ 3x
❑ Different versions ⇒ Electronic parts catalogue
Steel bolt
❑ 25 Nm
Aluminium bolt

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❑ Renew after removing

❑ 8 Nm +180°
11 - Air conditioner compressor regulating valve - N280-
❑ Checking ⇒ Vehicle diagnostic tester and ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations
❑ Removing and installing ⇒ Air conditioner with refrigerant R134a; Rep. gr. 87 ; Renewing components
of refrigerant circuit , or ⇒ Air conditioners with refrigerant R1234yf - General information; Rep. gr. 87 ;
Refrigerant circuit; Renewing components
12 - Air conditioner compressor
❑ Different versions ⇒ Electronic parts catalogue
❑ Detaching and attaching refrigerant line
⇒ “4.4 Detaching and attaching refrigerant lines at air conditioner compressor”, page 163
❑ Detaching and attaching at bracket
⇒ “4.3 Detaching and attaching air conditioner compressor at bracket”, page 155
❑ Removing and installing ⇒ “4.5 Removing and installing air conditioner compressor”, page 170
13 - Electrical connector
❑ For air conditioner compressor regulating valve - N280- and air conditioning system magnetic clutch -
N25-
14 - Pulley with overload protection
❑ Different versions ⇒ Electronic parts catalogue
❑ Exploded view ⇒ “4.2 Exploded view - pulley”, page 147
❑ Depending on engine version and air conditioner compressor with or without air conditioning system
magnetic clutch - N25-
15 - Poly V-belt
❑ Removing and installing ⇒ Engine; Rep. gr. 13 ; Cylinder block (pulley end); Removing and installing
poly V-belt

4. Air conditioner compressor 143

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4.1.2 Exploded view - air conditioner compressor, vehicles with V6 2.9 ltr. TFSI
engine

1 - Pulley with overload protec‐

tion
❑ Removing and installing
⇒ “4.2.3 Exploded view
- Denso air conditioner
compressor pulley (with
air conditioning system
magnetic clutch N25 )”,
page 150
❑ Exploded view
⇒ “4.2 Exploded view -
pulley”, page 147
❑ With air conditioning
system magnetic clutch
- N25-
❑ Different versions ⇒
Electronic parts cata‐
logue
2 - Poly V-belt
❑ Removing and installing
poly V-belt for air condi‐
tioner compressor ⇒
Engine; Rep. gr. 13 ;
Cylinder block (pulley
end); Removing and in‐
stalling poly V-belt
3 - Bolts
❑ 40 Nm
4 - Bracket for ancillaries
❑ Removing and installing
⇒ Engine; Rep. gr. 13 ;
Cylinder block (pulley
end); Removing and in‐
stalling bracket for ancil‐
laries
5 - Locking sleeve
6 - Air conditioner compressor regulating valve - N280-
❑ Checking ⇒ Vehicle diagnostic tester
❑ Removing and installing ⇒ Air conditioner with refrigerant R134a; Rep. gr. 87 ; Renewing components
of refrigerant circuit , or ⇒ Air conditioners with refrigerant R1234yf - General information; Rep. gr. 87 ;
Refrigerant circuit; Renewing components
7 - Air conditioner compressor
❑ Different versions ⇒ Electronic parts catalogue
❑ Detaching and attaching refrigerant line
⇒ “4.4.1 Detaching and attaching refrigerant lines at mechanically driven air conditioner compressor -
vehicles with 4-cyl./V6 TDI engine (except S6/S7 models with TDI engine) and with V6 2.9 ltr. TFSI
engine”, page 164
❑ Detaching and attaching at bracket
⇒ “4.3.4 Detaching and attaching air conditioner compressor at bracket - vehicles with V6 2.9 ltr. TFSI
engine”, page 160
❑ Removing and installing
⇒ “4.5.6 Removing and installing air conditioner compressor - vehicles with V6 2.9 ltr. TFSI engine”, page
179

144 Rep. gr.87 - Air conditioning system

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8 - Oil drain plug

❑ 30 Nm
9 - O-ring
❑ Renew; for correct version refer to ⇒ Electronic parts catalogue
❑ Before installing, lubricate with refrigerant oil ⇒ “4.12 Refrigerant circuit seals”, page 14
10 - Refrigerant line (low-pressure side)
❑ Detaching and attaching refrigerant line
⇒ “4.4 Detaching and attaching refrigerant lines at air conditioner compressor”, page 163
11 - Bolt
❑ Exploded view
⇒ “2.6.1 Exploded view - refrigerant lines, air conditioner compressor and condenser”, page 46
12 - Bolt
❑ Exploded view
⇒ “2.6.1 Exploded view - refrigerant lines, air conditioner compressor and condenser”, page 46
13 - Refrigerant line (high-pressure side)
❑ Detaching and attaching refrigerant line
⇒ “4.4 Detaching and attaching refrigerant lines at air conditioner compressor”, page 163
14 - O-ring
❑ Renew; for correct version refer to ⇒ Electronic parts catalogue
❑ Before installing, lubricate with refrigerant oil ⇒ “4.12 Refrigerant circuit seals”, page 14

4. Air conditioner compressor 145

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4.1.3 Exploded view - electrically driven air conditioner compressor

1 - Bolt
❑ Tightening torque
⇒ Item 7 (page 51)
2 - Refrigerant line
❑ Low-pressure side
❑ Removing and installing
⇒ “4.4.3 Detaching and
attaching refrigerant
lines at electrical air
conditioner compressor
V470 ”, page 166
3 - O-ring
❑ Renew if removed
⇒ “4.12 Refrigerant cir‐
cuit seals”, page 14 ; for
correct version refer to
⇒ Electronic parts cata‐
logue
❑ Before installing, lubri‐
cate lightly with refriger‐
ant oil
4 - 8-pin connector
❑ With control wire from
thermal management
control unit - J1024-
⇒ Current flow dia‐
grams, Electrical fault
finding and Fitting loca‐
tions
5 - Bolt
❑ Tightening torque
⇒ Item 4 (page 51)
6 - Refrigerant line
❑ High-pressure side
❑ Removing and installing
⇒ “4.4.3 Detaching and attaching refrigerant lines at electrical air conditioner compressor V470 ”,
page 166
7 - O-ring
❑ Renew if removed ⇒ “4.12 Refrigerant circuit seals”, page 14 ; for correct version refer to ⇒ Electronic
parts catalogue
❑ Lubricate lightly with refrigerant oil prior to installing
8 - 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 ⇒ Rep. gr. 93 ; High-voltage wires; Overview of fitting locations - high-voltage
wires
9 - Electrically driven air conditioner compressor
❑ With control unit for air conditioning compressor - J842- and electrical air conditioner compressor - V470-
❑ Detaching and attaching at bracket
⇒ “4.3.5 Detaching and attaching electrically driven air conditioner compressor at bracket”, page 163
❑ Detaching and attaching refrigerant lines
⇒ “4.4.3 Detaching and attaching refrigerant lines at electrical air conditioner compressor V470 ”,
page 166
❑ Removing and installing
⇒ “4.5.8 Removing and installing electrically driven air conditioner compressor”, page 182

146 Rep. gr.87 - Air conditioning system

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❑ Electrical air conditioner compressor - V470- is supplied with electric power via a fuse fitted in power and
control electronics for electric drive - JX1-
⇒ Fig. ““Fuse for electrical air conditioner compressor -V470- ”“ , page 147 and ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations
10 - Bolt
❑ 25 Nm
11 - Threaded pin
❑ 9 Nm
12 - Nut
❑ 4x
❑ 25 Nm
13 - Crash retainer
14 - Grommet

Fuse for electrical air conditioner compressor - V470-

The fuse -arrow- for the electrical air conditioner compressor -
V470- is fitted in the power and control electronics for electric
drive - JX1- and cannot currently be renewed separately (intro‐
duction of fuse as replacement part not yet finalised) ⇒ Electronic
parts catalogue .
– If necessary, renew fuse or power and control electronics for
electric drive ⇒ Rep. gr. 93 ; Power and control electronics
for electric drive; Removing and installing power and control
electronics for electric drive .

4.2 Exploded view - pulley

⇒ “4.2.1 Exploded view - Denso air conditioner compressor pulley
(version 1)”, page 147
⇒ “4.2.2 Exploded view - Denso air conditioner compressor pulley
(version 2)”, page 149
⇒ “4.2.3 Exploded view - Denso air conditioner compressor pulley
(with air conditioning system magnetic clutch N25 )”, page 150
⇒ “4.2.4 Exploded view - Sanden air conditioner compressor pul‐
ley”, page 151
⇒ “4.2.5 Exploded view - Sanden air conditioner compressor pul‐
ley (with air conditioning system magnetic clutch N25 )”,
page 153

4.2.1 Exploded view - “Denso” air conditioner

compressor pulley (version 1)
♦ If the pulley overload protection device has been triggered,
check that the air conditioner compressor can rotate freely be‐
fore renewing the pulley. The air conditioner compressor must
be renewed completely if it does not rotate freely.
♦ Various pulley versions with differing diameters may be fitted
depending on the type of air conditioner compressor and the
engine version ⇒ Electronic parts catalogue .
♦ The replacement pulley is supplied with drive plate and cap.
The pulley and the drive plate are held together by a bolt (bolt
is not required; can be disposed of). This bolt is used during
manufacturing to insert a pre-determined amount of a specific
grease into the thread of the drive plate (sufficient for fitting the
drive plate onto the compressor shaft once; do not re-use a

4. Air conditioner compressor 147

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drive plate that has been unscrewed) ⇒ Electronic parts cata‐

logue .

1 - Cap
2 - Drive plate
❑ Renew
❑ Tightening torque:
30 Nm
❑ Screwed onto compres‐
sor shaft
❑ Clean thread of com‐
pressor shaft before
screwing on drive plate
❑ Thread of new drive
plate has been lubrica‐
ted at factory with a pre-
determined amount of a
specific grease
❑ Different versions ⇒
Electronic parts cata‐
logue
❑ 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
❑ Before fitting, coat rub‐
ber elements lightly with
lubricant (e.g. tyre as‐
sembly paste or soap)
❑ Detaching and attach‐
ing
⇒ “4.7.1 Removing and
installing pulley (without
air conditioning system
magnetic clutch N25 ) -
Denso air conditioner compressor (version 1)”, page 188
3 - Circlip
❑ Renew
❑ Ensure correct installation position (flat side facing air conditioner compressor)
❑ Removing and installing
⇒ “4.7.1 Removing and installing pulley (without air conditioning system magnetic clutch N25 ) - Denso
air conditioner compressor (version 1)”, page 188
4 - Pulley
❑ Different versions (depending e.g. on type of engine) ⇒ Electronic parts catalogue
❑ Detaching and attaching
⇒ “4.7.1 Removing and installing pulley (without air conditioning system magnetic clutch N25 ) - Denso
air conditioner compressor (version 1)”, page 188
5 - Air conditioner compressor
❑ Different versions may be fitted, depending on engine type and country-specific version of vehicle ⇒
Electronic parts catalogue .
❑ Clean air conditioner compressor flange before fitting pulley
❑ Clean thread of compressor shaft and apply a small quantity of grease to thread

148 Rep. gr.87 - Air conditioning system

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4.2.2 Exploded view - “Denso” air conditioner

compressor pulley (version 2)
– Perform preparations
⇒ “4.6 Preparations for renewing pulley”, page 187 .

1 - Circlip with rubber disc

❑ Removing and installing
⇒ “4.7.2 Removing and
installing pulley (without
air conditioning system
magnetic clutch N25 ) -
Denso air conditioner
compressor (version
2)”, page 190
❑ Vulcanised rubber disc
provides noise insula‐
tion when compressor
output is low and engine
is idling
2 - Drive plate
❑ Screwed onto compres‐
sor shaft
❑ Different versions ⇒
Electronic parts cata‐
logue
❑ 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
❑ Removing and installing
⇒ “4.7.2 Removing and
installing pulley (without
air conditioning system
magnetic clutch N25 ) -
Denso air conditioner
compressor (version
2)”, page 190
❑ Tightening torque: 35
Nm
3 - Circlip
❑ Renew
❑ Ensure correct installation position (flat side facing air conditioner compressor)
❑ Removing and installing
⇒ “4.7.2 Removing and installing pulley (without air conditioning system magnetic clutch N25 ) - Denso
air conditioner compressor (version 2)”, page 190
4 - Spacer
❑ Dimensions: 17.5 x 10 x 3 mm
5 - Rubber elements
❑ 6x, ensure correct installation
⇒ “4.7.2 Removing and installing pulley (without air conditioning system magnetic clutch N25 ) - Denso
air conditioner compressor (version 2)”, page 190
❑ Before fitting, coat rubber elements with lubricant (e.g. tyre assembly paste or soap)

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6 - Pulley
❑ Different versions ⇒ Electronic parts catalogue
❑ Removing and installing
⇒ “4.7.2 Removing and installing pulley (without air conditioning system magnetic clutch N25 ) - Denso
air conditioner compressor (version 2)”, page 190
7 - Air conditioner compressor
❑ Without air conditioning system magnetic clutch - N25-
❑ Different versions may be fitted, depending on engine type and country-specific version of vehicle ⇒
Electronic parts catalogue .
❑ Clean air conditioner compressor flange before fitting pulley

4.2.3 Exploded view - “Denso” air conditioner

compressor pulley (with air conditioning
system magnetic clutch - N25- )
– Perform preparations
⇒ “4.6 Preparations for renewing pulley”, page 187 .

1 - Cap
❑ Not always fitted
2 - Clutch plate
❑ Renew
❑ Tightening torque:
30 Nm
❑ Detaching and attach‐
ing
⇒ “4.8.2 Detaching and
attaching clutch plate -
Denso air conditioner
compressor”, page 193
❑ Screwed onto compres‐
sor shaft
❑ Different versions ⇒
Electronic parts cata‐
logue
❑ 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 when magnetic
clutch -N25- is activated
3 - Washer
4 - Spacer
❑ For adjusting gap be‐
tween clutch plate and
pulley
❑ Checking gap
⇒ “4.8.5 Checking gap
between pulley and
clutch plate - Denso air
conditioner compressor”, page 194

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5 - Circlip
❑ Renew
❑ Ensure correct installation position (flat side facing air conditioner compressor)
❑ When fitting circlip, take care not to bend it open more than necessary.
– Ensure that circlip is fitted correctly (bevelled side -A- faces away from air conditioner compressor; flat
side faces compressor).

6 - Pulley
❑ The pulley is sensitive to impact and should therefore be treated with care.
❑ Clean air conditioner compressor flange before fitting pulley.
❑ Different versions (depending e.g. on type of engine) ⇒ Electronic parts catalogue
❑ If pulley cannot be detached from air conditioner compressor flange by hand, refer to
⇒ “4.8.4 Detaching pulley”, page 194 .
7 - Circlip
❑ Renew
❑ Ensure correct installation position (flat side facing air conditioner compressor)
❑ When fitting circlip, take care not to bend it open more than necessary.
– Ensure that circlip is fitted correctly (bevelled side -A- faces away from air conditioner compressor; flat
side faces compressor).

8 - Solenoid
❑ When installing, make sure retainer for cable -B- is positioned correctly.
❑ Depending on version, connector -D- may be attached to air conditioner compressor with a bracket.
❑ On air conditioner compressors on which wiring for activating -N25- and -N280- is combined in a 3-pin
connector, eject wire leading to -N25- from connector using a suitable release tool from wiring harness
repair set - VAS 1978 B- ⇒ Electrical system; Rep. gr. 97 ; Releasing and dismantling connector housings
9 - Air conditioner compressor
❑ Different versions may be fitted, depending on engine type and country-specific version of vehicle ⇒
Electronic parts catalogue .
❑ Clean air conditioner compressor flange before fitting pulley.
❑ Clean thread of compressor shaft and apply a small quantity of grease to thread.

4.2.4 Exploded view - “Sanden” air condition‐

er compressor pulley
– Perform preparations
⇒ “4.6 Preparations for renewing pulley”, page 187 .

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1 - Nut
❑ 25 Nm
❑ A plastic cap may be fit‐
ted additionally to pro‐
tect 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‐
tronic parts catalogue .

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)
❑ 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 com‐
pressors with a smaller capacity. On these air conditioner compressors, the pulley is slightly different to
the version shown here (e.g. no rubber elements -B-) ⇒ Electronic parts catalogue .

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6 - Air conditioner compressor

❑ Clean air conditioner compressor drive shaft before fitting pulley

4.2.5 Exploded view - “Sanden” air condition‐

er compressor pulley (with air condition‐
ing system magnetic clutch - N25- )
– Perform preparations
⇒ “4.6 Preparations for renewing pulley”, page 187 .
– Remove pulley with air conditioning system magnetic clutch -
N25-
⇒ “4.8 Removing and installing pulley with air conditioning
system magnetic clutch N25 ”, page 192 .

1 - Nut
❑ 25 Nm
❑ Apply locking fluid and
insert nut. For locking
fluid, refer to ⇒ Elec‐
tronic parts catalogue .
❑ 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.
2 - Clutch plate
❑ Renew
❑ Detaching and attach‐
ing
⇒ “4.8.3 Detaching and
attaching clutch plate -
Sanden air conditioner
compressor (with
N25 )”, page 193
❑ Attached to air condi‐
tioner compressor drive
shaft
❑ Different versions ⇒
Electronic parts cata‐
logue
❑ 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 when magnetic
clutch -N25- is activated
3 - Spacer
❑ For adjusting gap between clutch plate and pulley
❑ Checking gap
⇒ “4.8.6 Checking gap between pulley and clutch plate - Sanden air conditioner compressor (with N25 )”,
page 195
4 - Circlip
❑ Renew

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❑ Ensure correct installation position (flat side facing air conditioner compressor)
❑ When fitting circlip, take care not to bend it open more than necessary.
– Ensure that circlip is fitted correctly (bevelled side -A- faces away from air conditioner compressor; flat
side faces compressor).

5 - Pulley
❑ The pulley is sensitive to impact and should therefore be treated with care.
❑ Clean air conditioner compressor flange before fitting pulley.
❑ Different versions (depending e.g. on type of engine) ⇒ Electronic parts catalogue
❑ If pulley cannot be detached from air conditioner compressor flange by hand, refer to
⇒ “4.8.4 Detaching pulley”, page 194 .
6 - Circlip
❑ Renew
❑ When fitting circlip, take care not to bend it open more than necessary.
– Ensure that circlip is fitted correctly (bevelled side -A- faces away from air conditioner compressor; flat
side faces compressor).

7 - Solenoid
❑ When installing, make sure retainer for cable -B- is positioned correctly.
❑ Depending on version, connector may be attached to air conditioner compressor with a bracket.
❑ Air conditioner compressor on which wiring for activating -N25- and -N280- is combined in 3-pin con‐
nector: Unplug connector from -N280- or disconnect wire to -N25- from connector
⇒ Item 12 (page 154) using a suitable release tool from wiring harness repair set - VAS 1978 B- ⇒
Electrical system; Rep. gr. 97 ; Releasing and dismantling connector housings
8 - Bolt
❑ 3 Nm
❑ For securing bracket ⇒ Item 9 (page 154) , for connector ⇒ Item 12 (page 154) and earth connection
of -N25-
❑ Before installing, check and if necessary clean contact surfaces on air conditioner compressor and
bracket.
9 - Bracket
10 - Bolt
❑ 3 Nm
11 - Bracket
12 - Connector
❑ Different versions, depending on air conditioner compressor and -N280- (1, 2 or 3 pins)
13 - Air conditioner compressor
❑ Different versions may be fitted, depending on engine type and country-specific version of vehicle ⇒
Electronic parts catalogue .
❑ Clean air conditioner compressor flange before fitting pulley.
❑ Clean thread of compressor shaft and apply a small quantity of grease to thread.

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4.3 Detaching and attaching air conditioner

compressor at bracket
⇒ “4.3.1 Detaching and attaching air conditioner compressor at
bracket - vehicles with 4-cyl. TDI engine”, page 155
⇒ “4.3.2 Detaching and attaching air conditioner compressor at
bracket - vehicles with 4-cyl. TFSI engine”, page 156
⇒ “4.3.3 Detaching and attaching air conditioner compressor at
bracket - vehicles with V6 engine (except those with 2.9 ltr. TFSI
engine)”, page 159
⇒ “4.3.4 Detaching and attaching air conditioner compressor at
bracket - vehicles with V6 2.9 ltr. TFSI engine”, page 160
⇒ “4.3.5 Detaching and attaching electrically driven air conditioner
compressor at bracket”, page 163

4.3.1 Detaching and attaching air conditioner

compressor at bracket - vehicles with 4-
cyl. TDI engine
Detaching
– Detach poly V-belt from air conditioner compressor ⇒ Engine;
Rep. gr. 13 ; Cylinder block (pulley end); Removing and in‐
stalling poly V-belt .
– Disconnect supply line at injector for reducing agent -arrow-
and move clear.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
– Remove wheel spoiler (left-side) ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Wheel housing liners; Exploded view -
wheel housing liner (front) .
– Release wheel housing liner in vicinity of bumper cover (front)
⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front) .

– Unscrew nuts -1 and 3-.

– Move reducing agent supply line clear -arrow-.
– Detach bracket -2- with reducing agent supply line and place
it down in wheel housing.

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– Unplug electrical connectors -A, C-.

– Remove bolts -arrows-.

NOTICE
Risk of damage to refrigerant lines and hoses when detaching
and pivoting air conditioner compressor.
– Do not stretch, kink or bend refrigerant lines and hoses.

– Suspend air conditioner compressor -B- from lock carrier with

a piece of wire.

Installing
Installation is carried out in reverse order; note the following:
– Before securing air conditioner compressor, check position of
both dowel sleeves -A- in bracket or compressor -B-.
• There are different versions of the dowel sleeves -A- (different
lengths); for correct version refer to ⇒ Electronic parts cata‐
logue .
• Make sure that the dowel sleeves -A- are positioned correctly
and that the contact surfaces are clean. If the dowel sleeves
are not installed correctly or the contact surfaces -C- at the
bracket or air conditioner compressor are dirty or damaged,
this could lead to misalignment between the air conditioner
compressor and the engine. After a period of operation, mis‐
alignment can cause damage to the poly V-belt or the air
conditioner compressor.
Tightening torques
♦ ⇒ “4.1 Exploded view - air conditioner compressor”,
page 141
♦ ⇒ Engine; Rep. gr. 13 ; Cylinder block (pulley end); Exploded
view - cylinder block (pulley end)

4.3.2 Detaching and attaching air conditioner

compressor at bracket - vehicles with 4-
cyl. TFSI engine
Detaching
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
– Remove front left wheel spoiler ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Wheel housing liners; Exploded view -
wheel housing liner (front) .
– Remove closure plate at bumper cover ⇒ General body re‐
pairs, exterior; Rep. gr. 63 ; Bumper (front); Exploded view -
bumper cover .

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– Detach poly V-belt from air conditioner compressor ⇒ Engine;

Rep. gr. 13 ; Cylinder block (pulley end); Removing and in‐
stalling poly V-belt .
– Unplug electrical connector -2- for charge pressure sender -
G31- .
– Loosen screw-type clip -1- and detach air pipe from throttle
valve module - J338- .

– Release hose clip -1-, disconnect air hose and detach it down‐
wards.

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– Unplug electrical connector -B-.

Vehicles with 2.0 ltr. TFSI engine and starter-alternator

NOTICE
Risk of damage to refrigerant lines and hoses when detaching
and pivoting air conditioner compressor.
– Do not stretch, kink or bend refrigerant lines and hoses.

– Remove bolts -arrows-.

Note
♦ Due to the routing of the refrigerant line, a bolt on the air con‐
ditioner compressor cannot be removed completely (not
enough space because of refrigerant line).
♦ This bolt must be slackened in stages as a final step; pull the
air conditioner compressor slightly off the bracket while doing
so.
♦ This way the refrigerant lines can remain attached.
Vehicles with 2.0 ltr. TFSI engine without starter-alternator

NOTICE
Risk of damage to refrigerant lines and hoses when detaching
and pivoting air conditioner compressor.
– Do not stretch, kink or bend refrigerant lines and hoses.

– Remove bolts -arrows-.

All vehicles (continued)
– Suspend air conditioner compressor -A- from lock carrier with
a piece of wire.

Installing
Installation is carried out in reverse order; note the following:
– Before securing air conditioner compressor, check position of
both dowel sleeves -A- in bracket or compressor -B-.
• There are different versions of the dowel sleeves -A- (different
lengths); for correct version refer to ⇒ Electronic parts cata‐
logue .
• Make sure that the dowel sleeves -A- are positioned correctly
and that the contact surfaces are clean. If the dowel sleeves
are not installed correctly or the contact surfaces -C- at the
bracket or air conditioner compressor are dirty or damaged,
this could lead to misalignment between the air conditioner
compressor and the engine. After a period of operation, mis‐
alignment can cause damage to the poly V-belt or the air
conditioner compressor.
Tightening torques
♦ ⇒ “4.1 Exploded view - air conditioner compressor”,
page 141

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4.3.3 Detaching and attaching air conditioner

compressor at bracket - vehicles with V6
engine (except those with 2.9 ltr. TFSI
engine)
Detaching
– Remove wheel spoiler (left-side) ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Wheel housing liners; Exploded view -
wheel housing liner (front) .
– Detach poly V-belt from air conditioner compressor ⇒ Engine;
Rep. gr. 13 ; Cylinder block (pulley end); Removing and in‐
stalling poly V-belt .
– Remove bolts -arrows-, move coolant pipe -1- clear with cool‐
ant hoses attached, and let it hang down.

All vehicles with V6 TDI engine

– Drain coolant for engine coolant circuit ⇒ 4-cylinder direct in‐
jection engine (2.0 ltr. 4-valve TFSI, EA 888 Gen. III); Rep. gr.
19 ; Cooling system/coolant; Draining and filling cooling sys‐
tem .
– Remove coolant pipe (front bottom) ⇒ Engine; Rep. gr. 19 ;
Coolant pipes; Removing and installing coolant pipes .
– Lift retaining clip -arrow-, disconnect coolant hose (bottom left)
from radiator and drain off remaining coolant.

All vehicles
– Unplug electrical connector -A-.

NOTICE
Risk of damage to refrigerant lines and hoses when detaching
and pivoting air conditioner compressor.
– Do not stretch, kink or bend refrigerant lines and hoses.

– Remove bolts -arrows-.

– Suspend air conditioner compressor -B- from lock carrier with
a piece of wire.

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Installing
Installation is carried out in reverse order; note the following:
– Before securing air conditioner compressor, check position of
both dowel sleeves -A- in bracket or compressor -B-.
• There are different versions of the dowel sleeves -A- (different
lengths); for correct version refer to ⇒ Electronic parts cata‐
logue .
• Make sure that the dowel sleeves -A- are positioned correctly
and that the contact surfaces are clean. If the dowel sleeves
are not installed correctly or the contact surfaces -C- at the
bracket or air conditioner compressor are dirty or damaged,
this could lead to misalignment between the air conditioner
compressor and the engine. After a period of operation, mis‐
alignment can cause damage to the poly V-belt or the air
conditioner compressor.
All vehicles with V6 TDI engine
– Fill up coolant for engine coolant circuit and bleed coolant cir‐
cuit ⇒ 4-cylinder direct injection engine (2.0 ltr. 4-valve TFSI,
EA 888 Gen. III); Rep. gr. 19 ; Cooling system/coolant; Drain‐
ing and filling cooling system .
Tightening torques
♦ ⇒ “4.1 Exploded view - air conditioner compressor”,
page 141
♦ ⇒ Engine; Rep. gr. 19 ; Coolant pipes; Exploded view - coolant
pipes

4.3.4 Detaching and attaching air conditioner

compressor at bracket - vehicles with V6
2.9 ltr. TFSI engine
Special tools and workshop equipment required
♦ Support bracket - 10-222A-

♦ Tensioning strap - T10038-

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♦ Universal wedge no. 7 from scraper set - VAS 6845-

Detaching
– De-energise 48 V system ⇒ Electrical system; Rep. gr. 27 ;
Battery; Disconnecting and connecting battery .
– Remove engine cover panel and heat shield ⇒ Engine; Rep.
gr. 10 ; Engine cover panel; Removing and installing engine
cover panel .
– Set up support bracket - 10-222A- on longitudinal members
(left and right).
– Hook spindle - 10-222A/11- onto engine lifting eye (front left).
– Lift engine slightly so that load on engine mounting (left-side)
is relieved.
– Remove wheel spoiler (left-side) ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Wheel housing liners; Exploded view -
wheel housing liner (front) .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
– Remove closure plate at bumper cover ⇒ General body re‐
pairs, exterior; Rep. gr. 63 ; Bumper (front); Exploded view -
bumper cover .

– Remove bolts -arrows-, move coolant pipe -1- clear with cool‐
ant hoses attached, and let it hang down.
– Detach poly V-belt from air conditioner compressor ⇒ Engine;
Rep. gr. 13 ; Cylinder block (pulley end); Removing and in‐
stalling poly V-belt .

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– Unplug electrical connector -1-.

– Remove bolts -arrows-.

To remove bolts, proceed as follows:

– Loosen bolt -2- for engine mounting (both sides) several turns.

– Pull engine slightly towards right side using tensioning strap -

T10038- , as shown.
– Lift engine slightly with spindle - 10-222A/11- and remove bolt
for air conditioner compressor at top.
– Detach spindle and tensioning strap.
– Release bumper cover (bottom) at lock carrier ⇒ General body
repairs, exterior; Rep. gr. 63 ; Bumper (front); Removing and
installing bumper cover .

– Unclip and remove air duct -2-.

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– Press locking tab on left of radiator cowl -1- -arrow-, push ra‐
diator cowl upwards slightly and secure it, as shown, with
universal wedge -3-.

NOTICE
Risk of damage to refrigerant lines and hoses when detaching
and pivoting air conditioner compressor.
– Do not stretch, kink or bend refrigerant lines and hoses.

– Detach bolt (bottom) -2-, detach air conditioner compressor

and swivel it away from engine as far as possible without kink‐
ing or straining refrigerant hoses.
– Attach air conditioner compressor to vehicle (e.g. with a piece
of wire) so that refrigerant hoses are not kinked or strained.
Installing
Installation is carried out in reverse order; note the following:
– To make it easier to position the air conditioner compressor,
drive back the bushes for the securing bolts slightly.
• Stiff mounting bushes on the air conditioner compressor must
be released as otherwise the clamping force of the bush will
not be adequate even if tightened to the correct torque.
Install heat shield and engine cover panel ⇒ Engine; Rep. gr.
10 ; Engine cover panel; Removing and installing engine cover
panel .
Tightening torques
♦ ⇒ “4.1.2 Exploded view - air conditioner compressor, vehicles
with V6 2.9 ltr. TFSI engine”, page 144
♦ ⇒ Engine; Rep. gr. 10 ; Assembly mountings; Exploded view
- assembly mountings
♦ ⇒ Engine; Rep. gr. 19 ; Coolant pipes; Exploded view - coolant
pipes
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front)

4.3.5 Detaching and attaching electrically

driven air conditioner compressor at
bracket
The procedure for detaching the electrical air conditioner com‐
pressor - V470- from the bracket (without removing it) is not
described for this vehicle. Due to the additional refrigerant and
coolant lines and the senders in the refrigerant lines in the vicinity
of the air conditioner compressor, there is a risk of damaging the
air conditioner compressor when moving components out of the
way.
⇒ “4.5.8 Removing and installing electrically driven air conditioner
compressor”, page 182
⇒ “4.4.3 Detaching and attaching refrigerant lines at electrical air
conditioner compressor V470 ”, page 166

4.4 Detaching and attaching refrigerant

lines at air conditioner compressor
⇒ “4.4.1 Detaching and attaching refrigerant lines at mechanically
driven air conditioner compressor - vehicles with 4-cyl./V6 TDI

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engine (except S6/S7 models with TDI engine) and with V6 2.9
ltr. TFSI engine”, page 164
⇒ “4.4.2 Detaching and attaching refrigerant lines at mechanically
driven air conditioner compressor - vehicles with V6 3.0 ltr. TFSI
engine and S6/S7 models with TDI engine”, page 165
⇒ “4.4.3 Detaching and attaching refrigerant lines at electrical air
conditioner compressor V470 ”, page 166

4.4.1 Detaching and attaching refrigerant

lines at mechanically driven air condi‐
tioner compressor - vehicles with 4-cyl./
V6 TDI engine (except S6/S7 models
with TDI engine) and with V6 2.9 ltr.
TFSI engine
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

Detaching
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
– Switch off ignition.
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station .
– Remove wheel spoiler (left-side) ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Wheel housing liners; Exploded view -
wheel housing liner (front) .

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CAUTION
Risk of frostbite from escaping pressurised refrigerant
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 re‐
frigerant 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 pres‐
sure in the refrigerant circuit.

– Remove bolts -B, D- from above.

– Disconnect refrigerant lines -A, C- and take them out down‐
wards.
Attaching
Installation is carried out in reverse order; note the following:
– Renew O-rings ⇒ “4.12 Refrigerant circuit seals”, page 14 .
– If fitted, check that dowel pin is not damaged and is seated
correctly.
– Thoroughly clean air conditioner compressor and refrigerant
lines in connection area and check for damage.
– Insert refrigerant lines in connections on air conditioner com‐
pressor so they are free of tension and bolt them on.
– After attaching, check routing of refrigerant lines: they must be
fitted tension-free in appropriate brackets and must not make
contact with any other components.
– Evacuate and charge refrigerant circuit ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air
conditioners with refrigerant R1234yf - General information;
Rep. gr. 87 ; Working with the air conditioner service station .
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22 Starting up air conditioner after charging refrigerant
circuit”, page 108 .
Tightening torques
♦ ⇒ “4.1.1 Exploded view - air conditioner compressor, all vehi‐
cles except those with V6 2.9 ltr. TFSI engine”, page 141
♦ ⇒ “2.6.1 Exploded view - refrigerant lines, air conditioner com‐
pressor and condenser”, page 46

4.4.2 Detaching and attaching refrigerant

lines at mechanically driven air condi‐
tioner compressor - vehicles with V6 3.0
ltr. TFSI engine and S6/S7 models with
TDI engine
Special tools and workshop equipment required

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♦ Engine bung set - VAS 6122-

Detaching
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
– Switch off ignition.
– Remove air conditioner compressor ⇒ page 170 .
– Remove bolts -B, D-.
– Detach refrigerant lines -A, C-.
Attaching
Installation is carried out in reverse order; note the following:
– Renew O-rings ⇒ “4.12 Refrigerant circuit seals”, page 14 .
– If fitted, check that dowel pin is not damaged and is seated
correctly.
– Thoroughly clean air conditioner compressor and refrigerant
lines in connection area and check for damage.
– Insert refrigerant lines in connections on air conditioner com‐
pressor so they are free of tension and bolt them on.
– After attaching, check routing of refrigerant lines: they must be
fitted tension-free in appropriate brackets and must not make
contact with any other components.
– Evacuate and charge refrigerant circuit ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air
conditioners with refrigerant R1234yf - General information;
Rep. gr. 87 ; Working with the air conditioner service station .
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22 Starting up air conditioner after charging refrigerant
circuit”, page 108 .
Tightening torques
♦ ⇒ “4.1.1 Exploded view - air conditioner compressor, all vehi‐
cles except those with V6 2.9 ltr. TFSI engine”, page 141
♦ ⇒ “2.6.1 Exploded view - refrigerant lines, air conditioner com‐
pressor and condenser”, page 46

4.4.3 Detaching and attaching refrigerant

lines at electrical air conditioner com‐
pressor - V470-
Special tools and workshop equipment required

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♦ Engine bung set - VAS 6122-

Detaching
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
Working with ignition switched on or high-voltage system active
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
– Switch on ignition.
– Initiate basic setting of air conditioner via thermal manage‐
ment control unit - J1024- ; use the Extract, evacuate and
charge refrigerant circuit routine stored there to open
electrically actuated valves ⇒ Vehicle diagnostic tester.
– Switch off ignition.
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station .
– Remove coolant expansion tank for high-voltage coolant cir‐
cuit ⇒ 4-cylinder direct injection engine (2.0 ltr. 4-valve TFSI,
EA 888 Gen. III); Rep. gr. 19 ; Cooling system/coolant; Ex‐
ploded view - coolant expansion tank .

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– Mark electrical connectors -B- and -F- with corresponding

senders to prevent interchange with other connectors or send‐
ers.
– Unplug electrical connectors -B, F-.

CAUTION
Risk of frostbite from escaping pressurised refrigerant
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 re‐
frigerant 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 pres‐
sure in the refrigerant circuit.

– Remove bolts -A, D- from above.

– Open bracket -H- and move service connection clear.
– Disconnect refrigerant lines -C, E- and take them out down‐
wards.
Attaching
Installation is carried out in reverse order; note the following:

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– Renew O-rings -3-

⇒ “4.12 Refrigerant circuit seals”, page 14 .
– If fitted, check that dowel pins -4- at refrigerant lines are not
damaged and are seated correctly.
– Thoroughly clean air conditioner compressor and refrigerant
lines in connection area and check for damage.
– Insert refrigerant lines in connections on air conditioner com‐
pressor so they are free of tension and bolt them on.
– After attaching, check routing of refrigerant lines: they must be
fitted tension-free in appropriate brackets and must not make
contact with any other components.
– 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 .
– Switch on ignition.
– Initiate air conditioner basic setting via thermal management
control unit - J1024- and use a routine stored there to open
electrically actuated valves ( Stop routine: Charging/
flushing refrigerant circuit ) ⇒ Vehicle diagnostic test‐
er.
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22.2 Starting up air conditioner after charging refrigerant
circuit - vehicles with high-voltage system”, page 109 .
Tightening torques
♦ ⇒ “4.1.3 Exploded view - electrically driven air conditioner
compressor”, page 146
♦ ⇒ “2.6.3 Exploded view - refrigerant lines, vehicles with high-
voltage system”, page 50

4. Air conditioner compressor 169

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4.5 Removing and installing air conditioner

compressor
⇒ “4.5.1 Notes on mechanically driven air conditioner compres‐
sors”, page 170
⇒ “4.5.2 Removing and installing air conditioner compressor - ve‐
hicles with 4-cyl. TDI engine”, page 170
⇒ “4.5.3 Removing and installing air conditioner compressor - ve‐
hicles with V6 TDI engine (except S6/S7 models with TDI en‐
gine)”, page 172
⇒ “4.5.4 Removing and installing air conditioner compressor - S6/
S7 models with TDI engine”, page 174
⇒ “4.5.5 Removing and installing air conditioner compressor - ve‐
hicles with 4-cyl. TFSI engine”, page 176
⇒ “4.5.6 Removing and installing air conditioner compressor - ve‐
hicles with V6 2.9 ltr. TFSI engine”, page 179
⇒ “4.5.7 Removing and installing air conditioner compressor - ve‐
hicles with V6 3.0 ltr. TFSI engine”, page 180
⇒ “4.5.8 Removing and installing electrically driven air conditioner
compressor”, page 182

4.5.1 Notes on mechanically driven air condi‐

tioner compressors
♦ The compressor version may differ depending on the produc‐
tion period and engine ⇒ Electronic parts catalogue .
♦ An air conditioner compressor with or without air conditioning
system magnetic clutch - N25- may be installed, depending on
the vehicle model, production period and engine.
♦ The air conditioner compressor without air conditioning sys‐
tem magnetic clutch - N25- is always driven when the engine
is running. Since the air conditioner compressor version (with
or without -N25- ) cannot always be distinguished clearly from
above, only start the engine if the refrigerant circuit has been
assembled properly. If, for example, the refrigerant lines are
not connected to the air conditioner compressor when the en‐
gine is running, the compressor might heat up (internal heat
generation) so much that this can lead to irreparable damage
to the compressor. The internal heat generation is caused by
the air conditioner compressor operating against a fixed re‐
sistance even at approximately 0 % delivery rate (sealed
circuit).
♦ To prevent the air conditioner compressor from being dam‐
aged irreparably when the refrigerant circuit is empty, it is
designed so that delivery is reduced to roughly 0 % and lubri‐
cation is maintained via an internal oil circuit with the residual
oil left in the air conditioner compressor.
♦ As replacement air conditioner compressors of this type with
different oil capacities are available, make sure to observe the
oil quantity in the compressor ⇒ “5 Technical data”, page 16 .

4.5.2 Removing and installing air conditioner

compressor - vehicles with 4-cyl. TDI
engine
Special tools and workshop equipment required

170 Rep. gr.87 - Air conditioning system

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♦ Engine bung set - VAS 6122-

• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
Removing
– Switch off ignition.
– Detach refrigerant lines from air conditioner compressor
⇒ “4.4 Detaching and attaching refrigerant lines at air condi‐
tioner compressor”, page 163 .
– Detach poly V-belt from air conditioner compressor ⇒ Engine;
Rep. gr. 13 ; Cylinder block (pulley end); Removing and in‐
stalling poly V-belt .
– Disconnect supply line at injector for reducing agent -arrow-
and move clear.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
– Remove wheel spoiler (left-side) ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Wheel housing liners; Exploded view -
wheel housing liner (front) .
– Release wheel housing liner in vicinity of bumper cover (front)
⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front) .

– Unscrew nuts -1 and 3-.

– Move reducing agent supply line clear -arrow-.
– Detach bracket -2- with reducing agent supply line and place
it down in wheel housing.

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– Unplug electrical connectors -A, C-.

– Remove bolts -arrows-.
– Push coolant hoses slightly to side and remove air conditioner
compressor -B- towards left side.
Installing
Installation is carried out in reverse order; note the following:
– If the air conditioner compressor is being renewed (e.g. due to
internal damage), observe the notes on renewing the air con‐
ditioner compressor ⇒ 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 .
♦ 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 conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Refrigerant circuit; Renewing components .

– Before securing air conditioner compressor, check position of

both dowel sleeves -A- in bracket or compressor -B-.
• There are different versions of the dowel sleeves -A- (different
lengths); for correct version refer to ⇒ Electronic parts cata‐
logue .
• Make sure that the dowel sleeves -A- are positioned correctly
and that the contact surfaces are clean. If the dowel sleeves
are not installed correctly or the contact surfaces -C- at the
bracket or air conditioner compressor are dirty or damaged,
this could lead to misalignment between the air conditioner
compressor and the engine. After a period of operation, mis‐
alignment can cause damage to the poly V-belt or the air
conditioner compressor.
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 .
– Before fitting poly V-belt, turn air conditioner compressor 10
times via pulley in direction of rotation (to prevent damage to
compressor on initial activation).
– Evacuate and charge refrigerant circuit ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air
conditioners with refrigerant R1234yf - General information;
Rep. gr. 87 ; Working with the air conditioner service station .
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22 Starting up air conditioner after charging refrigerant
circuit”, page 108 .
Tightening torques
♦ ⇒ “4.1 Exploded view - air conditioner compressor”,
page 141
♦ Bracket ⇒ Engine; Rep. gr. 13 ; Cylinder block (pulley end);
Exploded view - cylinder block (pulley end)

4.5.3 Removing and installing air conditioner

compressor - vehicles with V6 TDI en‐

172 Rep. gr.87 - Air conditioning system

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gine (except S6/S7 models with TDI en‐

gine)
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
Removing
– Switch off ignition.
– Detach refrigerant lines from air conditioner compressor
⇒ “4.4 Detaching and attaching refrigerant lines at air condi‐
tioner compressor”, page 163 .
– Detach poly V-belt from air conditioner compressor ⇒ Engine;
Rep. gr. 13 ; Cylinder block (pulley end); Removing and in‐
stalling poly V-belt .
– Unplug electrical connector -A-.
– Remove bolts -arrows-.
– Take out air conditioner compressor -B- towards left.
Installing
Installation is carried out in reverse order; note the following:
– If the air conditioner compressor is being renewed (e.g. due to
internal damage), observe the notes on renewing the air con‐
ditioner compressor ⇒ 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 .
♦ 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 conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Refrigerant circuit; Renewing components .

4. Air conditioner compressor 173

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– Before securing air conditioner compressor, check position of

both dowel sleeves -A- in bracket or compressor -B-.
• There are different versions of the dowel sleeves -A- (different
lengths); for correct version refer to ⇒ Electronic parts cata‐
logue .
• Make sure that the dowel sleeves -A- are positioned correctly
and that the contact surfaces are clean. If the dowel sleeves
are not installed correctly or the contact surfaces -C- at the
bracket or air conditioner compressor are dirty or damaged,
this could lead to misalignment between the air conditioner
compressor and the engine. After a period of operation, mis‐
alignment can cause damage to the poly V-belt or the air
conditioner compressor.
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 .
– Before fitting poly V-belt, turn air conditioner compressor 10
times via pulley in direction of rotation (to prevent damage to
compressor on initial activation).
– Evacuate and charge refrigerant circuit ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air
conditioners with refrigerant R1234yf - General information;
Rep. gr. 87 ; Working with the air conditioner service station .
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22 Starting up air conditioner after charging refrigerant
circuit”, page 108 .
Tightening torques
♦ ⇒ “4.1 Exploded view - air conditioner compressor”,
page 141

4.5.4 Removing and installing air conditioner

compressor - S6/S7 models with TDI
engine
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
Removing
– Switch off ignition.
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners

174 Rep. gr.87 - Air conditioning system

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with refrigerant R1234yf - General information; Rep. gr. 87 ;

Working with the air conditioner service station .
– Detach poly V-belt from air conditioner compressor ⇒ Engine;
Rep. gr. 13 ; Cylinder block (pulley end); Removing and in‐
stalling poly V-belt .
– Remove wheel spoiler (left-side) ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Wheel housing liners; Exploded view -
wheel housing liner (front) .
– Unfasten front section of wheel housing liner and press to one
side ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel
housing liners; Exploded view - wheel housing liner (front) .
– Drain coolant for engine coolant circuit ⇒ 4-cylinder direct in‐
jection engine (2.0 ltr. 4-valve TFSI, EA 888 Gen. III); Rep. gr.
19 ; Cooling system/coolant; Draining and filling cooling sys‐
tem .
– Remove coolant pipe (front bottom) ⇒ Engine; Rep. gr. 19 ;
Coolant pipes; Removing and installing coolant pipes .
– Lift retaining clip -arrow-, disconnect coolant hose (bottom left)
from radiator and drain off remaining coolant.

– Remove bolts -arrows- and push coolant pipe (left-side) -2- in

wheel housing to one side.
– Release screw-type clip -1- and detach air hose.

– Unplug electrical connector -A-.

– Remove bolts -arrows-.
– Remove air conditioner compressor -B- downwards.
– Remove refrigerant lines from air conditioner compressor
⇒ “4.4 Detaching and attaching refrigerant lines at air condi‐
tioner compressor”, page 163 .

4. Air conditioner compressor 175

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Installing
Installation is carried out in reverse order; note the following:
– Before securing air conditioner compressor, check position of
both dowel sleeves -A- in bracket or compressor -B-.
• There are different versions of the dowel sleeves -A- (different
lengths); for correct version refer to ⇒ Electronic parts cata‐
logue .
• Make sure that dowel sleeves -A- are correctly positioned and
that contact surfaces are clean. If the dowel sleeves are not
installed correctly or the contact surfaces -C- at the bracket or
air conditioner compressor are dirty or damaged, this could
lead to misalignment between the air conditioner compressor
and the engine. After a period of operation, misalignment can
cause damage to the poly V-belt or the air conditioner com‐
pressor.
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 .
– Before fitting poly V-belt, turn air conditioner compressor 10
times via pulley in direction of rotation (to prevent damage to
compressor on initial activation).
– Evacuate and charge refrigerant circuit ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air
conditioners with refrigerant R1234yf - General information;
Rep. gr. 87 ; Working with the air conditioner service station .
– Fill up coolant for engine coolant circuit ⇒ 4-cylinder direct
injection engine (2.0 ltr. 4-valve TFSI, EA 888 Gen. III); Rep.
gr. 19 ; Cooling system/coolant; Draining and filling cooling
system .
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22 Starting up air conditioner after charging refrigerant
circuit”, page 108 .
– Bleed engine coolant circuit ⇒ 4-cylinder direct injection en‐
gine (2.0 ltr. 4-valve TFSI, EA 888 Gen. III); Rep. gr. 19 ;
Cooling system/coolant; Draining and filling cooling system .
Tightening torques
♦ ⇒ “4.1 Exploded view - air conditioner compressor”,
page 141

4.5.5 Removing and installing air conditioner

compressor - vehicles with 4-cyl. TFSI
engine
Special tools and workshop equipment required

176 Rep. gr.87 - Air conditioning system

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♦ Engine bung set - VAS 6122-

• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
Removing
– Switch off ignition.
– Detach refrigerant lines from air conditioner compressor
⇒ “4.4 Detaching and attaching refrigerant lines at air condi‐
tioner compressor”, page 163 .
– Detach poly V-belt from air conditioner compressor ⇒ Engine;
Rep. gr. 13 ; Cylinder block (pulley end); Removing and in‐
stalling poly V-belt .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
– Unplug electrical connector -2- for charge pressure sender -
G31- .
– Loosen screw-type clip -1- and detach air pipe from throttle
valve module - J338- .

– Release hose clip -1-, disconnect air hose and detach it down‐
wards.

4. Air conditioner compressor 177

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– Unplug electrical connector -B-.

– Remove bolts -arrows-.
– Take out air conditioner compressor -A- towards left side.
Installing
Installation is carried out in reverse order; note the following:
– If the air conditioner compressor is being renewed (e.g. due to
internal damage), observe the notes on renewing the air con‐
ditioner compressor ⇒ 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 .
♦ 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 conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Refrigerant circuit; Renewing components .

– Before securing air conditioner compressor, check position of

both dowel sleeves -A- in bracket or compressor -B-.
• There are different versions of the dowel sleeves -A- (different
lengths); for correct version refer to ⇒ Electronic parts cata‐
logue .
• Make sure that the dowel sleeves -A- are positioned correctly
and that the contact surfaces are clean. If the dowel sleeves
are not installed correctly or the contact surfaces -C- at the
bracket or air conditioner compressor are dirty or damaged,
this could lead to misalignment between the air conditioner
compressor and the engine. After a period of operation, mis‐
alignment can cause damage to the poly V-belt or the air
conditioner compressor.
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 .
– Before fitting poly V-belt, turn air conditioner compressor 10
times via pulley in direction of rotation (to prevent damage to
compressor on initial activation).
– Evacuate and charge refrigerant circuit ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air
conditioners with refrigerant R1234yf - General information;
Rep. gr. 87 ; Working with the air conditioner service station .
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22 Starting up air conditioner after charging refrigerant
circuit”, page 108 .
Tightening torques
♦ ⇒ “4.1 Exploded view - air conditioner compressor”,
page 141
♦ ⇒ Engine; Rep. gr. 21 ; Charge air system; Exploded view -
charge air system

178 Rep. gr.87 - Air conditioning system

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4.5.6 Removing and installing air conditioner

compressor - vehicles with V6 2.9 ltr.
TFSI engine
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

Removing
– Detach refrigerant lines from air conditioner compressor
⇒ “4.4.1 Detaching and attaching refrigerant lines at mechan‐
ically driven air conditioner compressor - vehicles with 4-cyl./
V6 TDI engine (except S6/S7 models with TDI engine) and
with V6 2.9 ltr. TFSI engine”, page 164 .
– Detach air conditioner compressor from bracket
⇒ “4.3.4 Detaching and attaching air conditioner compressor
at bracket - vehicles with V6 2.9 ltr. TFSI engine”, page 160 .
Installing
Installation is carried out in reverse order; note the following:
– If the air conditioner compressor is being renewed (e.g. due to
internal damage), observe the notes on renewing the air con‐
ditioner compressor ⇒ 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 .
♦ 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 conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Refrigerant circuit; Renewing components .
– Attach air conditioner compressor and connect refrigerant
lines.
– Before fitting poly V-belt, turn air conditioner compressor 10
times via pulley in direction of rotation (to prevent damage to
compressor on initial activation).
– Evacuate and charge refrigerant circuit ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air
conditioners with refrigerant R1234yf - General information;
Rep. gr. 87 ; Working with the air conditioner service station .
– Re-install remaining components (removed earlier).
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22 Starting up air conditioner after charging refrigerant
circuit”, page 108 .

4. Air conditioner compressor 179

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Tightening torques
♦ ⇒ “4.1.2 Exploded view - air conditioner compressor, vehicles
with V6 2.9 ltr. TFSI engine”, page 144
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front)

4.5.7 Removing and installing air conditioner

compressor - vehicles with V6 3.0 ltr.
TFSI engine
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
Removing
– Switch off ignition.
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station .
– Remove wheel spoiler (left-side) ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Wheel housing liners; Exploded view -
wheel housing liner (front) .
– Detach poly V-belt from air conditioner compressor ⇒ Engine;
Rep. gr. 13 ; Cylinder block (pulley end); Removing and in‐
stalling poly V-belt .
– Remove bolts -arrows-, move coolant pipe -1- clear with cool‐
ant hoses attached, and let it hang down.

180 Rep. gr.87 - Air conditioning system

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– Unplug electrical connector -A-.

NOTICE
Risk of damage to refrigerant lines and hoses when detaching
and pivoting air conditioner compressor.
– Do not stretch, kink or bend refrigerant lines and hoses.

– Remove bolts -arrows-.

– Remove air conditioner compressor -B- downwards.
– Remove refrigerant lines from air conditioner compressor
⇒ “4.4 Detaching and attaching refrigerant lines at air condi‐
tioner compressor”, page 163 .
Installing
Installation is carried out in reverse order; note the following:
– If the air conditioner compressor is being renewed (e.g. due to
internal damage), observe the notes on renewing the air con‐
ditioner compressor ⇒ 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 .
♦ 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 conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Refrigerant circuit; Renewing components .

4. Air conditioner compressor 181

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– Before securing air conditioner compressor, check position of

both dowel sleeves -A- in bracket or compressor -B-.
• There are different versions of the dowel sleeves -A- (different
lengths); for correct version refer to ⇒ Electronic parts cata‐
logue .
• Make sure that the dowel sleeves -A- are positioned correctly
and that the contact surfaces are clean. If the dowel sleeves
are not installed correctly or the contact surfaces -C- at the
bracket or air conditioner compressor are dirty or damaged,
this could lead to misalignment between the air conditioner
compressor and the engine. After a period of operation, mis‐
alignment can cause damage to the poly V-belt or the air
conditioner compressor.
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 .
– Before fitting poly V-belt, turn air conditioner compressor 10
times via pulley in direction of rotation (to prevent damage to
compressor on initial activation).
– Evacuate and charge refrigerant circuit ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air
conditioners with refrigerant R1234yf - General information;
Rep. gr. 87 ; Working with the air conditioner service station .
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22 Starting up air conditioner after charging refrigerant
circuit”, page 108 .
Tightening torques
♦ ⇒ “4.1 Exploded view - air conditioner compressor”,
page 141

4.5.8 Removing and installing electrically driv‐

en air conditioner compressor
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-

Removing
• For all subsequent work, seal off any open lines and connec‐
tions immediately using clean plugs from engine bung set -
VAS 6122- .
For all work on vehicles with high-voltage system, note additional
warnings for working on such vehicles
⇒ “1 Safety precautions”, page 1 .
Working with ignition switched on or high-voltage system active

182 Rep. gr.87 - Air conditioning system

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– Switch off (deactivate) auxiliary air conditioner function ⇒

Owner's Manual .
– Switch on ignition.
– Initiate basic setting of air conditioner via thermal manage‐
ment control unit - J1024- ; use the Extract, evacuate and
charge refrigerant circuit routine stored there to open
electrically actuated valves ⇒ Vehicle diagnostic tester.
– Switch off ignition.
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station .

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or electric
arcs.
– Have an Audi high-voltage technician (HVT) or an Audi high-
voltage expert (HVE) de-energise the high-voltage system.

– De-energise high-voltage system ⇒ Rep. gr. 93 ; De-ener‐

gising high-voltage system .
– Drain coolant for engine coolant circuit ⇒ 4-cylinder direct in‐
jection engine (2.0 ltr. 4-valve TFSI, EA 888 Gen. III); Rep. gr.
19 ; Cooling system/coolant; Draining and filling cooling sys‐
tem .
– Remove coolant expansion tank for engine coolant circuit ⇒
4-cylinder direct injection engine (2.0 ltr. 4-valve TFSI, EA 888
Gen. III); Rep. gr. 19 ; Cooling system/coolant; Exploded view
- coolant expansion tank .
– Remove coolant expansion tank for high-voltage coolant cir‐
cuit ⇒ 4-cylinder direct injection engine (2.0 ltr. 4-valve TFSI,
EA 888 Gen. III); Rep. gr. 19 ; Cooling system/coolant; Ex‐
ploded view - coolant expansion tank .
– Lift retaining clips -1, 2- and detach coolant connection from
radiator.

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– Unplug electrical connector -1- for charge pressure sender -

G31- .
– Loosen screw-type clip -2- and detach air pipe from throttle
valve module - J338- .
– Carefully push air pipe towards rear, taking care not to damage
it.

– Lift retaining clip -1- and disconnect coolant hose.

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– Mark electrical connectors -B- and -F- with corresponding

senders to prevent interchange with other connectors or send‐
ers.
– Unplug electrical connectors -B, F, G-.
– Open bracket -H- and move service connection clear.

CAUTION
Risk of frostbite from escaping pressurised refrigerant
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 re‐
frigerant 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 pres‐
sure in the refrigerant circuit.

– Remove bolts -A, D- and detach refrigerant lines -C, E-.

– Seal off refrigerant lines -C, E- and connections immediately
with clean plugs from engine bung set - VAS 6122- .

– Unscrew nuts -C- and detach crash retainer -A-.

– Release and unplug electrical connectors -B- (high-voltage
wire) from electrical air conditioner compressor - V470- ⇒
Rep. gr. 93 ; High-voltage wires; Overview of fitting locations
- high-voltage wires .
– Cover low-voltage and high-voltage wire connectors and mat‐
ing plug at air conditioner compressor to prevent damage and
contamination (e.g. with clean plugs from engine bung set -
VAS 6122- ).

– Remove nuts -B-.

– Remove threaded pins -C- and bolt -A-, and take electrical air
conditioner compressor - V470- -D- out upwards.
Installing
Installation is carried out in reverse order; note the following:
– If the air conditioner compressor is being renewed (e.g. due to
internal damage), observe the notes on renewing the air con‐
ditioner compressor ⇒ 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 .
♦ 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 conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Refrigerant circuit; Renewing components .

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– Renew O-rings -3-

⇒ “4.12 Refrigerant circuit seals”, page 14 .
– If fitted, check that dowel pins -4- at refrigerant lines are not
damaged and are seated correctly.

– Before bolting on air conditioner compressor -D-, check sur‐

faces of compressor (at compressor and engine bracket) and
clean if necessary ⇒ Electrical system; General information;
Rep. gr. 97 ; Contact surface cleaning set - VAS 6410- .
• Prior to installation, check attachment points on air conditioner
compressor and engine bracket. The contact surfaces must
be clean and free of rust and grease.

– Plug in electrical connector -B- at air conditioner compressor

and make sure it engages properly ⇒ Rep. gr. 93 ; High-
voltage wires; Overview of fitting locations - high-voltage
wires .

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– Plug in electrical connectors -B, F, G- at air conditioner com‐

pressor and secure at specified positions.
– Re-install remaining components removed in reverse order.

WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or electric
arcs.
– Have an Audi high-voltage technician (HVT) or an Audi high-
voltage expert (HVE) re-energise the high-voltage system.

– Re-energise high-voltage system ⇒ Rep. gr. 93 ; Re-ener‐

gising high-voltage system .
– 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 .
– Switch on ignition.
– Initiate air conditioner basic setting via thermal management
control unit - J1024- and use a routine stored there to open
electrically actuated valves ( Stop routine: Charging/
flushing refrigerant circuit ) ⇒ Vehicle diagnostic test‐
er.
– Fill up coolant for engine coolant circuit ⇒ 4-cylinder direct
injection engine (2.0 ltr. 4-valve TFSI, EA 888 Gen. III); Rep.
gr. 19 ; Cooling system/coolant; Draining and filling cooling
system .
– Use the Compressor run-in function to start up electrical air
conditioner compressor - V470- ⇒ Vehicle diagnostic tester.
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22.2 Starting up air conditioner after charging refrigerant
circuit - vehicles with high-voltage system”, page 109 .
– Bleed engine coolant circuit ⇒ 4-cylinder direct injection en‐
gine (2.0 ltr. 4-valve TFSI, EA 888 Gen. III); Rep. gr. 19 ;
Cooling system/coolant; Draining and filling cooling system .
Tightening torques
♦ ⇒ “4.1.3 Exploded view - electrically driven air conditioner
compressor”, page 146
♦ ⇒ “2.6.3 Exploded view - refrigerant lines, vehicles with high-
voltage system”, page 50
♦ ⇒ 4-cylinder direct injection engine (2.0 ltr. 4-valve TFSI, EA
888 Gen. III); Rep. gr. 21 ; Charge air system; Exploded view
- hose connections for charge air system
♦ ⇒ 4-cylinder direct injection engine (2.0 ltr. 4-valve TFSI, EA
888 Gen. III); Rep. gr. 19 ; Cooling system/coolant; Exploded
view - coolant expansion tank

4.6 Preparations for renewing pulley

– Switch off ignition.
– Remove noise insulation (front) ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Noise insulation; Exploded view - noise
insulation .

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– Detach poly V-belt from pulley of air conditioner compressor

⇒ Engine; Rep. gr. 13 ; Cylinder block (pulley end); Removing
and installing poly V-belt .

4.7 Removing and installing pulley (without

magnetic clutch)
⇒ “4.7.1 Removing and installing pulley (without air conditioning
system magnetic clutch N25 ) - Denso air conditioner compressor
(version 1)”, page 188
⇒ “4.7.2 Removing and installing pulley (without air conditioning
system magnetic clutch N25 ) - Denso air conditioner compressor
(version 2)”, page 190
⇒ “4.7.3 Removing and installing pulley (without air conditioning
system magnetic clutch N25 ) - “Sanden” air conditioner com‐
pressor”, page 191

4.7.1 Removing and installing pulley (without

air conditioning system magnetic clutch
- N25- ) - “Denso” air conditioner com‐
pressor (version 1)
♦ Notes on renewing pulley -E-
⇒ “4.2.1 Exploded view - Denso air conditioner compressor
pulley (version 1)”, page 147
♦ Pulley is made of plastic, is sensitive to impact and should be
treated with care.
♦ If the overload protection device of the drive plate -C- has been
triggered, the pulley -E- can rotate together with the outer sec‐
tion of the drive plate -C- without the compressor shaft -B- and
the hexagonal bolt -D- attached to the drive plate (inner section
of drive plate -C-) rotating simultaneously.

Detaching
– Perform preparations
⇒ “4.6 Preparations for renewing pulley”, page 187 .
– Remove cap -A-.
– Hold compressor shaft -B- e.g. with a commercially available
hexagon socket wrench (7 mm) and turn drive plate -C- with
pulley -E- in direction of -arrow-.
Note
♦ The torque for driving the air conditioner compressor is applied
to the compressor shaft via the threaded connection between
the drive plate -C- and the compressor shaft.
♦ If the drive plate -C- has become so firmly attached to the
compressor shaft that it can no longer be loosened (the 7 mm
hexagon socket wrench -B- can no longer transmit the nec‐
essary torque), the compressor must be renewed.
– Detach drive plate -C-.

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– Remove circlip -A-.

– Detach pulley -B-.
Attaching
• Bend circlip -A- open only as far as it is necessary for assem‐
bly.
– Clean air conditioner compressor flange before fitting pulley
-B-.
– Install pulley -B-.
– Ensure that new circlip -A- is fitted correctly (bevelled side
-C- faces away from air conditioner compressor; flat side faces
compressor).
– Clean thread of compressor shaft.
Note
♦ Thread of new drive plate has been lubricated at factory with
a pre-determined amount of a specific grease.
– Before installing drive plate, coat rubber elements -D- lightly
with lubricant (e.g. tyre fitting paste or soap solution).
– Insert rubber elements -D- in pulley -B- as shown.

– Press rubber element of drive plate -C- into pulley -E- until
drive plate -C- makes contact with thread of compressor shaft
-B-.
– Secure drive plate -C- to compressor shaft -B- by turning in
direction opposite to -arrow-.
– Hold compressor shaft -B- e.g. with a commercially available
hexagon socket wrench (7 mm) and turn drive plate -C- with
pulley -E- in direction opposite to that of -arrow-.
Tightening torques
♦ ⇒ “4.2.1 Exploded view - Denso air conditioner compressor
pulley (version 1)”, page 147

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4.7.2 Removing and installing pulley (without

air conditioning system magnetic clutch
- N25- ) - “Denso” air conditioner com‐
pressor (version 2)
♦ Notes on renewing pulley
⇒ “4.2.2 Exploded view - Denso air conditioner compressor
pulley (version 2)”, page 149
♦ Pulley is made of plastic, is sensitive to impact and should be
treated with care.
♦ If overload protection device of drive plate -C- has been trig‐
gered, remove circlip -A- and then prise drive plate off pulley
-D-.
♦ Circlip -A- with a vulcanised rubber disc is fitted to minimise
noise
⇒ “4.2.2 Exploded view - Denso air conditioner compressor
pulley (version 2)”, page 149 and ⇒ Electronic parts cata‐
logue .
Removing
– Perform preparations
⇒ “4.6 Preparations for renewing pulley”, page 187 .
– Remove poly V-belt ⇒ Engine; Rep. gr. 13 ; Cylinder block
(pulley end); Removing and installing poly V-belt .

– Using a small screwdriver or long-nose pliers, carefully re‐

move circlip -A- (with vulcanised rubber disc).
– Hold compressor shaft -B- with a commercially available hex‐
agon key and turn drive plate -C- with pulley -E- in direction of
-arrow E-.
– Detach drive plate -C-.

– Remove circlip -A-.

– Detach pulley -B-.
Note
♦ If the pulley cannot be detached with the air conditioner com‐
pressor installed, remove the air conditioner compressor
⇒ “4.5 Removing and installing air conditioner compressor”,
page 170 .

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Installing
– Clean air conditioner compressor flange before fitting pulley.
– Install pulley -B-.
• Bend circlip -A- open only as far as it is necessary for assem‐
bly.
– Ensure that new circlip -A- is fitted correctly (bevelled side
-C- faces away from air conditioner compressor; flat side faces
compressor).
– Insert rubber elements -D- in pulley -B- as shown.
– Before installing drive plate, coat rubber elements -D- lightly
with lubricant (e.g. tyre fitting paste or soap solution).

– Insert drive plate -C- in rubber elements -D- (refer to top illus‐
tration) until it makes contact with compressor shaft -B-.

– Secure drive plate -C- to compressor shaft -B- by turning in

direction of -arrow F-.
– Tighten drive plate -C- (via pulley -D-) by turning in direction
of arrow -F- with a commercially available strap wrench (with
fabric strap). Counterhold compressor shaft -B- using a com‐
mercially available hexagon key while doing so.
– Fit circlip -A- (with vulcanised rubber disc).
Tightening torques
♦ ⇒ “4.2.2 Exploded view - Denso air conditioner compressor
pulley (version 2)”, page 149

4.7.3 Removing and installing pulley (without

air conditioning system magnetic clutch
- N25- ) - “Sanden” air conditioner com‐
pressor
♦ Pulley is made of plastic, is sensitive to impact and should be
treated with care.
♦ If the pulley overload protection device has been triggered,
check that the air conditioner compressor can rotate freely be‐
fore renewing the pulley. The air conditioner compressor must
be renewed completely if it does not rotate freely.
♦ 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.
– Remove poly V-belt ⇒ Engine; Rep. gr. 13 ; Cylinder block
(pulley end); Removing and installing poly V-belt .

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– Removing and installing pulley

⇒ “4.2.4 Exploded view - Sanden air conditioner compressor
pulley”, page 151 .

4.8 Removing and installing pulley with air

conditioning system magnetic clutch -
N25-
⇒ “4.8.1 Notes on pulley with air conditioning system magnetic
clutch N25 ”, page 192
⇒ “4.8.2 Detaching and attaching clutch plate - Denso air condi‐
tioner compressor”, page 193
⇒ “4.8.3 Detaching and attaching clutch plate - Sanden air con‐
ditioner compressor (with N25 )”, page 193
⇒ “4.8.4 Detaching pulley”, page 194
⇒ “4.8.5 Checking gap between pulley and clutch plate - Denso
air conditioner compressor”, page 194
⇒ “4.8.6 Checking gap between pulley and clutch plate - Sanden
air conditioner compressor (with N25 )”, page 195

4.8.1 Notes on pulley with air conditioning

system magnetic clutch - N25-
♦ If the pulley overload protection device has been triggered,
check that the air conditioner compressor can rotate freely be‐
fore renewing the pulley. The air conditioner compressor must
be renewed completely if it does not rotate freely.
♦ It is usually not necessary to unfasten the air conditioner com‐
pressor from the engine to detach the pulley. Depending on
the engine version, however, it may be necessary to unfasten
the lock carrier from the vehicle and pull it forwards slightly (to
create some space) ⇒ General body repairs, exterior; Rep.
gr. 50 ; Lock carrier; Removing and installing lock carrier .
♦ If the pulley cannot be detached with the air conditioner com‐
pressor in position (this depends on the vehicle and engine
version), detach the air conditioner compressor with the re‐
frigerant lines connected
⇒ “4.3 Detaching and attaching air conditioner compressor at
bracket”, page 155 .
♦ Various pulley versions with differing diameters may be fitted
depending on the type of air conditioner compressor and the
engine version ⇒ Electronic parts catalogue .
♦ The pulley and magnetic clutch are available as a replacement
part (single part number). The pulley and the drive plate are
held together by a bolt (bolt is not required; can be disposed
of). This bolt is used during manufacturing to insert a pre-de‐
termined amount of a specific grease into the thread of the
drive plate (sufficient for fitting the drive plate onto the com‐
pressor shaft once; do not re-use a drive plate that has been
unscrewed) ⇒ Electronic parts catalogue .
♦ The following illustration shows an air conditioner compressor
with a separate connector for the activation of -N25- ; this air
conditioner compressor has a separate connector for the ac‐
tivation of the air conditioner compressor regulating valve -
N280- . On a different version of the air conditioner
compressor, the wiring for activating -N25- and -N280- is com‐
bined in a 3-pin connector. If necessary, remove the wire to -
N25- from the connector using a suitable release tool from the
wiring harness repair set - VAS 1978 B- ⇒ Electrical system;
Rep. gr. 97 ; Releasing and dismantling connector housings .

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4.8.2 Detaching and attaching clutch plate -

“Denso” air conditioner compressor
Detaching
– Perform preparations
⇒ “4.6 Preparations for renewing pulley”, page 187 .
– Remove cap -A-.
– Hold compressor shaft -B- e.g. with a commercially available
hexagon socket wrench (7 mm) and turn clutch plate -C- in
direction of -arrow-.
Note
♦ The torque for driving the air conditioner compressor is applied
to the compressor shaft via the threaded attachment of the
clutch plate -C-. If the clutch plate -C- has become so firmly
attached to the air conditioner compressor shaft -B- that it can
no longer be loosened (the 7 mm hexagon socket wrench can
no longer transmit the necessary torque), the compressor
must be renewed.
Attaching
Attaching is carried out in the reverse order; note the following:
♦ Thread of new clutch plate has been lubricated at factory with
a pre-determined amount of a specific grease.
– Clean contact surfaces of clutch plate and pulley before at‐
taching.
– Clean thread of compressor shaft before screwing on clutch
plate.
– After tightening, check gap width between pulley and clutch
plate and correct if necessary
⇒ “4.8.5 Checking gap between pulley and clutch plate - Den‐
so air conditioner compressor”, page 194 .
Tightening torques
♦ ⇒ “4.2.3 Exploded view - Denso air conditioner compressor
pulley (with air conditioning system magnetic clutch N25 )”,
page 150

4.8.3 Detaching and attaching clutch plate -

“Sanden” air conditioner compressor
(with -N25- )
Detaching
– Perform preparations
⇒ “4.6 Preparations for renewing pulley”, page 187 .

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– If fitted, remove cap (not fitted here).

– Using e.g. a commercially available two-hole pin wrench -C-,
hold the clutch plate -B- in position and remove nut -A-.
Attaching
Attaching is carried out in the reverse order; note the following:
– Clean contact surfaces of clutch plate and pulley before at‐
taching.
– Clean thread of compressor shaft before fitting clutch plate.
– Tighten nut -A-.
– After tightening nut, check gap width between pulley and
clutch plate and correct if necessary
⇒ “4.8.6 Checking gap between pulley and clutch plate - San‐
den air conditioner compressor (with N25 )”, page 195 .
Tightening torques
♦ ⇒ “4.2.5 Exploded view - Sanden air conditioner compressor
pulley (with air conditioning system magnetic clutch N25 )”,
page 153

4.8.4 Detaching pulley

♦ If the pulley -A- is supposed to be re-used, the arms of the
puller must be applied so that the outside of the pulley is not
squashed.
♦ If the pulley -A- cannot be detached by hand from the flange
of the air conditioner compressor after removing the circlip
(e.g. because of dirt), detach it carefully as described below.
– Carefully detach pulley -A- using a 3-arm puller -B-; note the
following:
• Do not support spindle of puller -B- on compressor shaft when
detaching pulley -A-.
• To support spindle of puller -B- at compressor flange, use a
sleeve -C- (e.g. sleeve V.A.G 1719/1 from magnetic clutch
puller - V.A.G 1719- ).
– After detaching pulley -A-, thoroughly clean compressor
flange; it must be possible to slide pulley -A- on by hand.

4.8.5 Checking gap between pulley and clutch

plate - “Denso” air conditioner compres‐
sor
• The gap must be within the permissible range around the en‐
tire circumference.
• The gap can also be measured when the air conditioner com‐
pressor is installed.
• If the gap is outside the permissible range, detach the clutch
plate and adjust the gap to the correct dimension by removing
or inserting spacers
⇒ “4.2.3 Exploded view - Denso air conditioner compressor
pulley (with air conditioning system magnetic clutch N25 )”,
page 150 .

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Procedure
• Clutch plate -C- tightened to correct torque on air conditioner
compressor shaft -E-
⇒ “4.8.2 Detaching and attaching clutch plate - Denso air
conditioner compressor”, page 193 .
– Use a depth gauge -F- to measure dimension “1” between
pulley -B- and clutch plate -C- at 3 points on circumference of
clutch plate -C-; note down measured values.
– Apply a voltage of 12 V to wire to solenoid in connector -A-.
♦ Depending on the version of the air conditioner compressor,
connector -A- may have one or three pins. On 3-pin connec‐
tors, the two wires to the air conditioner compressor regulating
valve - N280- are also incorporated into the connector.
♦ There are different versions of the connector -A-; this illustra‐
tion shows an air conditioner compressor on which the sole‐
noid and -N280- are connected to the vehicle wiring harness
via 2 connectors.
– Apply earth to compressor housing -D-.
– Use a depth gauge -F- to measure dimension “2” between
pulley -B- and clutch plate -C- at 3 points on circumference of
clutch plate -C-; note down measured values.
– Calculate gap based on measured values (dimensions “1” and
“2”).
Gap specification: 0.4 ... 0.6 mm (up to 0.8 mm with a used mag‐
netic clutch)

4.8.6 Checking gap between pulley and clutch

plate - “Sanden” air conditioner com‐
pressor (with -N25- )
• The gap must be within the permissible range around the en‐
tire circumference.
• The gap can also be measured when the air conditioner com‐
pressor is installed.
• If the gap is outside the permissible range, detach the clutch
plate and adjust the gap to the correct dimension by removing
or inserting spacers
⇒ “4.2.5 Exploded view - Sanden air conditioner compressor
pulley (with air conditioning system magnetic clutch N25 )”,
page 153 .

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Procedure
• Nut -F- for securing drive unit of clutch plate -A- tightened to
correct torque on air conditioner compressor shaft -E-
⇒ “4.2.5 Exploded view - Sanden air conditioner compressor
pulley (with air conditioning system magnetic clutch N25 )”,
page 153
– Using slide gauge -C-, measure dimension of pulley -B- with
clutch plate -A- at 3 points around circumference of clutch
plate -A- (note down measured values as dimension “1”).
– Apply a voltage of 12 V to wire -D- to solenoid in connector
-G- (in this case contact “3”).
♦ Depending on the version of the air conditioner compressor,
connector -G- may have one or three pins. On 3-pin connec‐
tors, the two wires to the air conditioner compressor regulating
valve - N280- are also incorporated into the connector.
♦ There are different versions of connector -G-; this illustration
shows an air conditioner compressor on which the solenoid
and -N280- are connected to the vehicle wiring harness via a
3-pin connector ⇒ Current flow diagrams, Electrical fault find‐
ing and Fitting locations.
– Apply earth to compressor housing -E-.
– Using slide gauge -C-, measure dimension of pulley -B- with
clutch plate -A- at 3 points around circumference of clutch
plate -A- (note down measured values as dimension “2”).
– Calculate gap based on measured values (mean value of di‐
mensions “1” and “2” in each case).
Gap specification: 0.35 ... 0.65 mm (up to 0.8 mm with a used
magnetic clutch)

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5 Control motors
⇒ “5.1 Overview of fitting locations - control motors (front)”, page
198
⇒ “5.2 Exploded view - control motors (front)”, page 203
⇒ “5.3 Exploded view - control motors (rear)”, page 211
⇒ “5.4 General information and procedure for removing and in‐
stalling control motors”, page 211
⇒ “5.5 Removing and installing fresh air flap control motor V438
”, page 212
⇒ “5.6 Removing and installing defroster flap control motor V107
”, page 214
⇒ “5.7 Removing and installing left footwell flap control motor
V108 ”, page 217
⇒ “5.8 Removing and installing right footwell flap control motor
V109 ”, page 219
⇒ “5.9 Removing and installing left centre vent control motor V110
- vehicles with PR number 9AQ”, page 221
⇒ “5.10 Removing and installing right centre vent control motor
V111 - vehicles with PR number 9AQ”, page 223
⇒ “5.11 Removing and installing air recirculation flap control motor
V113 ”, page 224
⇒ “5.12 Removing and installing rear temperature flap control
motor V137 / rear left air quantity flap control motor V239 ”, page
226
⇒ “5.13 Removing and installing left temperature flap control mo‐
tor V158 ”, page 227
⇒ “5.14 Removing and installing right temperature flap control
motor V159 ”, page 228
⇒ “5.15 Removing and installing right B-pillar and footwell shut-
off flap control motor V211 / left B-pillar and footwell shut-off flap
control motor V212 ”, page 230
⇒ “5.16 Removing and installing left side vent control motor V299
- vehicles with PR number 9AQ”, page 231
⇒ “5.17 Removing and installing left centre vent control motor
V110 - vehicles with PR number 9AK/KH5”, page 233
⇒ “5.18 Removing and installing right centre vent control motor
V111 - vehicles with PR number 9AK/KH5”, page 235
⇒ “5.19 Removing and installing right side vent control motor
V300 - vehicles with PR number 9AQ”, page 236
⇒ “5.20 Removing and installing rear air distribution flap control
motor V427 / rear right air distribution control motor V594 ”, page
238
⇒ “5.21 Removing and installing rear left air distribution control
motor V593 ”, page 239
⇒ “5.22 Removing and installing rear right air quantity flap control
motor V240 ”, page 240
⇒ “5.23 Removing and installing brackets for control motors on
front heater and air conditioning unit”, page 242

5.1 Overview of fitting locations - control

motors (front)

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⇒ “5.1.1 Overview of fitting locations - control motors (front), ve‐

hicles with PR number 9AK/KH5 ”, page 199
⇒ “5.1.2 Overview of fitting locations - control motors (front), ve‐
hicles with PR number 9AQ”, page 201

5.1.1 Overview of fitting locations - control motors (front), vehicles with PR num‐
ber 9AK/KH5

1 - Rear temperature flap con‐

trol motor - V137-
❑ Removing and installing
⇒ “5.12 Removing and
installing rear tempera‐
ture flap control motor
V137 / rear left air quan‐
tity flap control motor
V239 ”, page 226
❑ Removing and installing
bracket
⇒ “5.23.1 Removing and
installing bracket for
rear temperature flap
control motor V137 /
rear left air quantity flap
control motor V239 ”,
page 242
2 - Left temperature flap con‐
trol motor - V158-
❑ Removing and installing
⇒ “5.13 Removing and
installing left tempera‐
ture flap control motor
V158 ”, page 227
❑ Removing and installing
bracket
⇒ “5.23.3 Removing and
installing bracket for
control motors (left-
side) - vehicles with PR
number 9AK/KH5”,
page 245
3 - Defroster flap control motor
- V107-
❑ Removing and installing
⇒ “5.6 Removing and in‐
stalling defroster flap
control motor V107 ”, page 214
❑ Removing and installing bracket
⇒ “5.23.3 Removing and installing bracket for control motors (left-side) - vehicles with PR number 9AK/
KH5”, page 245
❑ Right-hand drive vehicles: Defroster flap control motor - V107- is not installed on left side of heater and
air conditioning unit, but on right side
4 - Left centre vent control motor - V110-
❑ Removing and installing
⇒ “5.17 Removing and installing left centre vent control motor V110 - vehicles with PR number 9AK/KH5”,
page 233
❑ Removing and installing bracket
⇒ “5.23.3 Removing and installing bracket for control motors (left-side) - vehicles with PR number 9AK/
KH5”, page 245

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5 - Heater and air conditioning unit

❑ Removing and installing ⇒ “6.8 Removing and installing heater and air conditioning unit”, page 270
❑ Removing and installing bracket ⇒ “6.4 Exploded view - evaporator housing”, page 258
6 - Air recirculation flap control motor - V113-
❑ Removing and installing
⇒ “5.11 Removing and installing air recirculation flap control motor V113 ”, page 224
7 - Fresh air flap control motor - V438-
❑ Removing and installing ⇒ “5.5 Removing and installing fresh air flap control motor V438 ”, page 212
8 - Right temperature flap control motor - V159-
❑ Removing and installing
⇒ “5.14 Removing and installing right temperature flap control motor V159 ”, page 228
❑ Removing and installing bracket
⇒ “5.23.5 Removing and installing bracket for control motors (right-side) - vehicles with PR number 9AK/
KH5”, page 249
9 - Right centre vent control motor - V111-
❑ Removing and installing
⇒ “5.18 Removing and installing right centre vent control motor V111 - vehicles with PR number 9AK/
KH5”, page 235
❑ Removing and installing bracket
⇒ “5.23.5 Removing and installing bracket for control motors (right-side) - vehicles with PR number 9AK/
KH5”, page 249
10 - Rear air distribution flap control motor - V427-
❑ Removing and installing
⇒ “5.20 Removing and installing rear air distribution flap control motor V427 / rear right air distribution
control motor V594 ”, page 238
❑ Removing and installing bracket
⇒ “5.23.6 Removing and installing bracket for rear air distribution flap control motor V427 / rear right air
distribution control motor V594 ”, page 250

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5.1.2 Overview of fitting locations - control motors (front), vehicles with PR num‐
ber 9AQ

1 - Rear left air quantity flap

control motor - V239-
❑ Removing and installing
⇒ “5.12 Removing and
installing rear tempera‐
ture flap control motor
V137 / rear left air quan‐
tity flap control motor
V239 ”, page 226
❑ Removing and installing
bracket
⇒ “5.23.1 Removing and
installing bracket for
rear temperature flap
control motor V137 /
rear left air quantity flap
control motor V239 ”,
page 242
2 - Left temperature flap con‐
trol motor - V158-
❑ Removing and installing
⇒ “5.13 Removing and
installing left tempera‐
ture flap control motor
V158 ”, page 227
❑ Removing and installing
bracket
⇒ “5.23.2 Removing and
installing bracket for
control motors (left-
side) - vehicles with PR
number 9AQ”,
page 243
3 - Defroster flap control motor
- V107-
❑ Removing and installing
⇒ “5.6 Removing and in‐
stalling defroster flap
control motor V107 ”, page 214
❑ Removing and installing bracket
⇒ “5.23.2 Removing and installing bracket for control motors (left-side) - vehicles with PR number 9AQ”,
page 243
❑ Right-hand drive vehicles: Defroster flap control motor - V107- is not installed on left side of heater and
air conditioning unit, but on right side
4 - Left centre vent control motor - V110-
❑ Removing and installing
⇒ “5.9 Removing and installing left centre vent control motor V110 - vehicles with PR number 9AQ”, page
221
❑ Removing and installing bracket
⇒ “5.23.2 Removing and installing bracket for control motors (left-side) - vehicles with PR number 9AQ”,
page 243
5 - Left side vent control motor - V299-
❑ Removing and installing
⇒ “5.16 Removing and installing left side vent control motor V299 - vehicles with PR number 9AQ”, page
231

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❑ Removing and installing bracket

⇒ “5.23.2 Removing and installing bracket for control motors (left-side) - vehicles with PR number 9AQ”,
page 243
6 - Left footwell flap control motor - V108-
❑ Removing and installing
⇒ “5.7 Removing and installing left footwell flap control motor V108 ”, page 217
❑ Removing and installing bracket
⇒ “5.23.2 Removing and installing bracket for control motors (left-side) - vehicles with PR number 9AQ”,
page 243
7 - Rear left air distribution control motor - V593-
❑ Removing and installing
⇒ “5.21 Removing and installing rear left air distribution control motor V593 ”, page 239
❑ Removing and installing bracket
⇒ “5.23.2 Removing and installing bracket for control motors (left-side) - vehicles with PR number 9AQ”,
page 243
8 - Heater and air conditioning unit
❑ Removing and installing ⇒ “6.8 Removing and installing heater and air conditioning unit”, page 270
❑ Removing and installing bracket ⇒ “6.4 Exploded view - evaporator housing”, page 258
9 - Air recirculation flap control motor - V113-
❑ Removing and installing
⇒ “5.11 Removing and installing air recirculation flap control motor V113 ”, page 224
10 - Fresh air flap control motor - V438-
❑ Removing and installing ⇒ “5.5 Removing and installing fresh air flap control motor V438 ”, page 212
11 - Right temperature flap control motor - V159-
❑ Removing and installing
⇒ “5.14 Removing and installing right temperature flap control motor V159 ”, page 228
❑ ⇒ “5.23.4 Removing and installing bracket for control motors (right-side) - vehicles with PR number 9AQ”,
page 247
12 - Rear right air quantity flap control motor - V240-
❑ Removing and installing
⇒ “5.22 Removing and installing rear right air quantity flap control motor V240 ”, page 240
❑ Removing and installing bracket
⇒ “5.23.8 Removing and installing bracket for rear right air quantity flap control motor V240 ”,
page 252
13 - Right footwell flap control motor - V109-
❑ Removing and installing
⇒ “5.8 Removing and installing right footwell flap control motor V109 ”, page 219
❑ Removing and installing bracket
⇒ “5.23.4 Removing and installing bracket for control motors (right-side) - vehicles with PR number 9AQ”,
page 247
14 - Rear right air distribution control motor - V594-
❑ Removing and installing
⇒ “5.20 Removing and installing rear air distribution flap control motor V427 / rear right air distribution
control motor V594 ”, page 238
❑ Removing and installing bracket
⇒ “5.23.6 Removing and installing bracket for rear air distribution flap control motor V427 / rear right air
distribution control motor V594 ”, page 250
15 - Right side vent control motor - V300-
❑ Removing and installing
⇒ “5.19 Removing and installing right side vent control motor V300 - vehicles with PR number 9AQ”,
page 236
❑ Removing and installing bracket
⇒ “5.23.4 Removing and installing bracket for control motors (right-side) - vehicles with PR number 9AQ”,
page 247

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16 - Right centre vent control motor - V111-

❑ Removing and installing
⇒ “5.10 Removing and installing right centre vent control motor V111 - vehicles with PR number 9AQ”,
page 223
❑ Removing and installing bracket
⇒ “5.23.4 Removing and installing bracket for control motors (right-side) - vehicles with PR number 9AQ”,
page 247

5.2 Exploded view - control motors (front)

⇒ “5.2.1 Distinguishing features of control motors from different
manufacturers”, page 203
⇒ “5.2.2 Exploded view - control motors (front left), vehicles with
PR number 9AQ”, page 204
⇒ “5.2.3 Exploded view - control motors (front right), vehicles with
PR number 9AQ”, page 205
⇒ “5.2.4 Exploded view - control motors (front left), vehicles with
PR number 9AK/KH5”, page 207
⇒ “5.2.5 Exploded view - control motors (front right), vehicles with
PR number 9AK/KH5 ”, page 208
⇒ “5.2.6 Exploded view - control motors on air intake box”,
page 210

5.2.1 Distinguishing features of control motors

from different manufacturers
At the start of production, this vehicle was only fitted with version
1 Mahle heater and air conditioning units. Later, this vehicle may
also be fitted with version 2 Mahle heater and air conditioning
units (introduction not yet finalised) ⇒ Electronic parts catalogue .
♦ Version 1 “Mahle” heater and air conditioning units have con‐
trol motors -1- with open shaft -2-.
♦ Version 2 “Mahle” heater and air conditioning units have con‐
trol motors -3- with closed shaft -4-.

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5.2.2 Exploded view - control motors (front left), vehicles with PR number 9AQ

1 - Bolt
❑ 1 Nm
2 - Defroster flap control motor
- V107-
❑ ⇒ “5.6 Removing and in‐
stalling defroster flap
control motor V107 ”,
page 214
❑ Right-hand drive vehi‐
cles: Defroster flap con‐
trol motor - V107- is not
installed on left side of
heater and air condition‐
ing unit, but on right side
3 - Gear wheel
❑ This gear wheel has one
wide tooth and one long
tooth; this design en‐
sures that it can only be
assembled with the oth‐
er gear wheel in one po‐
sition
⇒ “5.6 Removing and in‐
stalling defroster flap
control motor V107 ”,
page 214 .
❑ Removing and installing
⇒ “5.23.2 Removing and
installing bracket for
control motors (left-
side) - vehicles with PR
number 9AQ”,
page 243
4 - Bolt
❑ 1 Nm
5 - Bracket for control motors
(left-side)
❑ Removing and installing
⇒ “5.23.2 Removing and installing bracket for control motors (left-side) - vehicles with PR number 9AQ”,
page 243
6 - Connecting element
7 - Heater and air conditioning unit
❑ Air distribution housing (view from left side)
8 - Connecting element
9 - Bracket for rear left air distribution control motor - V593-
❑ Removing and installing
⇒ “5.23.7 Removing and installing bracket for rear left air distribution control motor V593 ”, page 251
10 - Rear left air distribution control motor - V593-
❑ Removing and installing
⇒ “5.21 Removing and installing rear left air distribution control motor V593 ”, page 239
11 - Bracket for rear left air quantity flap control motor - V239-
❑ Removing and installing
⇒ “5.23.1 Removing and installing bracket for rear temperature flap control motor V137 / rear left air
quantity flap control motor V239 ”, page 242

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12 - Rear left air quantity flap control motor - V239-

❑ Removing and installing
⇒ “5.12 Removing and installing rear temperature flap control motor V137 / rear left air quantity flap
control motor V239 ”, page 226
13 - Left footwell flap control motor - V108-
❑ Removing and installing
⇒ “5.7 Removing and installing left footwell flap control motor V108 ”, page 217
14 - Left centre vent control motor - V110-
❑ Removing and installing
⇒ “5.9 Removing and installing left centre vent control motor V110 - vehicles with PR number 9AQ”, page
221
15 - Left side vent control motor - V299-
❑ Removing and installing
⇒ “5.16 Removing and installing left side vent control motor V299 - vehicles with PR number 9AQ”, page
231
16 - Left temperature flap control motor - V158-
❑ Removing and installing
⇒ “5.13 Removing and installing left temperature flap control motor V158 ”, page 227

5.2.3 Exploded view - control motors (front right), vehicles with PR number 9AQ

1 - Connecting element
2 - Heater and air conditioning
unit
3 - Connecting element
4 - Bracket for control motors
(right-side)
❑ Removing and installing
⇒ “5.23.4 Removing and
installing bracket for
control motors (right-
side) - vehicles with PR
number 9AQ”,
page 247
5 - Bolt
❑ 1 Nm
6 - Right temperature flap con‐
trol motor - V159-
❑ Removing and installing
⇒ “5.14 Removing and
installing right tempera‐
ture flap control motor
V159 ”, page 228
7 - Bolt
❑ 1 Nm
8 - Right centre vent control
motor - V111-
❑ Removing and installing
⇒ “5.10 Removing and
installing right centre
vent control motor V111
- vehicles with PR num‐
ber 9AQ”, page 223

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9 - Right side vent control motor - V300-

❑ Removing and installing
⇒ “5.19 Removing and installing right side vent control motor V300 - vehicles with PR number 9AQ”,
page 236
10 - Rear right air quantity flap control motor - V240-
❑ Removing and installing
⇒ “5.22 Removing and installing rear right air quantity flap control motor V240 ”, page 240
11 - Right footwell flap control motor - V109-
❑ Removing and installing
⇒ “5.8 Removing and installing right footwell flap control motor V109 ”, page 219
12 - Rear right air distribution control motor - V594-
❑ Removing and installing
⇒ “5.20 Removing and installing rear air distribution flap control motor V427 / rear right air distribution
control motor V594 ”, page 238
13 - Bracket for rear right air quantity flap control motor - V240-
❑ Removing and installing
⇒ “5.23.8 Removing and installing bracket for rear right air quantity flap control motor V240 ”,
page 252
14 - Bracket for rear right air distribution control motor - V594-
❑ Removing and installing
⇒ “5.23.6 Removing and installing bracket for rear air distribution flap control motor V427 / rear right air
distribution control motor V594 ”, page 250
15 - Connecting element

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5.2.4 Exploded view - control motors (front left), vehicles with PR number 9AK/
KH5

1 - Heater and air conditioning

unit
2 - Connecting element
3 - Connecting element
4 - Gear wheel
❑ This gear wheel has one
wide tooth and one long
tooth; this design en‐
sures that it can only be
assembled with the oth‐
er gear wheel in one po‐
sition
⇒ “5.6 Removing and in‐
stalling defroster flap
control motor V107 ”,
page 214 .
❑ Removing and installing
⇒ “5.23.3 Removing and
installing bracket for
control motors (left-
side) - vehicles with PR
number 9AK/KH5”,
page 245
5 - Bracket for control motors
(left-side)
❑ Do not remove due to
cam plate installed be‐
hind
❑ Removing and installing
⇒ “5.23.3 Removing and
installing bracket for
control motors (left-
side) - vehicles with PR
number 9AK/KH5”,
page 245
6 - Bolt
❑ 1 Nm
7 - Left centre vent control motor - V110-
❑ Removing and installing
⇒ “5.17 Removing and installing left centre vent control motor V110 - vehicles with PR number 9AK/KH5”,
page 233
8 - Left temperature flap control motor - V158-
❑ Removing and installing
⇒ “5.13 Removing and installing left temperature flap control motor V158 ”, page 227
9 - Defroster flap control motor - V107-
❑ Removing and installing ⇒ “5.6 Removing and installing defroster flap control motor V107 ”, page 214
❑ Right-hand drive vehicles: Defroster flap control motor - V107- is not installed on left side of heater and
air conditioning unit, but on right side
10 - Bracket for rear temperature flap control motor - V137-
❑ Removing and installing
⇒ “5.23.1 Removing and installing bracket for rear temperature flap control motor V137 / rear left air
quantity flap control motor V239 ”, page 242

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11 - Rear temperature flap control motor - V137-

❑ Removing and installing
⇒ “5.12 Removing and installing rear temperature flap control motor V137 / rear left air quantity flap
control motor V239 ”, page 226
12 - Lever
13 - Connecting element
❑ Do not remove due to connection with cam plate
14 - Lever
❑ Do not remove due to connection with cam plate
15 - Cam plate
❑ Do not remove due to connection with levers

5.2.5 Exploded view - control motors (front right), vehicles with PR number 9AK/
KH5

1 - Heater and air conditioning

unit
2 - Connecting element
❑ Do not remove due to
connection with cam
plate
3 - Connecting element
❑ Do not remove due to
connection with cam
plate
4 - Cam plate
❑ Do not remove due to
connection with levers
5 - Lever
❑ Do not remove due to
connection with cam
plate
6 - Lever
❑ Do not remove due to
connection with cam
plate
7 - Bracket for control motors
(right-side)
❑ Do not remove due to
cam plate installed be‐
hind
❑ Removing and installing
⇒ “5.23.5 Removing and
installing bracket for
control motors (right-
side) - vehicles with PR
number 9AK/KH5”,
page 249
8 - Bolt
❑ 1 Nm

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9 - Right temperature flap control motor - V159-

❑ Removing and installing
⇒ “5.14 Removing and installing right temperature flap control motor V159 ”, page 228
10 - Right centre vent control motor - V111-
❑ Removing and installing
⇒ “5.18 Removing and installing right centre vent control motor V111 - vehicles with PR number 9AK/
KH5”, page 235
11 - Rear air distribution flap control motor - V427-
❑ Removing and installing
⇒ “5.20 Removing and installing rear air distribution flap control motor V427 / rear right air distribution
control motor V594 ”, page 238
12 - Bracket for control motor -V427-
❑ Do not remove due to cam plate installed behind
❑ Removing and installing
⇒ “5.23.6 Removing and installing bracket for rear air distribution flap control motor V427 / rear right air
distribution control motor V594 ”, page 250
13 - Connecting element
❑ Do not remove due to connection with levers and cam plate
14 - Cam plate
❑ Do not remove due to connection with levers

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5.2.6 Exploded view - control motors on air intake box

1 - Bolt
❑ 1 Nm
2 - Air recirculation flap control
motor - V113-
❑ Removing and installing
⇒ “5.11 Removing and
installing air recircula‐
tion flap control motor
V113 ”, page 224
3 - Fresh air flap control motor
- V438-
❑ Removing and installing
⇒ “5.5 Removing and in‐
stalling fresh air flap
control motor V438 ”,
page 212
4 - Connecting element
5 - Shaft with lever
6 - Bracket
7 - Air intake box

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5.3 Exploded view - control motors (rear)

1 - Bolt
❑ 1 Nm
2 - Right B-pillar and footwell
shut-off flap control motor -
V211-
❑ Removing and installing
⇒ “5.15 Removing and
installing right B-pillar
and footwell shut-off flap
control motor V211 / left
B-pillar and footwell
shut-off flap control mo‐
tor V212 ”, page 230
3 - Air duct to rear vent
❑ Removing and installing
⇒ “7.8 Removing and in‐
stalling air duct for rear
vent”, page 296
4 - Left B-pillar and footwell
shut-off flap control motor -
V212-
❑ Removing and installing
⇒ “5.15 Removing and
installing right B-pillar
and footwell shut-off flap
control motor V211 / left
B-pillar and footwell
shut-off flap control mo‐
tor V212 ”, page 230

5.4 General information and procedure for

removing and installing control motors
♦ At the start of production, this vehicle was only fitted with ver‐
sion 1 Mahle heater and air conditioning units. Later, this
vehicle may also be fitted with version 2 Mahle heater and air
conditioning units (introduction not yet finalised) ⇒ Electronic
parts catalogue .
♦ Depending on the production period, different versions of the
levers and connecting elements may be fitted at the heater
and air conditioning unit ⇒ Electronic parts catalogue .
♦ The illustrations show the procedure for removing and instal‐
ling a control motor with an open shaft.
♦ The control motors on this vehicle are equipped with an elec‐
tronic feature which enables a new control motor to learn its
position at the heater and air conditioning unit during basic
setting; only then can it be activated by the onboard supply
control unit - J519- (all control motors are currently identical)
⇒ Vehicle diagnostic tester.

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♦ Version 1 “Mahle” heater and air conditioning units have con‐

trol motors -1- with open shaft -2-.
♦ Version 2 “Mahle” heater and air conditioning units have con‐
trol motors -3- with closed shaft -4-.
• Before removing a control motor, mark the position of the con‐
nector and control motor on the heater and air conditioning
unit.
• The actuator socket for the control motor has no stop. It rotates
permanently if the control motor is activated. A control motor
should therefore not be activated after it has been detached.
• After installing a control motor, perform basic setting for the
control motor.
Procedure
– Connect ⇒ Vehicle diagnostic tester.
– Select Diagnosis mode and begin diagnosis.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 0009 - Electronic central electrics - J519
♦ 0009 - Electronic central electrics, functions
♦ 0009 - Basic setting for AC functions
♦ ⇒ Basic setting 2 (adapt flap limit stops)

5.5 Removing and installing fresh air flap

control motor - V438-
• Before removing control motors, note general information and
procedure for removing and installing control motors
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Set front passenger seat to rearmost position.
– Switch off ignition.

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– Remove plugs -A-.

– Unfasten and detach insulating mat -B- from air intake box of
heater and air conditioning unit.

– Mark connector -C- and control motor -B- (to prevent possible
interchange if several connectors are unplugged at the same
time).
– Unscrew bolts -A-.
– Detach control motor -B- from shaft -D- of flap.
– Unplug connector -C-.

Installing
Installation is carried out in reverse order; note the following:
– Check that connecting elements and levers to flaps -A-, -B-
and -C- are assembled correctly and can move freely.

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NOTICE
Risk of damage to electronics of control motor if actuator socket
is turned.
– Only turn actuator socket for control motor with wiring har‐
ness connected.
– Carefully turn actuator socket for control motor slowly and
by hand.

• The actuator socket for the control motor has no stop. It rotates
permanently if the control motor is activated. A control motor
should therefore not be activated after it has been detached.
• Check the connection between the actuator socket for the
control motor and the shaft to ensure that there is no play.
– Check shaft -A- and actuator socket -B- for control motor -C-.
They must be properly aligned for assembly.
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.6 Exploded view - control motors on air intake box”,
page 210

5.6 Removing and installing defroster flap

control motor - V107-
• Before removing control motors, note general information and
procedure for removing and installing control motors
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
• Right-hand drive vehicles: Defroster flap control motor - V107-
is not fitted on left side of heater and air conditioning unit, but
on right side.

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♦ The defroster flap is not actuated directly, but by -V107- via

gear wheels. The gear wheels -A- and -C- have one wide tooth
-D- and one long tooth -E- / one wide tooth gap -F- and one
long tooth gap -G- so that they can only be assembled in one
position.
♦ The gear wheel -A- is held in position by a retaining lug -B- to
prevent it from falling out of the mounting when -V107- is re‐
moved.
♦ If the gear wheel -A- was pulled out of the bracket while re‐
moving -V107- , the gear wheel must be inserted again
⇒ “5.23 Removing and installing brackets for control motors
on front heater and air conditioning unit”, page 242 .
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Move driver seat to rearmost position.
– Switch off ignition.
– 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) .
– Depending on version: Remove knee airbag ⇒ General body
repairs, interior; Rep. gr. 69 ; Knee airbags; Removing and
installing knee airbag with igniter .
– Remove footwell vent (driver side)
⇒ “7.4 Removing and installing footwell vent (driver side)”,
page 294 .
– Remove dash panel vent (driver side) ⇒ General body repairs,
interior; Rep. gr. 70 ; Dash panel; Removing and installing
outer dash panel vents .
– Remove mounting bracket and press it as far as possible to
side ⇒ Brake system; Rep. gr. 46 ; Brake pedal; Removing
and installing mounting bracket . Steering column remains fit‐
ted.

– Unfasten air duct (left-side) -C- above dash panel cross mem‐
ber and press it as far outwards as possible -arrow-; remove
fasteners -A, B- to do so.

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– Mark connector -A- and control motor -C- (to prevent possible
interchange if several connectors are unplugged at the same
time).
– Remove bolts -B-.
– Pull control motor -C- off shaft of gear wheel -E-.
– Unplug connector -A-.

Installing
Installation is carried out in reverse order; note the following:
– Check that gear wheel -A- is installed correctly.
– Turn gear wheel -A- to check that defroster flap is actuated
correctly and moves freely.

NOTICE
Risk of damage to electronics of control motor if actuator socket
is turned.
– Only turn actuator socket for control motor with wiring har‐
ness connected.
– Carefully turn actuator socket for control motor slowly and
by hand.

• The actuator socket for the control motor has no stop. It rotates
permanently if the control motor is activated. A control motor
should therefore not be activated after it has been detached.
• Check the connection between the actuator socket for the
control motor and the shaft to ensure that there is no play.
– Check shaft -A- and actuator socket -B- for control motor -C-.
They must be properly aligned for assembly.
– Fit actuator socket -B- for control motor to shaft -A- of flap.

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– Check connection between actuator socket -D- of control mo‐

tor -C- and shaft -E-. There must not be any play.
– Plug in connector -A-.
– Tighten bolts -B-.
– Route wiring harness to connector -A- so that it cannot come
into contact with moving components.
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.6 Exploded view - control motors on air intake box”,
page 210

5.7 Removing and installing left footwell flap

control motor - V108-
• Before removing control motors, note general information and
procedure for removing and installing control motors
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Move front left seat to rearmost position.
– Switch off ignition.
– Remove dash panel cover (driver side) ⇒ General body re‐
pairs, interior; Rep. gr. 70 ; Dash panel; Removing and
installing outer dash panel vents .
– Depending on version: Remove knee airbag ⇒ General body
repairs, interior; Rep. gr. 69 ; Knee airbags; Removing and
installing knee airbag with igniter .
– Remove footwell vent (left-side)
⇒ “7.4 Removing and installing footwell vent (driver side)”,
page 294 .

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– Mark connector -C- and control motor -B- (to prevent possible
interchange if several connectors are unplugged at the same
time).
– Unscrew bolts -A-.
– Detach control motor -B- from shaft -D- of flap.
– Unplug connector -C-.

Installing
Installation is carried out in reverse order; note the following:

NOTICE
Risk of damage to electronics of control motor if actuator socket
is turned.
– Only turn actuator socket for control motor with wiring har‐
ness connected.
– Carefully turn actuator socket for control motor slowly and
by hand.

• The actuator socket for the control motor has no stop. It rotates
permanently if the control motor is activated. A control motor
should therefore not be activated after it has been detached.
• Check the connection between the actuator socket for the
control motor and the shaft to ensure that there is no play.
– Check shaft -A- and actuator socket -B- for control motor -C-.
They must be properly aligned for assembly.
– Fit actuator socket -B- for control motor to shaft -A- of flap.

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– Plug in connector -C-.

– Tighten bolts -A-.
– Route wiring harness to connector -C- so that it cannot come
into contact with moving components.
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.2 Exploded view - control motors (front left), vehicles
with PR number 9AQ”, page 204

5.8 Removing and installing right footwell

flap control motor - V109-
• Before removing control motors, note general information and
procedure for removing and installing control motors
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Move front right seat to rearmost position.
– Switch off ignition.
– Remove glove box ⇒ General body repairs, interior; Rep. gr.
68 ; Storage compartments/covers/trim panels; Removing and
installing glove box .
– Remove footwell vent (right-side)
⇒ “7.5 Removing and installing footwell vent (front passenger
side)”, page 295 .

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– Mark connector -A- and control motor -C- (to prevent possible
interchange if several connectors are unplugged at the same
time).
– Unplug connector -A-.
– Remove bolts -B-.
– Pull control motor -C- off shaft -D- for actuating flaps.

Installing
Installation is carried out in reverse order; note the following:

NOTICE
Risk of damage to electronics of control motor if actuator socket
is turned.
– Only turn actuator socket for control motor with wiring har‐
ness connected.
– Carefully turn actuator socket for control motor slowly and
by hand.

• The actuator socket for the control motor has no stop. It rotates
permanently if the control motor is activated. A control motor
should therefore not be activated after it has been detached.
• Check the connection between the actuator socket for the
control motor and the shaft to ensure that there is no play.
– Check shaft -A- and actuator socket -B- for control motor -C-.
They must be properly aligned for assembly.
– Fit actuator socket -B- for control motor to shaft -A- of flap.

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– Tighten bolts -B-.

– Plug in connector -A-.
– Route wiring harness to connector -A- so that it cannot come
into contact with moving components.
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.3 Exploded view - control motors (front right), vehicles
with PR number 9AQ”, page 205

5.9 Removing and installing left centre vent

control motor - V110- - vehicles with PR
number 9AQ
• Before removing control motors, note general information and
procedure for removing and installing control motors
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Move front left seat to rearmost position.
– Switch off ignition.
– 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) .
– Depending on version: Remove knee airbag ⇒ General body
repairs, interior; Rep. gr. 69 ; Knee airbags; Removing and
installing knee airbag with igniter .
– Remove footwell vent (left-side)
⇒ “7.4 Removing and installing footwell vent (driver side)”,
page 294 .
– Remove dash panel vent (left-side) ⇒ General body repairs,
interior; Rep. gr. 70 ; Dash panel; Removing and installing
outer dash panel vents .
– Remove mounting bracket and press it as far as possible to
side ⇒ Brake system; Rep. gr. 46 ; Brake pedal; Removing
and installing mounting bracket . Steering column remains fit‐
ted.

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– Unfasten air duct (left-side) -C- above dash panel cross mem‐
ber and press it as far outwards as possible -arrow-; remove
fasteners -A, B- to do so.

– Mark connector -C- and control motor -B- (to prevent possible
interchange if several connectors are unplugged at the same
time).
– Unscrew bolts -A-.
– Detach control motor -B- from shaft -D- of flap.
– Unplug connector -C-.

Installing
Installation is carried out in reverse order; note the following:

NOTICE
Risk of damage to electronics of control motor if actuator socket
is turned.
– Only turn actuator socket for control motor with wiring har‐
ness connected.
– Carefully turn actuator socket for control motor slowly and
by hand.

• The actuator socket for the control motor has no stop. It rotates
permanently if the control motor is activated. A control motor
should therefore not be activated after it has been detached.
• Check the connection between the actuator socket for the
control motor and the shaft to ensure that there is no play.
– Check shaft -A- and actuator socket -B- for control motor -C-.
They must be properly aligned for assembly.
– Fit actuator socket -B- for control motor to shaft -A- of flap.

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– Plug in connector -C-.

– Tighten bolts -A-.
– Route wiring harness to connector -C- so that it cannot come
into contact with moving components.
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.2 Exploded view - control motors (front left), vehicles
with PR number 9AQ”, page 204

5.10 Removing and installing right centre

vent control motor - V111- - vehicles with
PR number 9AQ
• Before removing control motors, note general information and
procedure for removing and installing control motors
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Move front right seat to rearmost position.
– Switch off ignition.
– Remove glove box ⇒ General body repairs, interior; Rep. gr.
68 ; Storage compartments/covers/trim panels; Removing and
installing glove box .
– Remove footwell vent (right-side)
⇒ “7.5 Removing and installing footwell vent (front passenger
side)”, page 295 .
– Remove dash panel vents (centre and passenger side) ⇒
General body repairs, interior; Rep. gr. 70 ; Dash panel; Re‐
moving and installing centre vent .
– Unfasten air duct (right-side) -A- above dash panel cross
member and press it as far outwards as possible -arrow-; re‐
move fasteners -B, C- to do so.

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– Mark connector -A- and control motor -C- (to prevent possible
interchange if several connectors are unplugged at the same
time).
– Unscrew bolts -B-, detach air duct for dash panel vent (right-
side) from front heater and air conditioning unit, if necessary,
and push slightly to the side.
– Pull control motor -C- off shaft -D- for actuating flaps.
– Unplug connector -A-.

Installing
Installation is carried out in reverse order; note the following:

NOTICE
Risk of damage to electronics of control motor if actuator socket
is turned.
– Only turn actuator socket for control motor with wiring har‐
ness connected.
– Carefully turn actuator socket for control motor slowly and
by hand.

• The actuator socket for the control motor has no stop. It rotates
permanently if the control motor is activated. A control motor
should therefore not be activated after it has been detached.
• Check the connection between the actuator socket for the
control motor and the shaft to ensure that there is no play.
– Check shaft -A- and actuator socket -B- for control motor -C-.
They must be properly aligned for assembly.
– Fit actuator socket -B- for control motor to shaft -A- of flap.

– Plug in connector -A-.

– Tighten bolts -B-.
– Route wiring harness to connector -A- so that it cannot come
into contact with moving components.
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.3 Exploded view - control motors (front right), vehicles
with PR number 9AQ”, page 205

5.11 Removing and installing air recirculation

flap control motor - V113-
• Before removing control motors, note general information and
procedure for removing and installing control motors
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .

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All vehicles (continued)

– Set front passenger seat to rearmost position.
– Switch off ignition.
– Remove plugs -A-.
– Unfasten and detach insulating mat -B- from air intake box of
heater and air conditioning unit.

– Mark connector -C- and control motor -B- (to prevent possible
interchange if several connectors are unplugged at the same
time).
– Unscrew bolts -A-.
– Detach control motor -B- from shaft -D- of flap.
– Unplug connector -C-.

Installing
Installation is carried out in reverse order; note the following:

NOTICE
Risk of damage to electronics of control motor if actuator socket
is turned.
– Only turn actuator socket for control motor with wiring har‐
ness connected.
– Carefully turn actuator socket for control motor slowly and
by hand.

• The actuator socket for the control motor has no stop. It rotates
permanently if the control motor is activated. A control motor
should therefore not be activated after it has been detached.
• Check the connection between the actuator socket for the
control motor and the shaft to ensure that there is no play.
– Check shaft -A- and actuator socket -B- for control motor -C-.
They must be properly aligned for assembly.
– Fit actuator socket -B- for control motor to shaft -A- of flap.

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– Plug in connector -C-.

– Tighten bolts -A-.
– Route wiring harness to connector -C- so that it cannot come
into contact with moving components.
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.6 Exploded view - control motors on air intake box”,
page 210

5.12 Removing and installing rear tempera‐

ture flap control motor - V137- / rear left
air quantity flap control motor - V239-
• Before removing control motors, note general information and
procedure for removing and installing control motors
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Move front left seat to rearmost position.
– Switch off ignition.
– 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) .
– Depending on version: Remove knee airbag ⇒ General body
repairs, interior; Rep. gr. 69 ; Knee airbags; Removing and
installing knee airbag with igniter .
– Remove footwell vent (left-side)
⇒ “7.4 Removing and installing footwell vent (driver side)”,
page 294 .
– Remove centre console trim (front) ⇒ General body repairs,
interior; Rep. gr. 68 ; Centre console; Exploded view - centre
console .
– Mark connector -C- and control motor -B- (to prevent possible
interchange if several connectors are unplugged at the same
time).
– Unscrew bolts -A-.
– Detach control motor -B- from shaft -D- of flap.
– Unplug connector -C-.

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Installing
Installation is carried out in reverse order; note the following:

NOTICE
Risk of damage to electronics of control motor if actuator socket
is turned.
– Only turn actuator socket for control motor with wiring har‐
ness connected.
– Carefully turn actuator socket for control motor slowly and
by hand.

• The actuator socket for the control motor has no stop. It rotates
permanently if the control motor is activated. A control motor
should therefore not be activated after it has been detached.
• Check the connection between the actuator socket for the
control motor and the shaft to ensure that there is no play.
– Check shaft -A- and actuator socket -B- for control motor -C-.
They must be properly aligned for assembly.
– Fit actuator socket -B- for control motor to shaft -A- of flap.

– Plug in connector -C-.

– Tighten bolts -A-.
– Route wiring harness to connector -C- so that it cannot come
into contact with moving components.
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.2 Exploded view - control motors (front left), vehicles
with PR number 9AQ”, page 204
♦ ⇒ “5.2.4 Exploded view - control motors (front left), vehicles
with PR number 9AK/KH5”, page 207

5.13 Removing and installing left tempera‐

ture flap control motor - V158-
• Before removing control motors, note general information and
procedure for removing and installing control motors
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Remove left side vent control motor - V299- / left centre vent
control motor - V110-
⇒ “5.16 Removing and installing left side vent control motor
V299 - vehicles with PR number 9AQ”, page 231 .

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– Mark connector -C- and control motor -B- (to prevent possible
interchange if several connectors are unplugged at the same
time).
– Unscrew bolts -A-.
– Detach control motor -B- from shaft -D- of flap.
– Unplug connector -C-.

Installing
Installation is carried out in reverse order; note the following:

NOTICE
Risk of damage to electronics of control motor if actuator socket
is turned.
– Only turn actuator socket for control motor with wiring har‐
ness connected.
– Carefully turn actuator socket for control motor slowly and
by hand.

• The actuator socket for the control motor has no stop. It rotates
permanently if the control motor is activated. A control motor
should therefore not be activated after it has been detached.
• Check the connection between the actuator socket for the
control motor and the shaft to ensure that there is no play.
– Check shaft -A- and actuator socket -B- for control motor -C-.
They must be properly aligned for assembly.

– Attach control motor -B- to shaft -D- of flap.

– Plug in connector -C-.
– Tighten bolts -A-.
– Route wiring harness to connector -C- so that it cannot come
into contact with moving components.
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.2 Exploded view - control motors (front left), vehicles
with PR number 9AQ”, page 204
♦ ⇒ “5.2.4 Exploded view - control motors (front left), vehicles
with PR number 9AK/KH5”, page 207

5.14 Removing and installing right tempera‐

ture flap control motor - V159-
• Before removing control motors, note general information and
procedure for removing and installing control motors
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .

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Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Move front right seat to rearmost position.
– Switch off ignition.
– Remove glove box ⇒ General body repairs, interior; Rep. gr.
68 ; Storage compartments/covers/trim panels; Removing and
installing glove box .
– Remove air duct for glove box cooling
⇒ “7.6 Removing and installing air duct for glove box cooling”,
page 296 .
– Remove footwell vent (right-side)
⇒ “7.5 Removing and installing footwell vent (front passenger
side)”, page 295 .
– Mark connector -C- and control motor -B- (to prevent possible
interchange if several connectors are unplugged at the same
time).
– Unscrew bolts -A-.
– Detach control motor -B- from shaft -D- of flap.
– Unplug connector -C-.

Installing
Installation is carried out in reverse order; note the following:

NOTICE
Risk of damage to electronics of control motor if actuator socket
is turned.
– Only turn actuator socket for control motor with wiring har‐
ness connected.
– Carefully turn actuator socket for control motor slowly and
by hand.

• The actuator socket for the control motor has no stop. It rotates
permanently if the control motor is activated. A control motor
should therefore not be activated after it has been detached.
• Check the connection between the actuator socket for the
control motor and the shaft to ensure that there is no play.
– Check shaft -A- and actuator socket -B- for control motor -C-.
They must be properly aligned for assembly.
– Fit actuator socket -B- for control motor to shaft -A- of flap.

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– Plug in connector -C-.

– Tighten bolts -A-.
– Route wiring harness to connector -C- so that it cannot come
into contact with moving components.
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.3 Exploded view - control motors (front right), vehicles
with PR number 9AQ”, page 205
♦ ⇒ “5.2.5 Exploded view - control motors (front right), vehicles
with PR number 9AK/KH5 ”, page 208

5.15 Removing and installing right B-pillar

and footwell shut-off flap control motor -
V211- / left B-pillar and footwell shut-off
flap control motor - V212-
• Before removing control motors, note general information and
procedure for removing and installing control motors
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Remove air duct for rear vent
⇒ “7.8 Removing and installing air duct for rear vent”,
page 296 .
– Unscrew bolts -A-.
– Detach control motor -B- from shaft -C- of flap.
Installing
Installation is carried out in reverse order; note the following:

NOTICE
Risk of damage to electronics of control motor if actuator socket
is turned.
– Only turn actuator socket for control motor with wiring har‐
ness connected.
– Carefully turn actuator socket for control motor slowly and
by hand.

• The actuator socket for the control motor has no stop. It rotates
permanently if the control motor is activated. A control motor
should therefore not be activated after it has been detached.
• Check the connection between the actuator socket for the
control motor and the shaft to ensure that there is no play.

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– Check shaft -A- and actuator socket -B- for control motor -C-.
They must be properly aligned for assembly.
– Fit actuator socket -B- for control motor to shaft -A- of flap.

– Attach control motor -B- to shaft -C- of flap.

– Tighten bolts -A-.
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.6 Exploded view - control motors on air intake box”,
page 210

5.16 Removing and installing left side vent

control motor - V299- - vehicles with PR
number 9AQ
• Before removing control motors, note general information and
procedure for removing and installing control motors
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Move front left seat to rearmost position.
– Switch off ignition.
– 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) .
– Depending on version: Remove knee airbag ⇒ General body
repairs, interior; Rep. gr. 69 ; Knee airbags; Removing and
installing knee airbag with igniter .
– Remove footwell vent (left-side)
⇒ “7.4 Removing and installing footwell vent (driver side)”,
page 294 .
– Remove dash panel vent (driver side) ⇒ General body repairs,
interior; Rep. gr. 70 ; Dash panel; Removing and installing
outer dash panel vents .
– Remove mounting bracket and press it as far as possible to
side ⇒ Brake system; Rep. gr. 46 ; Brake pedal; Removing

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and installing mounting bracket . Steering column remains fit‐

ted.
– Unfasten air duct (left-side) -C- above dash panel cross mem‐
ber and press it as far outwards as possible -arrow-; remove
fasteners -A, B- to do so.

– Mark connector -C- and control motor -B- (to prevent possible
interchange if several connectors are unplugged at the same
time).
– Unscrew bolts -A-.
– Detach control motor -B- from shaft -D- of flap.
– Unplug connector -C-.

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Installing
Installation is carried out in reverse order; note the following:

NOTICE
Risk of damage to electronics of control motor if actuator socket
is turned.
– Only turn actuator socket for control motor with wiring har‐
ness connected.
– Carefully turn actuator socket for control motor slowly and
by hand.

• The actuator socket for the control motor has no stop. It rotates
permanently if the control motor is activated. A control motor
should therefore not be activated after it has been detached.
• Check the connection between the actuator socket for the
control motor and the shaft to ensure that there is no play.
– Check shaft -A- and actuator socket -B- for control motor -C-.
They must be properly aligned for assembly.
– Fit actuator socket -B- for control motor to shaft -A- of flap.

– Attach control motor -B- to shaft -D- of flap.

– Plug in connector -C-.
– Tighten bolts -A-.
– Route wiring harness to connector -C- so that it cannot come
into contact with moving components.
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.2 Exploded view - control motors (front left), vehicles
with PR number 9AQ”, page 204

5.17 Removing and installing left centre vent

control motor - V110- - vehicles with PR
number 9AK/KH5
• Before removing control motors, note general information and
procedure for removing and installing control motors
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Move front left seat to rearmost position.
– Switch off ignition.

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– 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) .
– Depending on version: Remove knee airbag ⇒ General body
repairs, interior; Rep. gr. 69 ; Knee airbags; Removing and
installing knee airbag with igniter .
– Remove footwell vent (left-side)
⇒ “7.4 Removing and installing footwell vent (driver side)”,
page 294 .
– Remove dash panel vent (driver side) ⇒ General body repairs,
interior; Rep. gr. 70 ; Dash panel; Removing and installing
outer dash panel vents .
– Remove mounting bracket and press it as far as possible to
side ⇒ Brake system; Rep. gr. 46 ; Brake pedal; Removing
and installing mounting bracket . Steering column remains fit‐
ted.
– Unfasten air duct (left-side) -C- above dash panel cross mem‐
ber and press it as far outwards as possible -arrow-; remove
fasteners -A, B- to do so.

– Mark connector -C- and control motor -B- (to prevent possible
interchange if several connectors are unplugged at the same
time).
– Unscrew bolts -A-.
– Detach control motor -B- from shaft -D- of flap.
– Unplug connector -C-.

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Installing
Installation is carried out in reverse order; note the following:

NOTICE
Risk of damage to electronics of control motor if actuator socket
is turned.
– Only turn actuator socket for control motor with wiring har‐
ness connected.
– Carefully turn actuator socket for control motor slowly and
by hand.

• The actuator socket for the control motor has no stop. It rotates
permanently if the control motor is activated. A control motor
should therefore not be activated after it has been detached.
• Check the connection between the actuator socket for the
control motor and the shaft to ensure that there is no play.
– Check shaft -A- and actuator socket -B- for control motor -C-.
They must be properly aligned for assembly.
– Fit actuator socket -B- for control motor to shaft -A- of flap.

– Attach control motor -B- to shaft -D- of flap.

– Plug in connector -C-.
– Tighten bolts -A-.
– Route wiring harness to connector -C- so that it cannot come
into contact with moving components.
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.4 Exploded view - control motors (front left), vehicles
with PR number 9AK/KH5”, page 207

5.18 Removing and installing right centre

vent control motor - V111- - vehicles with
PR number 9AK/KH5
• Before removing control motors, note general information and
procedure for removing and installing control motors
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Move front right seat to rearmost position.
– Switch off ignition.
– Remove glove box ⇒ General body repairs, interior; Rep. gr.
68 ; Storage compartments/covers/trim panels; Removing and
installing glove box .

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– Remove footwell vent (right-side)

⇒ “7.5 Removing and installing footwell vent (front passenger
side)”, page 295 .
– Mark connector -C- and control motor -B- (to prevent possible
interchange if several connectors are unplugged at the same
time).
– Unscrew bolts -A-.
– Detach control motor -B- from shaft -D- of flap.
– Unplug connector -C-.

Installing
Installation is carried out in reverse order; note the following:

NOTICE
Risk of damage to electronics of control motor if actuator socket
is turned.
– Only turn actuator socket for control motor with wiring har‐
ness connected.
– Carefully turn actuator socket for control motor slowly and
by hand.

• The actuator socket for the control motor has no stop. It rotates
permanently if the control motor is activated. A control motor
should therefore not be activated after it has been detached.
• Check the connection between the actuator socket for the
control motor and the shaft to ensure that there is no play.
– Check shaft -A- and actuator socket -B- for control motor -C-.
They must be properly aligned for assembly.

– Attach control motor -B- to shaft -D- of flap.

– Plug in connector -C-.
– Tighten bolts -A-.
– Route wiring harness to connector -C- so that it cannot come
into contact with moving components.
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.5 Exploded view - control motors (front right), vehicles
with PR number 9AK/KH5 ”, page 208

5.19 Removing and installing right side vent

control motor - V300- - vehicles with PR
number 9AQ
• Before removing control motors, note general information and
procedure for removing and installing control motors
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .

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Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Move front right seat to rearmost position.
– Switch off ignition.
– Remove glove box ⇒ General body repairs, interior; Rep. gr.
68 ; Storage compartments/covers/trim panels; Removing and
installing glove box .
– Remove footwell vent (right-side)
⇒ “7.5 Removing and installing footwell vent (front passenger
side)”, page 295 .
– Mark connector -C- and control motor -B- (to prevent possible
interchange if several connectors are unplugged at the same
time).
– Unscrew bolts -A-.
– Detach control motor -B- from shaft -D- of flap.
– Unplug connector -C-.

Installing
Installation is carried out in reverse order; note the following:

NOTICE
Risk of damage to electronics of control motor if actuator socket
is turned.
– Only turn actuator socket for control motor with wiring har‐
ness connected.
– Carefully turn actuator socket for control motor slowly and
by hand.

• The actuator socket for the control motor has no stop. It rotates
permanently if the control motor is activated. A control motor
should therefore not be activated after it has been detached.
• Check the connection between the actuator socket for the
control motor and the shaft to ensure that there is no play.
– Check shaft -A- and actuator socket -B- for control motor -C-.
They must be properly aligned for assembly.

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– Attach control motor -B- to shaft -D- of flap.

– Plug in connector -C-.
– Tighten bolts -A-.
– Route wiring harness to connector -C- so that it cannot come
into contact with moving components.
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.3 Exploded view - control motors (front right), vehicles
with PR number 9AQ”, page 205

5.20 Removing and installing rear air distri‐

bution flap control motor - V427- / rear
right air distribution control motor -
V594-
• Before removing control motors, note general information and
procedure for removing and installing control motors
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Move front right seat to rearmost position.
– Switch off ignition.
– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing centre con‐
sole .
– Mark connector -C- and control motor -B- (to prevent possible
interchange if several connectors are unplugged at the same
time).
– Unscrew bolts -A-.
– Detach control motor -B- from shaft -D- of flap.
– Unplug connector -C-.

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Installing
Installation is carried out in reverse order; note the following:

NOTICE
Risk of damage to electronics of control motor if actuator socket
is turned.
– Only turn actuator socket for control motor with wiring har‐
ness connected.
– Carefully turn actuator socket for control motor slowly and
by hand.

• The actuator socket for the control motor has no stop. It rotates
permanently if the control motor is activated. A control motor
should therefore not be activated after it has been detached.
• Check the connection between the actuator socket for the
control motor and the shaft to ensure that there is no play.
– Check shaft -A- and actuator socket -B- for control motor -C-.
They must be properly aligned for assembly.

– Attach control motor -B- to shaft -D- of flap.

– Plug in connector -C-.
– Tighten bolts -A-.
– Route wiring harness to connector -C- so that it cannot come
into contact with moving components.
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.3 Exploded view - control motors (front right), vehicles
with PR number 9AQ”, page 205
♦ ⇒ “5.2.5 Exploded view - control motors (front right), vehicles
with PR number 9AK/KH5 ”, page 208

5.21 Removing and installing rear left air dis‐

tribution control motor - V593-
• Before removing control motors, note general information and
procedure for removing and installing control motors
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Move front left seat to rearmost position.
– Switch off ignition.
– 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) .

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– Remove centre console ⇒ General body repairs, interior; Rep.

gr. 68 ; Centre console; Removing and installing centre con‐
sole .
– Mark connector -C- and control motor -B- (to prevent possible
interchange if several connectors are unplugged at the same
time).
– Unscrew bolts -A-.
– Detach control motor -B- from shaft -D- of flap.
– Unplug connector -C-.

Installing
Installation is carried out in reverse order; note the following:

NOTICE
Risk of damage to electronics of control motor if actuator socket
is turned.
– Only turn actuator socket for control motor with wiring har‐
ness connected.
– Carefully turn actuator socket for control motor slowly and
by hand.

• The actuator socket for the control motor has no stop. It rotates
permanently if the control motor is activated. A control motor
should therefore not be activated after it has been detached.
• Check the connection between the actuator socket for the
control motor and the shaft to ensure that there is no play.
– Check shaft -A- and actuator socket -B- for control motor -C-.
They must be properly aligned for assembly.
– Fit actuator socket -B- for control motor to shaft -A- of flap.

– Plug in connector -C-.

– Tighten bolts -A-.
– Route wiring harness to connector -C- so that it cannot come
into contact with moving components.
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.2 Exploded view - control motors (front left), vehicles
with PR number 9AQ”, page 204

5.22 Removing and installing rear right air

quantity flap control motor - V240-
• Before removing control motors, note general information and
procedure for removing and installing control motors
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .

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Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Move front right seat to rearmost position.
– Switch off ignition.
– Remove glove box ⇒ General body repairs, interior; Rep. gr.
68 ; Storage compartments/covers/trim panels; Removing and
installing glove box .
– Remove footwell vent (right-side)
⇒ “7.5 Removing and installing footwell vent (front passenger
side)”, page 295 .
– Remove centre console trim (front) ⇒ General body repairs,
interior; Rep. gr. 68 ; Centre console; Exploded view - centre
console .
– Mark connector -C- and control motor -B- (to prevent possible
interchange if several connectors are unplugged at the same
time).
– Unscrew bolts -A-.
– Detach control motor -B- from shaft -D- of flap.
– Unplug connector -C-.

Installing
Installation is carried out in reverse order; note the following:

NOTICE
Risk of damage to electronics of control motor if actuator socket
is turned.
– Only turn actuator socket for control motor with wiring har‐
ness connected.
– Carefully turn actuator socket for control motor slowly and
by hand.

• The actuator socket for the control motor has no stop. It rotates
permanently if the control motor is activated. A control motor
should therefore not be activated after it has been detached.
• Check the connection between the actuator socket for the
control motor and the shaft to ensure that there is no play.
– Check shaft -A- and actuator socket -B- for control motor -C-.
They must be properly aligned for assembly.

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– Attach control motor -B- to shaft -D- of flap.

– Plug in connector -C-.
– Tighten bolts -A-.
– Route wiring harness to connector -C- so that it cannot come
into contact with moving components.
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.3 Exploded view - control motors (front right), vehicles
with PR number 9AQ”, page 205

5.23 Removing and installing brackets for

control motors on front heater and air
conditioning unit
⇒ “5.23.1 Removing and installing bracket for rear temperature
flap control motor V137 / rear left air quantity flap control motor
V239 ”, page 242
⇒ “5.23.2 Removing and installing bracket for control motors (left-
side) - vehicles with PR number 9AQ”, page 243
⇒ “5.23.3 Removing and installing bracket for control motors (left-
side) - vehicles with PR number 9AK/KH5”, page 245
⇒ “5.23.4 Removing and installing bracket for control motors
(right-side) - vehicles with PR number 9AQ”, page 247
⇒ “5.23.5 Removing and installing bracket for control motors
(right-side) - vehicles with PR number 9AK/KH5”, page 249
⇒ “5.23.6 Removing and installing bracket for rear air distribution
flap control motor V427 / rear right air distribution control motor
V594 ”, page 250
⇒ “5.23.7 Removing and installing bracket for rear left air distri‐
bution control motor V593 ”, page 251
⇒ “5.23.8 Removing and installing bracket for rear right air quan‐
tity flap control motor V240 ”, page 252

5.23.1 Removing and installing bracket for rear

temperature flap control motor - V137- /
rear left air quantity flap control motor -
V239-
Removing
– Remove rear temperature flap control motor - V137- / rear left
air quantity flap control motor - V239-
⇒ “5.12 Removing and installing rear temperature flap control
motor V137 / rear left air quantity flap control motor V239 ”,
page 226 .

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– Remove bolts -B-.

– Detach bracket -A-.

Installing
Installation is carried out in reverse order; note the following:
– Check that connecting elements and levers -C- function prop‐
erly and are fitted in correct installation position.
– Install bracket -A-.
– Tighten bolts -B-.
– Install rear temperature flap control motor - V137- / rear left air
quantity flap control motor - V239-
⇒ “5.12 Removing and installing rear temperature flap control
motor V137 / rear left air quantity flap control motor V239 ”,
page 226 .
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.2 Exploded view - control motors (front left), vehicles
with PR number 9AQ”, page 204
♦ ⇒ “5.2.4 Exploded view - control motors (front left), vehicles
with PR number 9AK/KH5”, page 207

5.23.2 Removing and installing bracket for con‐

trol motors (left-side) - vehicles with PR
number 9AQ
• Before removing control motors, note general information and
procedure for removing and installing control motors
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Move front left seat to rearmost position.
– Using FRONT (defrost button), set air distribution to wind‐
screen and wait until air emerges from dash panel vents to
windscreen.
– Switch off ignition.
– Remove the following control motors:

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♦ Removing left side vent control motor - V299-

⇒ “5.16 Removing and installing left side vent control motor
V299 - vehicles with PR number 9AQ”, page 231
♦ Removing left footwell flap control motor - V108- or control
motor for left footwell temperature flap - V411-
⇒ “5.7 Removing and installing left footwell flap control motor
V108 ”, page 217
♦ Removing left centre vent control motor - V110-
⇒ “5.9 Removing and installing left centre vent control motor
V110 - vehicles with PR number 9AQ”, page 221
♦ Removing left temperature flap control motor - V158-
⇒ “5.13 Removing and installing left temperature flap control
motor V158 ”, page 227
♦ Removing defroster flap control motor - V107-
⇒ “5.6 Removing and installing defroster flap control motor
V107 ”, page 214
– Remove bolts -B-.
– Unfasten wiring harness -H- from bracket -A-.
– Remove bracket -A- (together with gear wheel -C-).

Installing
Installation is carried out in reverse order; note the following:
– Check that gear wheel -A- and actuating arms and shafts to
the various flaps -B- to -E- are positioned correctly and func‐
tion properly.
– Fit bracket in correct installation position.

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– Fit gear wheel -A-; to do so, wide tooth -D- must be aligned
with wide gap -F- and long tooth -E- with deep gap -G- on gear
wheel -C-.
– Check adjustment range of heater flap.
• It must be possible to rotate heater flap by 120°.

– Tighten bolts -B-.

– Check that actuators -C- to -G- and -I- are functioning correct‐
ly.
– Insert wiring harness -H- in bracket -A- so that it cannot come
into contact with moving components.
– Re-install control motors removed earlier in reverse sequence.
– Route wiring to the various control motors so that it cannot
come into contact with moving components.
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.2 Exploded view - control motors (front left), vehicles
with PR number 9AQ”, page 204

5.23.3 Removing and installing bracket for con‐

trol motors (left-side) - vehicles with PR
number 9AK/KH5
• Before removing control motors, note general information and
procedure for removing and installing control motors
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Move front left seat to rearmost position.
– Using FRONT (defrost button), set air distribution to wind‐
screen and wait until air emerges from dash panel vents to
windscreen.
– Switch off ignition.
– Remove the following control motors:
♦ Removing left centre vent control motor - V110-
⇒ “5.17 Removing and installing left centre vent control motor
V110 - vehicles with PR number 9AK/KH5”, page 233

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♦ Removing left temperature flap control motor - V158-

⇒ “5.13 Removing and installing left temperature flap control
motor V158 ”, page 227
♦ Removing defroster flap control motor - V107-
⇒ “5.6 Removing and installing defroster flap control motor
V107 ”, page 214
Removing
– Remove bolts -B-.
– Unfasten wiring harness -F- from bracket -A-.
– Hold cam plate -D- and remove bracket -A- together with gear
wheel -C-.

Installing
Installation is carried out in reverse order; note the following:
– Press catch -B- back and detach gear wheel -A-.

– Check that actuating arms to various flaps -B-, -C- are posi‐
tioned correctly in cam plate -A- and function properly.
– Insert cam plate -A- and check that it functions correctly.
– Check that actuating arm -D- is positioned correctly in cam
plate -A- and functions properly.
– Install bracket -G- without gear wheel -E-.

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– Fit gear wheel -A-; to do so, wide tooth -D- must be aligned
with wide gap -F- and long tooth -E- with deep gap -G- on gear
wheel -C-.
– Check adjustment range of heater flap.
• It must be possible to rotate heater flap by 120°.

– Tighten bolts -B-.

– Insert wiring harness -F- in bracket -A- so that it cannot come
into contact with moving components.
– Check that actuators -C, D, E- are functioning correctly.
– Re-install control motors removed earlier in reverse sequence.
– Route wiring to the various control motors so that it cannot
come into contact with moving components.
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.4 Exploded view - control motors (front left), vehicles
with PR number 9AK/KH5”, page 207

5.23.4 Removing and installing bracket for con‐

trol motors (right-side) - vehicles with PR
number 9AQ
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Move front right seat to rearmost position.
– Switch off ignition.
– Remove the following control motors:
♦ Removing right footwell flap control motor - V109- or control
motor for right footwell temperature flap - V412-
⇒ “5.8 Removing and installing right footwell flap control motor
V109 ”, page 219
♦ Removing right side vent control motor - V300-
⇒ “5.19 Removing and installing right side vent control motor
V300 - vehicles with PR number 9AQ”, page 236
♦ Removing right centre vent control motor - V111-
⇒ “5.10 Removing and installing right centre vent control motor
V111 - vehicles with PR number 9AQ”, page 223
♦ Removing right temperature flap control motor - V159-
⇒ “5.14 Removing and installing right temperature flap control
motor V159 ”, page 228

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♦ Removing defroster flap control motor - V107-

⇒ “5.6 Removing and installing defroster flap control motor
V107 ”, page 214 (only on vehicles with right-hand drive)
Removing
– Remove bolts -B-.
– Unfasten wiring harness -G- from bracket -A-.
– Remove bracket -A-.

Installing
Installation is carried out in reverse order; note the following:
– Check that actuating arms and connecting elements to the
various flaps -A- to -D- are positioned correctly and are func‐
tioning properly.

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– Install bracket -A-.

– Tighten bolts -B-.
– Insert wiring harness -G- in bracket -A- so that it cannot come
into contact with moving components.
– Check that actuators -C, D, E, F- are functioning correctly.
– Re-install control motors removed earlier in reverse sequence.
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.3 Exploded view - control motors (front right), vehicles
with PR number 9AQ”, page 205

5.23.5 Removing and installing bracket for con‐

trol motors (right-side) - vehicles with PR
number 9AK/KH5
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Move front right seat to rearmost position.
– Switch off ignition.
– Remove the following control motors:
♦ Removing right centre vent control motor - V111-
⇒ “5.18 Removing and installing right centre vent control motor
V111 - vehicles with PR number 9AK/KH5”, page 235
♦ Removing right temperature flap control motor - V159-
⇒ “5.14 Removing and installing right temperature flap control
motor V159 ”, page 228
♦ Removing defroster flap control motor - V107-
⇒ “5.6 Removing and installing defroster flap control motor
V107 ”, page 214 (only on vehicles with right-hand drive)
Removing
– Remove bolts -B-.
– Unfasten wiring harness -F- from bracket -A-.
– Hold cam plate -C- and remove bracket -A-.

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Installing
Installation is carried out in reverse order; note the following:
– Check that actuating arms to various flaps -A, B- are posi‐
tioned correctly in cam plate -C- and are functioning properly.
– Insert cam plate -C- and check that it is functioning correctly.
– Check that actuating arm -E- is positioned correctly in cam
plate -C- and is functioning properly.
– Check that actuating arm -D- is positioned correctly and is
functioning properly.

– Install bracket -A-.

– Tighten bolts -B-.
– Insert wiring harness -F- in bracket -A- so that it cannot come
into contact with moving components.
– Check that actuators -C, D, E- are functioning correctly.
– Re-install control motors removed earlier in reverse sequence.
– Route wiring to the various control motors so that it cannot
come into contact with moving components.
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.5 Exploded view - control motors (front right), vehicles
with PR number 9AK/KH5 ”, page 208

5.23.6 Removing and installing bracket for rear

air distribution flap control motor -
V427- / rear right air distribution control
motor - V594-
Removing
– Remove rear air distribution flap control motor - V427- / rear
right air distribution control motor - V594-
⇒ “5.20 Removing and installing rear air distribution flap con‐
trol motor V427 / rear right air distribution control motor V594
”, page 238 .
– Remove bolts -B-.
– Hold cam plate -C- in place.
– Remove bracket -A-.

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Installing
Installation is carried out in reverse order; note the following:
– Check that cam plate -C- and lever -D- are functioning properly
and are fitted in correct installation position.
– Install bracket -A-.
– Tighten bolts -B-.
– Install rear air distribution flap control motor - V427- / rear right
air distribution control motor - V594-
⇒ “5.20 Removing and installing rear air distribution flap con‐
trol motor V427 / rear right air distribution control motor V594
”, page 238 .
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.3 Exploded view - control motors (front right), vehicles
with PR number 9AQ”, page 205
♦ ⇒ “5.2.5 Exploded view - control motors (front right), vehicles
with PR number 9AK/KH5 ”, page 208

5.23.7 Removing and installing bracket for rear

left air distribution control motor - V593-
Removing
– Remove rear left air distribution control motor - V593-
⇒ “5.21 Removing and installing rear left air distribution control
motor V593 ”, page 239 .
– Remove bolts -B-.
– Hold cam plate -C- in place.
– Remove bracket -A-.

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Installing
Installation is carried out in reverse order; note the following:
– Check that cam plate -C- and lever -D- are functioning properly
and are fitted in correct installation position.
– Install bracket -A-.
– Tighten bolts -B-.
– Install rear left air distribution control motor - V593-
⇒ “5.21 Removing and installing rear left air distribution control
motor V593 ”, page 239 .
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.2 Exploded view - control motors (front left), vehicles
with PR number 9AQ”, page 204

5.23.8 Removing and installing bracket for rear

right air quantity flap control motor -
V240-
– Remove rear right air quantity flap control motor - V240-
⇒ “5.22 Removing and installing rear right air quantity flap
control motor V240 ”, page 240 .
– Unscrew bolts -A-.
– Remove bracket -B-.

Installing
Installation is carried out in reverse order; note the following:
– Check that connecting elements and levers -C- function prop‐
erly and are fitted in correct installation position.
– Install retainer -B-.
– Tighten bolts -A-.
– Install rear right air quantity flap control motor - V240-
⇒ “5.22 Removing and installing rear right air quantity flap
control motor V240 ”, page 240 .
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “5.2.3 Exploded view - control motors (front right), vehicles
with PR number 9AQ”, page 205

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6 Front heater and air conditioning unit

⇒ “6.1 Exploded view - heater and air conditioning unit”,
page 253
⇒ “6.2 Exploded view - attachments for front heater and air con‐
ditioning unit (air distribution housing, heat exchanger etc.)”, page
255
⇒ “6.3 Exploded view - air intake box of heater and air conditioning
unit”, page 257
⇒ “6.4 Exploded view - evaporator housing”, page 258
⇒ “6.5 Removing and installing evaporator”, page 260
⇒ “6.6 Cleaning evaporator”, page 262
⇒ “6.7 Removing and installing auxiliary air heater element Z35 ”,
page 268
⇒ “6.8 Removing and installing heater and air conditioning unit”,
page 270
⇒ “6.9 Detaching and attaching air intake box at heater and air
conditioning unit”, page 274
⇒ “6.10 Removing and installing dust and pollen filter”,
page 275
⇒ “6.11 Removing and installing fresh air blower V2 with fresh air
blower control unit J126 ”, page 276
⇒ “6.12 Removing and installing heat exchanger”, page 277
⇒ “6.13 Removing and installing condensation drain hose”, page
284
⇒ “6.14 Checking condensation drain hose”, page 285

6.1 Exploded view - heater and air conditioning unit

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1 - Bolt
❑ 1 Nm
2 - Air intake box
❑ Detaching and attach‐
ing air intake box at
heater and air condition‐
ing unit
⇒ “6.9 Detaching and at‐
taching air intake box at
heater and air condition‐
ing unit”, page 274
3 - Insulating mat
❑ Removing and installing
⇒ “6.11 Removing and
installing fresh air blow‐
er V2 with fresh air blow‐
er control unit J126 ”,
page 276
4 - Noise insulation cover
❑ Removing and installing
⇒ “6.10 Removing and
installing dust and pol‐
len filter”, page 275
5 - Threaded fasteners
❑ Removing and installing
⇒ “6.10 Removing and
installing dust and pol‐
len filter”, page 275
6 - Air distribution housing
(heater and air conditioning
unit with evaporator)
❑ Different versions ⇒
Electronic parts cata‐
logue
❑ Detaching and attach‐
ing evaporator housing at air distribution housing
⇒ “6.5 Removing and installing evaporator”, page 260
❑ ⇒ “5.2 Exploded view - control motors (front)”, page 203
7 - Wiring harness for heater and air conditioning unit
❑ Different versions ⇒ Electronic parts catalogue
❑ Mark assignment before unplugging connectors (identical connectors for different control motors and
temperature sensors, risk of interchanging)
❑ Secure wiring harness to attachment points on housing (with cable ties or at mountings) so that harness
cannot come into contact with moving components
8 - Insulating mat
❑ Fitted between air duct in air distribution housing and resonator chambers located there and in air intake
box

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6.2 Exploded view - attachments for front heater and air conditioning unit (air
distribution housing, heat exchanger etc.)

1 - Insulating mat
❑ Between air duct in air
distribution housing and
resonator chambers lo‐
cated there and in air in‐
take box
2 - Evaporator housing
❑ With factory-fitted evap‐
orator
❑ May not need to be dis‐
mantled further (de‐
pending on version)
⇒ “6.4 Exploded view -
evaporator housing”,
page 258
❑ Removing and installing
evaporator
⇒ “6.5.2 Removing and
installing evaporator in
front heater and air con‐
ditioning unit”,
page 261
3 - Evaporator output temper‐
ature sender - G263-
❑ Removing and installing
⇒ “10.6 Removing and
installing evaporator
output temperature
sender G263 ”,
page 319
❑ On right-hand drive ve‐
hicles, the evaporator
output temperature
sender - G263- is instal‐
led from the left of the
evaporator housing of
the heater and air con‐
ditioning unit (in the area
behind the coolant pipes to the heat exchanger)
4 - Plug
❑ Plug e.g. 8D0 819 598 ⇒ Electronic parts catalogue
❑ Only on heater and air conditioning units with an evaporator that has already been cleaned once
⇒ “6.6.2 Cleaning evaporator in heater and air conditioning unit using pressure-feed spray gun V.A.G
1538 and spray lance”, page 263
5 - Cap
❑ For connection to glove box cooling system
❑ Not fitted on vehicles with glove box cooling system
6 - Catch
❑ Open carefully
7 - Heat exchanger for heater
❑ Removing and installing ⇒ “6.12 Removing and installing heat exchanger”, page 277
❑ With foam seals; check that they are not damaged and are bonded on properly
⇒ “6.12 Removing and installing heat exchanger”, page 277

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8 - Bolt
❑ 1 Nm
9 - Cover for heat exchanger
❑ For vehicles with no auxiliary air heater element - Z35- ⇒ Electronic parts catalogue
❑ Different versions ⇒ Electronic parts catalogue
❑ Removing and installing ⇒ “6.12 Removing and installing heat exchanger”, page 277
10 - Cover for heat exchanger
❑ For vehicles with auxiliary air heater element - Z35- ⇒ Electronic parts catalogue
❑ Different versions ⇒ Electronic parts catalogue
❑ Removing and installing ⇒ “6.12 Removing and installing heat exchanger”, page 277 and
⇒ “6.7 Removing and installing auxiliary air heater element Z35 ”, page 268
11 - Auxiliary air heater element - Z35-
❑ Removing and installing ⇒ “6.7 Removing and installing auxiliary air heater element Z35 ”, page 268
❑ Installed depending on equipment version and engine
12 - Zone divider
❑ Only for vehicles with no auxiliary air heater element - Z35- ⇒ Electronic parts catalogue
❑ Different versions ⇒ Electronic parts catalogue
❑ Removing and installing ⇒ “6.12 Removing and installing heat exchanger”, page 277 and
⇒ “6.7 Removing and installing auxiliary air heater element Z35 ”, page 268
13 - Right footwell vent temperature sender - G262-
❑ Removing and installing
⇒ “10.5 Removing and installing right footwell vent temperature sender G262 ”, page 319
14 - Air distribution housing (heater and air conditioning unit with evaporator)
❑ Different versions ⇒ Electronic parts catalogue
❑ Removing and installing heater and air conditioning unit with evaporator
⇒ “6.8 Removing and installing heater and air conditioning unit”, page 270
15 - Left footwell vent temperature sender - G261-
❑ Removing and installing
⇒ “10.4 Removing and installing left footwell vent temperature sender G261 ”, page 318
16 - Screw-type clip
❑ Renew ⇒ Electronic parts catalogue
❑ Detaching and attaching at heat exchanger
⇒ “6.12 Removing and installing heat exchanger”, page 277
17 - Bolt
❑ 2 Nm
❑ Detaching and attaching at heat exchanger
⇒ “6.12 Removing and installing heat exchanger”, page 277
18 - O-ring
❑ Renew ⇒ Electronic parts catalogue
❑ Coat lightly with coolant before fitting ⇒ “6.12 Removing and installing heat exchanger”, page 277
19 - Spacer for coolant pipes
❑ Not installed
20 - Coolant pipe to heat exchanger
❑ Coolant return line
❑ Detaching and attaching at heat exchanger
⇒ “6.12 Removing and installing heat exchanger”, page 277
❑ Can only be renewed after heater and air conditioning unit has been removed
21 - Coolant pipe to heat exchanger
❑ Coolant supply line

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❑ Detaching and attaching at heat exchanger

⇒ “6.12 Removing and installing heat exchanger”, page 277
❑ Can only be renewed after heater and air conditioning unit has been removed
22 - Bracket for coolant pipes

6.3 Exploded view - air intake box of heater and air conditioning unit

1 - Foam seal
❑ To seal off fresh-air in‐
take duct at vehicle,
bonded to intake duct
❑ Check for damage and
renew if necessary ⇒
Electronic parts cata‐
logue
2 - Air intake box
❑ With air flow/fresh air
and air recirculation flap
❑ Do not dismantle any
further
3 - Lever
❑ Removing and installing
⇒ “5.2.6 Exploded view
- control motors on air
intake box”, page 210
❑ Coat guides of cam
plate, shaft bearings,
toothed segments and
pins on flap levers with a
small quantity of grease
⇒ Electronic parts cata‐
logue .
4 - Connecting element with
lever
❑ Removing and installing
⇒ “5.2.6 Exploded view
- control motors on air
intake box”, page 210
❑ Coat guides of cam
plate, shaft bearings,
toothed segments and
pins on flap levers with a
small quantity of grease
⇒ Electronic parts catalogue .
5 - Bracket
6 - Bolt
❑ 1 Nm
7 - Air recirculation flap control motor - V113-
❑ Removing and installing
⇒ “5.11 Removing and installing air recirculation flap control motor V113 ”, page 224
8 - Dust and pollen filter
❑ Removing and installing ⇒ “6.10 Removing and installing dust and pollen filter”, page 275
❑ Observe replacement intervals ⇒ Maintenance tables
❑ Different versions ⇒ Electronic parts catalogue

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9 - Cover for dust and pollen filter

❑ Removing and installing ⇒ “6.10 Removing and installing dust and pollen filter”, page 275
10 - Insulating mat
❑ Removing and installing
⇒ “6.11 Removing and installing fresh air blower V2 with fresh air blower control unit J126 ”, page 276
11 - Noise insulation cover
❑ Removing and installing ⇒ “6.10 Removing and installing dust and pollen filter”, page 275
12 - Threaded fasteners
❑ Removing and installing ⇒ “6.10 Removing and installing dust and pollen filter”, page 275
13 - Fresh air blower - V2- with fresh air blower control unit - J126-
❑ Removing and installing
⇒ “6.11 Removing and installing fresh air blower V2 with fresh air blower control unit J126 ”, page 276
❑ Checking ⇒ Vehicle diagnostic tester
14 - Fresh air flap control motor - V438-
❑ Removing and installing ⇒ “5.5 Removing and installing fresh air flap control motor V438 ”, page 212

6.4 Exploded view - evaporator housing

♦ The evaporator is currently supplied with the evaporator hous‐
ing as a replacement part. The evaporator housing should
therefore not be dismantled. If the evaporator is also supplied
as a separate part at a later time, the evaporator housing must
be dismantled ⇒ Electronic parts catalogue .

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1 - Bolt
❑ 5.5 Nm
2 - Expansion valve
❑ Removing and installing
⇒ “2.15 Removing and
installing expansion
valve”, page 81
3 - Retaining plate
❑ Removing and installing
⇒ “6.5.2 Removing and
installing evaporator in
front heater and air con‐
ditioning unit”,
page 261
4 - O-ring
❑ Renewing
⇒ “4.12 Refrigerant cir‐
cuit seals”, page 14
❑ For correct version refer
to ⇒ Electronic parts
catalogue
5 - O-ring
❑ Renewing
⇒ “4.12 Refrigerant cir‐
cuit seals”, page 14
❑ For correct version refer
to ⇒ Electronic parts
catalogue
6 - Support ring
❑ Support ring increases
contact pressure of
grommet to of plenum
chamber back panel
❑ Checking position of
support ring in grommet ⇒ “2.15 Removing and installing expansion valve”, page 81
7 - Grommet
❑ For sealing opening for refrigerant lines through plenum chamber back wall
❑ With support ring as a seal in plenum chamber back wall
⇒ “2.15 Removing and installing expansion valve”, page 81
❑ Currently forms part of replacement “evaporator housing” ⇒ Electronic parts catalogue
8 - Bolt
❑ 1 Nm
9 - Insulating mat
❑ Fitted between air duct in air distribution housing and resonator chambers located there and in air intake
box
10 - Evaporator housing (top section)
11 - Catch
❑ Open carefully
12 - Evaporator housing (bottom section)
❑ The two halves of the housing are held together by bolts ⇒ Item 8 (page 256) and retainers
⇒ Item 6 (page 255) .
– Before assembly, check both halves of housing for dirt and clean if necessary.

– Check “tongue-and-groove” joint to evaporator housing (top section) for damage.

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❑ If connections are damaged or not assembled properly, noise may occur during operation
❑ Repair minor damage to “tongue-and-groove” joints carefully using e.g. silicone adhesive sealant - D 176
001 A3- ⇒ Electronic parts catalogue
❑ Even very small leaks in “tongue-and-groove” joints can lead to whistling noises caused by escaping air
❑ To completely seal the connection points, coat them lightly e.g. with silicone grease (replacement part
number G 000 405 A2) ⇒ Electronic parts catalogue
13 - Cap
❑ For connection to glove box cooling system
❑ Only fitted on vehicles without glove box cooling as an optional extra
⇒ “7.6 Removing and installing air duct for glove box cooling”, page 296
14 - Seal
❑ Check for damage and correct installation on evaporator
15 - Evaporator
❑ Supplied as replacement part (not available for all versions) with various components required for fitting
(evaporator housing, O-rings, expansion valve etc.) ⇒ Electronic parts catalogue
❑ Check that foam seals are not damaged and are bonded on properly
❑ Removing and installing
⇒ “6.5.2 Removing and installing evaporator in front heater and air conditioning unit”, page 261

6.5 Removing and installing evaporator

⇒ “6.5.1 Removing and installing evaporator housing at heater
and air conditioning unit”, page 260
⇒ “6.5.2 Removing and installing evaporator in front heater and
air conditioning unit”, page 261

6.5.1 Removing and installing evaporator

housing at heater and air conditioning
unit
♦ Currently replacement units are not available for all versions
of the evaporator. Therefore, please check in advance wheth‐
er the replacement evaporator is available as a separate part
or as a complete replacement unit with the evaporator housing
⇒ Electronic parts catalogue . If the evaporator is only avail‐
able in combination with an evaporator housing, the evapora‐
tor housing does not have to be dismantled. The evaporator
and the evaporator housing are then renewed completely
⇒ “6.4 Exploded view - evaporator housing”, page 258 .
♦ When it has been removed, the evaporator contains refriger‐
ant oil which must be returned to the refrigerant circuit (to‐
gether with the new evaporator) ⇒ Air conditioner with
refrigerant R134a; Rep. gr. 87 ; Renewing components of re‐
frigerant circuit , or ⇒ Air conditioners with refrigerant R1234yf
- General information; Rep. gr. 87 ; Refrigerant circuit; Re‐
newing components .
Detaching
– Remove front heater and air conditioning unit
⇒ “6.8 Removing and installing heater and air conditioning
unit”, page 270 .
– Detach air intake box from heater and air conditioning unit
⇒ “6.9 Detaching and attaching air intake box at heater and air
conditioning unit”, page 274 .

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– Remove rear temperature flap control motor - V137- / rear left

air quantity flap control motor - V239- -C- and corresponding
bracket
⇒ “5.23.1 Removing and installing bracket for rear temperature
flap control motor V137 / rear left air quantity flap control motor
V239 ”, page 242 .
– Remove bracket -A-.
– Detach and remove both coolant pipes -B- from heat exchang‐
er
⇒ “6.12 Removing and installing heat exchanger”,
page 277 .
– Detach connector from evaporator output temperature sender
- G263-
⇒ “10.6 Removing and installing evaporator output tempera‐
ture sender G263 ”, page 319 .
– Remove bolts -E-.
– Carefully release retaining tabs -F-.
– Separate evaporator housing -G- and air distribution housing
-H-.

Installing
Installation is carried out in reverse order; note the following:
– Check evaporator housing -A- for dirt, paying special attention
to condensation drain ducts -C- and evaporator -D- itself.
– Check that flaps in air distribution housing -B- are not dam‐
aged and are installed properly.
– Check air distribution housing -B- for dirt or damage.
– Check connection points between air distribution housing -B-
and evaporator housing -A- (tongue-and-groove joint) for dam‐
age and coat them lightly e.g. with silicone grease to seal them
completely
⇒ “6.1 Exploded view - heater and air conditioning unit”, page
253 .
– Position evaporator housing on air distribution housing and
assemble.
– Check connection of heat exchanger and coolant pipes for
damage or dirt before installing
⇒ “6.12.2 Removing and installing heat exchanger”,
page 278 .
– Re-install remaining components removed in reverse order.
Tightening torques
♦ ⇒ “6.4 Exploded view - evaporator housing”, page 258

6.5.2 Removing and installing evaporator in

front heater and air conditioning unit
♦ Currently replacement units are not available for all versions
of the evaporator. Therefore, please check in advance wheth‐
er the replacement evaporator is available as a separate part
or as a complete replacement unit with the evaporator housing
⇒ Electronic parts catalogue . If the evaporator is only avail‐
able in combination with an evaporator housing, the evapora‐
tor housing does not have to be dismantled. The evaporator
and the evaporator housing are then renewed completely
⇒ “6.4 Exploded view - evaporator housing”, page 258 .
♦ When it has been removed, the evaporator contains refriger‐
ant oil which must be returned to the refrigerant circuit (to‐

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gether with the new evaporator) ⇒ Air conditioner with

refrigerant R134a; Rep. gr. 87 ; Renewing components of re‐
frigerant circuit , or ⇒ Air conditioners with refrigerant R1234yf
- General information; Rep. gr. 87 ; Refrigerant circuit; Re‐
newing components .
Removing
– Detach evaporator housing -A- from air distribution housing
-B- on front heater and air conditioning unit
⇒ “6.5.1 Removing and installing evaporator housing at heater
and air conditioning unit”, page 260 .
– Remove evaporator -D- from evaporator housing -A-.
Installing
Installation is carried out in reverse order; note the following:
– Check evaporator housing -A- for dirt, paying special attention
to condensation drain ducts -C- and evaporator -D- itself.
– Attach evaporator housing -A- to air distribution housing -B-
on front heater and air conditioning unit
⇒ “6.5.1 Removing and installing evaporator housing at heater
and air conditioning unit”, page 260 .

6.6 Cleaning evaporator

⇒ “6.6.1 Cleaning evaporator in front heater and air conditioning
unit with ultrasonic A/C cleaner”, page 262
⇒ “6.6.2 Cleaning evaporator in heater and air conditioning unit
using pressure-feed spray gun V.A.G 1538 and spray lance”,
page 263

6.6.1 Cleaning evaporator in front heater and

air conditioning unit with ultrasonic A/C
cleaner
Special tools and workshop equipment required
♦ Ultrasonic A/C cleaner (e.g. -VAS 6189A- ); for currently avail‐
able cleaners, refer to ⇒ Electronic parts catalogue .
♦ Cleaning fluid - VAS 6189/1-
Preparations
– Check whether the front heater and air conditioning unit evap‐
orator is really the source of the odour by switching from fresh
air to air recirculation mode.
• The odour can only be eliminated by cleaning with the ultra‐
sonic air conditioner cleaner if it actually occurs in the evapo‐
rator.
– Check plenum chamber and water drain of plenum chamber
and clean if necessary
⇒ “7.12 Checking plenum chamber water drain”, page 301 .
– Remove dust and pollen filter and check for odour and dirt
⇒ “6.10 Removing and installing dust and pollen filter”,
page 275 .
– Clean installation slot for dust and pollen filter of front heater
and air conditioning unit (remove leaves, dust and other dirt)
⇒ “6.10 Removing and installing dust and pollen filter”,
page 275 .
• On this vehicle, the dust and pollen filter is installed in front of
the fresh air blower - V2- and must therefore be removed when
the evaporator is cleaned.

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– Close cover for dust and pollen filter again on heater and air
conditioning unit.
– Start engine.
– Set air conditioner to “air recirculation mode” and switch off air
conditioner compressor (lamp in A/C or A/C MAX button off).
– Open all vents in dash panel and rear centre console.
– Set air conditioner to lowest possible temperature (tempera‐
ture setting “cold”) for all zones.
– Close windows and sun roof of vehicle.
– Set lowest fresh air blower speed and select “dash panel
vents” (rear centre console vents) as direction of air flow for all
zones.
– Select “dash panel vents” as direction of air flow on display
unit 2 for front information display and operating unit control
unit - J1060- .
– If fitted and if possible, use operating and display unit for rear
air conditioning system - E265- to set direction of air flow on
to vents in rear centre console.
Cleaning
– Fill ultrasonic A/C cleaner with cleaning fluid - VAS 6189/1-
(refer to operating instructions).
– Position ultrasonic A/C cleaner (e.g. -VAS 6189A- ) in front
passenger's footwell.
– Start up ultrasonic A/C cleaner (e.g. -VAS 6189A- ) as speci‐
fied in operating instructions, and position outlet hose so that
vapour emerging is drawn in by fresh air blower - V2- via
opening for air recirculation of heater and air conditioning unit
(behind glove box in vicinity of right wheel housing).
– Close vehicle's doors.
• The cleaning process takes roughly 15 to 20 minutes and is
completed when no further vapour emerges from the outlet
hose.
Final steps
– Switch off ultrasonic A/C cleaner (e.g. -VAS 6189A- ).
– Open doors and vent passenger compartment for at least 10
minutes.
– Take ultrasonic A/C cleaner (e.g. -VAS 6189A- ) out of vehicle.
– Switch off ignition.
– Install dust and pollen filter
⇒ “6.10 Removing and installing dust and pollen filter”,
page 275 .

6.6.2 Cleaning evaporator in heater and air

conditioning unit using pressure-feed
spray gun - V.A.G 1538- and spray lance
Special tools and workshop equipment required
♦ Pressure-feed spray gun - V.A.G 1538- (for currently available
pressure-feed spray guns, refer to ⇒ Electronic parts cata‐
logue )

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♦ Probe for evaporator cleaning, straight - V.A.G 1538/5- (short

version: approx. 500 mm, bent as specified for this vehicle)
-A- or probe for cleaning evaporator, curved - V.A.G 1538/6-
(medium version: approx. 600 mm, pre-bent) -A-; for currently
available probes, refer to ⇒ Electronic parts catalogue

♦ Angle drill (commercially available) and short 9 mm drill bit

(only required if evaporator has never been cleaned)
♦ Cleaning solution for air conditioner evaporator ⇒ Electronic
parts catalogue )
♦ Plug 8D0 819 598 ⇒ Electronic parts catalogue
♦ Vacuum cleaner (commercially available)
• Observe product data sheet of cleaning solution.
♦ 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.

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Recommended bend radius of spray lance VAG 1538/5 (com‐

pact) or VAG 1538/6 (medium length) -A- for this vehicle as shown
in illustration
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.
Preparations
– Switch on ignition.
– Open all dash panel vents.
– Switch on air conditioner.
– Check whether the front heater and air conditioning unit evap‐
orator is really the source of the odour by switching from fresh
air to air recirculation mode
⇒ “3.2 Notes on odours in vehicles with air conditioner”, page
7.
♦ 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 glove box ⇒ General body repairs, interior; Rep. gr.
68 ; Storage compartments/covers/trim panels; Removing and
installing glove box .
– Remove and check dust and pollen filter; renew if necessary
after cleaning evaporator
⇒ “6.10 Removing and installing dust and pollen filter”,
page 275 .
Note
♦ We recommend renewing the used dust and pollen filter every
time the evaporator is cleaned.
– With dust and pollen filter removed, check area in front of dust
and pollen filter (to intake duct for air in fresh air and air recir‐
culation mode) and clean, if necessary
⇒ “6.10 Removing and installing dust and pollen filter”,
page 275 .
– Check plenum chamber and water drain of plenum chamber
and clean if necessary
⇒ “7.12 Checking plenum chamber water drain”, page 301 .
– Place a drip tray under vehicle to collect cleaning fluid draining
from condensation drain (for location of condensation drain
opening, refer to
⇒ “6.13 Removing and installing condensation drain hose”,
page 284 ).
– Cover floor in front right footwell with waterproof sheeting and
absorbent paper.
Vehicles with an evaporator that has already been cleaned with
a spray lance:

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– Remove plug -C-.

Vehicles with an evaporator that has never been cleaned with a
spray lance:

NOTICE
Risk of damage from drill to heater and air conditioning unit or
flaps in heater and air conditioning unit
– Arrange connecting wires on heater and air conditioning unit
so that they cannot come into contact with drill bit or rotating
parts of drill.
– Proceed very carefully when drilling; operate drill at low
speed.
– Do not drill further than 10 mm into heater and air condition‐
ing unit.

– Using a commercially available angle drill and short drill bit (9

mm diameter), carefully drill a hole -B- into connection -A- at‐
tached to front heater and air conditioning unit for cleaning
evaporator.
– Deburr hole -B-.
Cleaning evaporator

CAUTION
Cleaning agent and its vapours pose a health hazard.
– Wear safety goggles and protective gloves and protective
clothing.
– Use the cleaning fluid only in well ventilated areas.
– Do not inhale cleaning agent vapours.

NOTICE
Cleaning fluid can cause damage to the vehicle.
– Ensure that fluid does not come into contact with electronic
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.

NOTICE
Other materials can form deposits in the heater and air condi‐
tioning unit.
– Only use pressure-feed spray guns and spray lances that
have not been used with other fluids.

– 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).
♦ Setting this pressure on the compressed-air supply means
that the spray lance has an operating pressure between 3.5
and 4.5 bar.

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– Connect pressure-feed spray gun VAS 1538 to compressed-

air supply.

– Insert spray lance -A- through opening -B- in heater and air
conditioning unit and into evaporator housing with spray di‐
rection towards evaporator.
Note
♦ The guide washer -C- is fitted opposite the outlet holes of the
spray lance; this allows you to identify and set the spray di‐
rection even when the spray lance is inserted.
• During the cleaning process, always check that the cleaning
fluid is flowing out through the condensation drain.
– Clean and rinse evaporator and surrounding area of housing
with 0.1 to 0.2. ltr. of cleaning solution by operating metering
lever on pressure-feed spray gun and moving spray lance
-A- back and forth.
– Check that fluid actually drains through condensation drain
and into drip tray under vehicle.
• If the fluid only drips out, the condensation drain must be
cleaned before the cleaning process can continue
⇒ “6.13 Removing and installing condensation drain hose”,
page 284 .
– Use entire contents of pressure-feed spray gun to clean evap‐
orator.
– Remove drip tray and dispose of collected cleaning agent.
Allow at least 30 minutes for cleaning solution to take effect. The
removed components can be re-installed in the vehicle during this
time.
– Insert plug -D- into hole -B- and check that it is seated tightly.
– Re-install all components previously removed.
– Open all doors or open the windows.
– Open all vents in dash panel and in vehicle interior.
– Switch on ignition after letting cleaning solution take effect.
– Adjust direction of air flow to “all vents” on display unit 2 for
front information display and operating unit control unit -
J1060- .
– Select maximum speed for fresh air blower - V2- on display
unit 2 for front information display and operating unit control
unit - J1060- .
– Then start engine and switch on air conditioner (air conditioner
compressor) (lamp in A/C or A/C MAX button on).
– If fitted, adjust direction of air flow to “all vents” on operating
and display unit for rear air conditioning system - E265- and
set rear fresh air blower - V80- to maximum speed.
– Allow air conditioner to run in this setting for approx. 10 mi‐
nutes (air conditioner compressor switched on), switching vent
temperature setting on display unit 2 for front information dis‐
play and operating unit control unit - J1060- from cold to warm
and back several times.

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6.7 Removing and installing auxiliary air

heater element - Z35-
The auxiliary air heater element - Z35- is only fitted on some ver‐
sions of the vehicle.
Removing
Vehicles with Low or MID version of air conditioner (PR no. 9AK
or KH5)
– Move front right seat to rearmost position.
– Switch off ignition.
– Remove glove box ⇒ General body repairs, interior; Rep. gr.
68 ; Storage compartments/covers/trim panels; Removing and
installing glove box .
– Remove footwell vent (right-side)
⇒ “7.5 Removing and installing footwell vent (front passenger
side)”, page 295 .
– Remove threaded fasteners -A-.
– Unfasten and detach insulating mat -B- from air intake box of
heater and air conditioning unit.
Vehicles with High version of air conditioner (PR no. 9AQ)
– Remove brackets for control motors
⇒ “5.23 Removing and installing brackets for control motors
on front heater and air conditioning unit”, page 242 .

All vehicles:
– Unplug electrical connector -B- for auxiliary air heater element
- Z35- -item A-.

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– Unscrew bolts -A-.

CAUTION
Danger of burns from metal surfaces of auxiliary air heater el‐
ement. Heater elements may be extremely hot.
Danger of burning the skin.
– Put on protective gloves.
– Never touch metal surfaces of heater element.

– Pull auxiliary air heater element - Z35- -B- out of installation

slot of heater and air conditioning unit.
Installing
Installation is carried out in reverse order; note the following:

– Check heater and air conditioning unit for dirt through instal‐
lation slot -C- (with cover -B- in position).
– If heater and air conditioning unit needs to be cleaned, un‐
screw bolts -A- and detach cover -B- for heat exchanger (right-
side).
– Check that foam seal -D- (if fitted) is not damaged and that it
is bonded on properly (check via installation slot -C- with cover
-B- in position).
– Vehicles with High version of air conditioner (PR no. 9AQ):
Remove bracket for rear right air quantity flap control motor -
V240-
⇒ “5.23.8 Removing and installing bracket for rear right air
quantity flap control motor V240 ”, page 252 .

– Check that foam seals -B, C- bonded (depending on version)

to heat exchanger -A- are not damaged and are bonded on
properly (check via .installation slot).
– Check that foam seals -B- and -C- are bonded onto heat ex‐
changer -A- properly.
♦ Foam seal -B- separates left and right sides of heat exchanger
-A-. Foam seal -C- separates air ducts for front and rear.
♦ If foam seals -B- and -C- are damaged or not bonded on cor‐
rectly, they may come loose when the auxiliary air heater
element - Z35- is inserted and cause problems in separating
and regulating the output temperatures on the left and right
sides as well as between the front and rear while the air con‐
ditioner is operating, depending on the setting. This may also
cause noise.
♦ If foam seals -B- and -C- are damaged or not bonded on prop‐
erly, bond them on securely or renew them ⇒ Electronic parts
catalogue .

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– Check that foam seal -D- at auxiliary air heater element - Z35-
-B- is not damaged and is bonded on properly.
♦ If foam seal -D- is damaged or not bonded on correctly, it may
come loose when the auxiliary air heater element - Z35- is in‐
serted and cause problems in separating and regulating the
output temperatures (front and rear) while the air conditioner
is operating, depending on the setting. This may also cause
noise.
♦ If foam seal -D- is damaged or not bonded on properly, bond
it on securely or renew it ⇒ Electronic parts catalogue .
– Insert auxiliary air heater element - Z35- -B- in installation slot
of heater and air conditioning unit.
– Tighten bolts -A-.

– Plug connector -B- in at auxiliary air heater element - Z35- .

– Re-install remaining components (removed earlier).
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “6.2 Exploded view - attachments for front heater and air
conditioning unit (air distribution housing, heat exchanger
etc.)”, page 255
♦ ⇒ General body repairs, interior; Rep. gr. 68 ; Storage com‐
partments/covers/trim panels; Exploded view - glove box

6.8 Removing and installing heater and air

conditioning unit
Special tools and workshop equipment required
♦ Hose clamps up to 25 mm - 3094-

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♦ Cooling system tester - V.A.G 1274B- (and appropriate adapt‐

ers)

♦ Engine bung set - VAS 6122-

♦ Commercially available compressed-air gun with rubber

mouthpiece
Removing
• When removing, note down bolt lengths and assignment for
re-installation.
• All cable ties and other wiring harness fasteners detached or
cut open during the removal of the heater and air conditioning
unit must be re-attached in the same positions during instal‐
lation.
• Seal off open connections in the lines at the connection point
using clean plugs, e.g. from engine bung set - VAS 6122- .
– Switch off ignition.
– Discharge refrigerant circuit ⇒ Air conditioner with refrigerant
R134a; Rep. gr. 87 ; Refrigerant circuit , or ⇒ Air conditioners
with refrigerant R1234yf - General information; Rep. gr. 87 ;
Working with the air conditioner service station .
– Remove plenum chamber partition panel ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Bulkhead; Removing and instal‐
ling plenum chamber partition panel .
– Drain coolant for engine coolant circuit ⇒ 4-cylinder direct in‐
jection engine (2.0 ltr. 4-valve TFSI, EA 888 Gen. III); Rep. gr.
19 ; Cooling system/coolant; Draining and filling cooling sys‐
tem .

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– Mark layout of coolant hoses at connections to heat exchanger

-B- (supply) and -A- (return to engine).
– Clamp off coolant hoses -A, B- using hose clamps (up to
25 mm) - 3094- .
– Cover area beneath connections for coolant hoses -A, B- in
plenum chamber e.g. with absorbent paper.
– Place a small container under connections for coolant hoses
-A, B- (to heat exchanger).
– Detach coolant hoses -A, B- from connections to heat ex‐
changer of heater and air conditioning unit.

– Attach a section of tubing (-A- and -C-) to each of the two con‐
nections at the heat exchanger.
– Place container -B- underneath other end of hose -C-.
– Using compressed-air gun -D-, carefully blow coolant out of
heat exchanger via hose -A- (in direction opposite to normal
coolant flow) into container -B-.
– Disconnect refrigerant lines from expansion valve (front) and
move them to one side (do not remove)
⇒ “2.15 Removing and installing expansion valve”, page 81 .

– Detach grommet -A- with support ring -B- towards passenger

compartment from plenum chamber back panel (removed and
installed together with heater and air conditioning unit).
– Remove dash panel cross member ⇒ General body repairs,
interior; Rep. gr. 70 ; Dash panel cross member; Removing
and installing dash panel cross member .
– Remove air duct (rear)
⇒ “7.7 Removing and installing air duct (rear)”, page 296 .

Vehicles with auxiliary air heater element - Z35-

– Unplug electrical connector -B- for auxiliary air heater element
- Z35- -item A-.
All vehicles (continued)

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– Detach condensation drain hose -A- from connection -B- on

both sides of heater and air conditioning unit.
– Protect floor covering in vicinity of centre tunnel with a sturdy
mat.
– Detach grommet -E- for coolant pipes to heat exchanger and
grommet -D- for expansion valve/connection from openings in
plenum chamber back panel.
– Carefully detach heater and air conditioning unit -C- slightly
from vehicle (making sure that no components are damaged
by any connections which have not yet been unfastened) and
remove it in direction of front passenger’s footwell.
Installing
Installation is carried out in reverse order; note the following:
• Check all seals and grommets at heater and air conditioning
unit for damage before installing, and renew any damaged
components.

– Coat grommets -B, C- with lubricant and install in plenum

chamber back panel -A-.
– Insert support ring -D- in grommet.
– Check position of coolant and refrigerant lines in the two grom‐
mets in plenum chamber back panel, and align heater and air
conditioning unit so that lines in grommets are free of tension.
– Vehicles with auxiliary air heater: Connect electrical wiring
⇒ “6.7 Removing and installing auxiliary air heater element
Z35 ”, page 268 .
– Attach refrigerant line to expansion valve (front)
⇒ “2.15 Removing and installing expansion valve”, page 81 .

– Attach coolant hoses -A, B- to coolant pipes going to heat ex‐

changer (observe marking) and secure with a clip.
– Fill up coolant for engine coolant circuit and bleed coolant cir‐
cuit ⇒ 4-cylinder direct injection engine (2.0 ltr. 4-valve TFSI,
EA 888 Gen. III); Rep. gr. 19 ; Cooling system/coolant; Drain‐
ing and filling cooling system .
– Switch on ignition.
– Then perform basic setting for control motors.
Procedure
– Connect ⇒ Vehicle diagnostic tester.
– Select Diagnosis mode and begin diagnosis.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 0009 - Electronic central electrics - J519
♦ 0009 - Electronic central electrics, functions
♦ 0009 - Basic setting for AC functions
– Start up air conditioner after charging refrigerant circuit
⇒ “2.22 Starting up air conditioner after charging refrigerant
circuit”, page 108 .

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6.9 Detaching and attaching air intake box

at heater and air conditioning unit
Detaching
– Remove front heater and air conditioning unit
⇒ “6.8 Removing and installing heater and air conditioning
unit”, page 270 .
– Detach noise insulation cover and insulating mat from air in‐
take box -C-
⇒ “6.1 Exploded view - heater and air conditioning unit”, page
253 .
– Mark and unplug connectors on control motors of air intake
box
⇒ “5.2.6 Exploded view - control motors on air intake box”,
page 210 .
– Mark routing of wiring harness -A- on air intake box -C- (or
document e.g. with photos) and detach from air intake box
⇒ “6.1 Exploded view - heater and air conditioning unit”, page
253 .
– Remove bolts -B-.
– Detach air intake box -C- from evaporator housing -D- on
heater and air conditioning unit
⇒ “6.1 Exploded view - heater and air conditioning unit”, page
253 .
Attaching
Perform installation steps in reverse sequence; observe the fol‐
lowing:
– Check that insulating mat -E- in evaporator housing -D- of
heater and air conditioning unit is not dirty (does not smell) and
that it is installed correctly.
– Check connection points between air intake box -C- and evap‐
orator housing -D- of heater and air conditioning unit (tongue
and groove joint) for damage and coat them lightly e.g. with
silicone grease to seal them completely.
♦ If connections are damaged or not assembled properly, noise
may occur during operation.
♦ Repair minor damage to “tongue-and-groove” joints carefully
using e.g. silicone adhesive sealant - D 176 001 A3- ⇒ Elec‐
tronic parts catalogue .
♦ Even very small leaks in “tongue-and-groove” joints can lead
to whistling noises caused by escaping air. To completely seal
the connection points, coat them lightly e.g. with silicone
grease (replacement part number G 000 405 A2) ⇒ Electronic
parts catalogue .
– Install front heater and air conditioning unit
⇒ “6.8 Removing and installing heater and air conditioning
unit”, page 270 .
– Re-install remaining components removed in reverse order.
Tightening torques
♦ ⇒ “6.1 Exploded view - heater and air conditioning unit”, page
253

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6.10 Removing and installing dust and pollen

filter
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Set front passenger seat to rearmost position.
– Switch off ignition.
– Remove plugs -A-.
– Unfasten and detach insulating mat -B- from air intake box of
heater and air conditioning unit.
– Cover floor covering beneath dust and pollen filter with paper.
Vehicles with air conditioner sensor for fine particle concentration
- G930- (PR no. 2V9)
– Detach air conditioner sensor for fine particle concentration -
G930- and move clear to one side
⇒ “11.11 Removing and installing air conditioner sensor for
fine particle concentration G930 ”, page 334 .

All vehicles (continued)

– Release catches -A- and detach slot cover -B-.
– Pull dust and pollen filter -E- out of slot in air intake box
-arrow-.
Installing
Installation is carried out in reverse order; note the following:
– Clean air intake box via slot for dust and pollen filter (e.g. with
a vacuum cleaner) after removing dust and pollen filter -E-.
– Install dust and pollen filter -E- correctly (“arrow” -item D- to‐
wards fresh air blower).
♦ If catches -A- no longer hold properly, slot cover -B- can also
be secured using bolts -C- (e.g. 3.5 or 3.9 x 16 mm flange bolt)
⇒ Electronic parts catalogue .
Tightening torques
♦ ⇒ “6.3 Exploded view - air intake box of heater and air condi‐
tioning unit”, page 257

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6.11 Removing and installing fresh air blower

- V2- with fresh air blower control unit -
J126-
The fresh air blower - V2- and the fresh air blower control unit -
J126- -C- form one component which must not be dismantled any
further ⇒ Electronic parts catalogue .
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Set front passenger seat to rearmost position.
– Switch off ignition.
– Remove glove box ⇒ General body repairs, interior; Rep. gr.
68 ; Storage compartments/covers/trim panels; Removing and
installing glove box .
– Remove bracket for control unit 1 for information electronics -
J794- and move it to one side with wiring attached ⇒ Com‐
munication; Rep. gr. 91 ; Infotainment system; Overview of
fitting locations - infotainment system .
– Remove footwell vent (passenger side)
⇒ “7.5 Removing and installing footwell vent (front passenger
side)”, page 295 .
– Remove air duct for glove box cooling
⇒ “7.6 Removing and installing air duct for glove box cooling”,
page 296 .

– Release connector -A- and unplug from -V2- (with -J126- )

-C-.
– Remove insulating mat -B-.

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– Unscrew bolts -A-.

CAUTION
Danger of burns due to hot cooling surface on fresh air blower
control unit
Take care not to burn your hands.
– Put on protective gloves.

NOTICE
Risk of damage to fresh air blower if handled incorrectly.
Risk of imbalance and operating problems.
– Avoid any force or strain on fan wheel.
– Do NOT move balancing weights on fan wheel.
– Do not set fresh air blower down on fan wheel.

– Carefully remove fresh air blower - V2- (with fresh air blower
control unit - J126- ) -B- from air intake box -C-.
Installing
Installation is carried out in reverse order; note the following:
– Check air intake box -C- for dirt via slot for -V2- -B- and clean
if necessary.
– When installing, make sure fresh air blower - V2- -B- is cor‐
rectly positioned in air intake box -C-.
Tightening torques
♦ ⇒ “6.3 Exploded view - air intake box of heater and air condi‐
tioning unit”, page 257

6.12 Removing and installing heat exchanger

⇒ “6.12.1 Preparations for removing heat exchanger”,
page 277
⇒ “6.12.2 Removing and installing heat exchanger”, page 278

6.12.1 Preparations for removing heat ex‐

changer
– Switch on ignition.
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Set direction of air flow to “DEF” (to windscreen) on display
unit 2 for front information display and operating unit control
unit - J1060- .
– On -J1060- , set temperature to “cold” for left and right sides.
– Move driver and front passenger seats as far towards rear as
possible.
– Switch off ignition.
– Depending on version: Remove knee airbag ⇒ General body
repairs, interior; Rep. gr. 69 ; Knee airbags; Removing and
installing knee airbag with igniter .

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– Remove left footwell vent (driver side)

⇒ “7.4 Removing and installing footwell vent (driver side)”,
page 294 .
– Remove bracket for control motor -V137- / -V239-
⇒ “5.23.1 Removing and installing bracket for rear temperature
flap control motor V137 / rear left air quantity flap control motor
V239 ”, page 242 .
– Remove air duct for glove box cooling
⇒ “7.6 Removing and installing air duct for glove box cooling”,
page 296 .
– Remove fresh air blower - V2- (with fresh air blower control
unit - J126- )
⇒ “6.11 Removing and installing fresh air blower V2 with fresh
air blower control unit J126 ”, page 276 .
– Remove bracket for control motors (right-side)
⇒ “5.23 Removing and installing brackets for control motors
on front heater and air conditioning unit”, page 242 .
Vehicles with auxiliary air heater element - Z35- (continued)
– Remove auxiliary air heater element - Z35-
⇒ “6.7 Removing and installing auxiliary air heater element
Z35 ”, page 268 .
– Unscrew bolts -B- and remove cover -A- for heat exchanger
(right-side).

Vehicles without auxiliary air heater (continued)

– Unscrew bolts -B- and remove cover -A- for heat exchanger
(right-side).
– Remove zone divider -C-.
All vehicles (continued)
⇒ “6.12.2 Removing and installing heat exchanger”, page 278

6.12.2 Removing and installing heat exchanger

Special tools and workshop equipment required
♦ Hose clamps up to 25 mm - 3094- or hose clamps up to 40 mm
- 3093-
♦ Commercially available compressed-air gun with rubber
mouthpiece

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♦ Cooling system tester - V.A.G 1274B- (and appropriate adapt‐

ers)

Removing
– Perform preparations for removing heat exchanger
⇒ “6.12.1 Preparations for removing heat exchanger”,
page 277 .
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .
– Move mounting for relay and fuse carrier -2- clear at body
brace and move it to one side.
– Drain coolant for engine coolant circuit ⇒ 4-cylinder direct in‐
jection engine (2.0 ltr. 4-valve TFSI, EA 888 Gen. III); Rep. gr.
19 ; Cooling system/coolant; Draining and filling cooling sys‐
tem .

– Mark layout of coolant hoses at connections to heat exchanger

-B- (supply) and -A- (return to engine).
– Clamp off coolant hoses -A, B- using hose clamps (up to
25 mm) - 3094- .
– Cover area beneath connections for coolant hoses -A, B- in
plenum chamber e.g. with absorbent paper.
– Place a small container under connections for coolant hoses
-A, B- (to heat exchanger).
– Detach coolant hoses -A, B- from connections to heat ex‐
changer of heater and air conditioning unit.

– Attach a section of tubing (-A- and -C-) to each of the two con‐
nections at the heat exchanger.
– Place container -B- underneath other end of hose -C-.
– Using compressed-air gun -D-, carefully blow coolant out of
heat exchanger via hose -A- (in direction opposite to normal
coolant flow) into container -B-.

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– Protect floor covering and centre tunnel beneath heat ex‐

changer (both sides) -A- with impermeable sheeting and ab‐
sorbent paper.
– Unscrew bolt from screw-type clip -B- and remove screw-type
clip.
– Unscrew bolt from screw-type clip -C- and remove screw-type
clip -B-.
Note
♦ The bolts in screw-type clips -B- and -C- can be removed using
a long Torx wrench -F-. Depending on the version of the heater
and air conditioning unit, hexagon socket head bolts with a
width of 3 mm can be used instead of the Torx bolts on certain
country-specific versions.
If the position of the screw-type clips -B- and/or -C- prevents ac‐
cess to the bolts, the clips can be turned carefully (using a little
force and a screwdriver).

– Check position of temperature flap for right side -A- in heater

and air conditioning unit with reference to position of lever
-B-; lever -B- must be in position shown.
Note
♦ Temperature flap (left-side) -F- was set to correct position be‐
fore ignition was switched off
⇒ “6.12.1 Preparations for removing heat exchanger”,
page 277 .

NOTICE
Risk of damaging temperature flaps -A- in heater and air con‐
ditioning unit when removing heat exchanger.
– Check lever -B- to ensure that temperature flap -A- is set to
“cold” position.

– Slide heat exchanger towards footwell (right-side) and at the

same time detach both coolant pipes -D- and -E- from con‐
nections of heat exchanger.
– Remove heat exchanger -A- from heater and air conditioning
unit in footwell (right-side) in direction of -arrow-.
– Remove O-rings from coolant pipes -D- and -E- (or connec‐
tions on heat exchanger).

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Installing
Installation is carried out in reverse order; note the following:
– Check that foam seals -B-, -C-, -D- and -E- on heat exchanger
-A- are not damaged and are bonded on properly; only install
heat exchanger if seals are not damaged and are bonded on
properly.
♦ Foam seals -B- and -F- separate left and right sides of the heat
exchanger -A-.
♦ Foam seals -C- and -E- separate air duct for front and rear that
passes through heat exchanger.
Note
♦ If one of the foam seals is damaged or loose, there may be
problems with the separation and regulation of the output tem‐
peratures after installation. This may also cause noise.
♦ Depending on the version, different foam seals are bonded
onto the heat exchanger. Currently, the available replacement
heat exchanger has bonded on seals for all versions of the
heater and air conditioning unit. Different heat exchangers will
be available as replacement parts at a later time (with or with‐
out foam seals -B-, -C-, -E- and -F-); refer to ⇒ Electronic parts
catalogue .

– Check heater and air conditioning unit for dirt through instal‐
lation slot for heat exchanger -C-.
– Remove any dirt or remnants of escaped coolant from the
heater and air conditioning unit (e.g. after removing a leaking
heat exchanger).
– Check that there are no edges or projections at installation slot
(top and bottom) for heat exchanger or on heater and air con‐
ditioning unit (both sides).
– Remove any residual material left at separation points during
manufacture of heater and air conditioning unit and round off
any edges.
– Check position of temperature flap for right side -A- and left
side -F- in heater and air conditioning unit. Temperature flaps
are set to “cold” position (illustrated).

– Check that connections -G- of heat exchanger -A- are not

damaged or dirty, then moisten with a small quantity of cool‐
ant.

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– Check connection area -F- for the two coolant pipes -D- and
-E- to heat exchanger for damage or dirt.
– Position one new screw-type clip -A- with a socket head bolt
-B- (M4 x 16 mm) in correct position on each of the two coolant
pipes -D- and -E-.
Note
♦ The two screw-type clips include factory-fitted M4 x 10 mm
socket head bolts; the screw-type clip can only be attached to
the connections on the heat exchanger after these bolts have
been removed. If M4 x 16 mm socket head bolts are used, the
screw-type clips can also be attached to the connections on
the heat exchanger with socket head bolts -B- fitted.
– Moisten new seals -C- with a small amount of coolant and at‐
tach them to the two coolant pipes -D- and -E-.
– To prevent the heat exchanger from being inserted too far,
install bracket for temperature flap control motor - V137-
⇒ “5.23.1 Removing and installing bracket for rear temperature
flap control motor V137 / rear left air quantity flap control motor
V239 ”, page 242 .
– Insert heat exchanger with the help of a second mechanic;
while doing so, make sure that connections -G- do not touch
housing of heater and air conditioning unit and are not dam‐
aged.
– When inserting heat exchanger, guide coolant pipes -D- and
-E- (with O-rings -C-) into connections -G- on heat exchanger
with the help of a second mechanic.
– Push coolant pipes -D- and -E- into connections on heat ex‐
changer -G- one after the other until they engage audibly, and
attach a screw-type clip -B- at connection point to heat ex‐
changer, as shown.
Note

♦ Screw-type clips -B- engage when they are pressed together.

♦ The bolts in screw-type clips -B- and -C- can be installed using
a long T15 Torx wrench -F-.
♦ If the position of screw-type clips -B- and/or -C- is not ideal,
the clips can be turned carefully (using a little force and a
screwdriver) before being tightened.

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– Secure screw-type clips -A- by tightening bolt -B-.

– Check that screw-type clips -A- are positioned properly on
connections of heat exchanger and coolant pipes.
– Check installation position of screw-type clips -A- and bolts
-B-. They must not make contact with heater and air condi‐
tioning unit or other components.
Vehicles with auxiliary air heater (continued)
– Install cover for heat exchanger (right-side) and auxiliary air
heater element - Z35-
⇒ “6.7 Removing and installing auxiliary air heater element
Z35 ”, page 268 .

Vehicles without auxiliary air heater (continued)

– Check foam seal -E- on zone divider -C- for damage and make
sure it is attached properly.
• If foam seals -B- are damaged or not bonded on properly, bond
them on securely or renew them ⇒ Electronic parts catalogue .
– Install zone divider -C- and cover for heat exchanger (right-
side) -A- on heater and air conditioning unit.

– Attach coolant hoses -A, B- to coolant pipes going to heat ex‐

changer (observe marking) and secure with a clip.
– Fill up coolant for engine coolant circuit and bleed coolant cir‐
cuit ⇒ 4-cylinder direct injection engine (2.0 ltr. 4-valve TFSI,
EA 888 Gen. III); Rep. gr. 19 ; Cooling system/coolant; Drain‐
ing and filling cooling system .

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Check connections at heat exchanger for leaks as follows:

– Check coolant circuit for leaks, paying particular attention to
connection between coolant pipes -D- and -E- and heat ex‐
changer ⇒ Engine; Rep. gr. 19 ; Cooling system/coolant;
Checking cooling system for leaks .
– Re-install all components removed in reverse order
⇒ “6.12.1 Preparations for removing heat exchanger”,
page 277 .
– Perform basic setting for air conditioner
⇒ “5.4 General information and procedure for removing and
installing control motors”, page 211 .
Tightening torques
♦ ⇒ “6.2 Exploded view - attachments for front heater and air
conditioning unit (air distribution housing, heat exchanger
etc.)”, page 255

6.13 Removing and installing condensation

drain hose
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Switch off ignition.
– Remove glove box (for access to condensation drain hose on
right side) ⇒ General body repairs, interior; Rep. gr. 68 ;
Storage compartments/covers/trim panels; Removing and in‐
stalling glove box .
– Remove dash panel cover (driver side) (for access to conden‐
sation drain hose on left side) ⇒ General body repairs, interior;
Rep. gr. 68 ; Storage compartments/covers/trim panels; Re‐
moving and installing dash panel cover (driver side) .
– Remove centre console footwell trim (front) ⇒ General body
repairs, interior; Rep. gr. 68 ; Centre console; Removing and
installing centre console footwell trim (front) .
– Carefully fold back floor covering in area of condensation drain
hose (front left or front right of centre tunnel) until condensation
drain is visible.
– Check that both condensation drain hoses -B- are routed cor‐
rectly and not dirty.
– Cover area beneath the two openings -D- (for drain holes of
condensation drain -C-) with absorbent paper to prevent any
water from running beneath floor covering.
– Remove the two condensation drain hoses -B-.
– Use e.g. a piece of wire to check for dirt in the two condensa‐
tion drains of the heater and air conditioning unit -A-.
– Check distance between insulating mat -E- in centre tunnel
and end of condensation drain hose -C- via openings -D- in
floor panel -F-. There must be enough of a gap for condensate
to drain out of condensation drain hose -B-.

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Installing
Installation is carried out in reverse order; note the following:
– Install the two condensation drain hoses -B- so that they are
not twisted or crushed (different versions for left and right
sides) ⇒ Electronic parts catalogue .
– Insert condensation drain hose -B- and press it into floor panel
-F- (with pre-tension).
– When fitting floor covering, take particular care to ensure that
it does not squash condensation drain hose -B-.
– If a condensation drain hose -B- is not fitted securely enough
to condensation drain of heater and air conditioning unit -A-,
secure it e.g. with a clip if necessary to prevent it from slipping
off.

6.14 Checking condensation drain hose

♦ This vehicle is fitted with two condensation drain hoses -B- (on
right and left of heater and air conditioning unit/centre tunnel).
– Make sure that condensation drain hoses are installed cor‐
rectly
⇒ “6.13 Removing and installing condensation drain hose”,
page 284 .
– Use e.g. a piece of wire to check for dirt in the two condensa‐
tion drains -B- of the heater and air conditioning unit -A-.
– Check that both condensation drain hoses -B- are routed cor‐
rectly and check for cross-sectional constrictions.

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7 Air duct
⇒ “7.1 Exploded view - routing of air flow and air distribution in
passenger compartment”, page 286
⇒ “7.2 Air intake and air outlet openings”, page 290
⇒ “7.3 Removing and installing air duct to dash panel vents (cen‐
tre)”, page 294
⇒ “7.4 Removing and installing footwell vent (driver side)”,
page 294
⇒ “7.5 Removing and installing footwell vent (front passenger
side)”, page 295
⇒ “7.6 Removing and installing air duct for glove box cooling”,
page 296
⇒ “7.7 Removing and installing air duct (rear)”, page 296
⇒ “7.8 Removing and installing air duct for rear vent”, page 296
⇒ “7.9 Removing and installing forced ventilation vents in pas‐
senger compartment”, page 297
⇒ “7.10 Checking forced ventilation vents in passenger compart‐
ment”, page 297
⇒ “7.11 Removing and installing fresh air intake”, page 298
⇒ “7.12 Checking plenum chamber water drain”, page 301
⇒ “7.13 Cleaning plenum chamber water drain”, page 301

7.1 Exploded view - routing of air flow and

air distribution in passenger compart‐
ment
⇒ “7.1.1 Exploded view - routing of air flow and air distribution in
passenger compartment (front)”, page 286
⇒ “7.1.2 Exploded view - air ducts and vents in rear passenger
compartment”, page 289

7.1.1 Exploded view - routing of air flow and air distribution in passenger com‐
partment (front)

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1 - Air duct
2 - Footwell vent (front left)
❑ Removing and installing
⇒ “7.4 Removing and in‐
stalling footwell vent
(driver side)”,
page 294
3 - Spreader rivet
4 - Dash panel vent (left-side)
❑ Removing and installing
⇒ General body repairs,
interior; Rep. gr. 70 ;
Dash panel; Exploded
view - dash panel
5 - Front heater and air condi‐
tioning unit
❑ Different versions ⇒
Electronic parts cata‐
logue
❑ Exploded view
⇒ “6.1 Exploded view -
heater and air condition‐
ing unit”, page 253
❑ Air intake, air outlet and
routing of air flow in
heater and air condition‐
ing unit
⇒ “7.2.2 Routing of air
flow in front heater and
air conditioning unit”,
page 292
6 - Spreader rivet
7 - Front left chest vent tem‐
perature sensor - G385-
❑ Removing and installing
⇒ “10.3.1 Removing and installing front left chest vent temperature sensor G385 ”, page 317
8 - Air duct (outer left)
❑ Different versions ⇒ Electronic parts catalogue
❑ Equipment version with driver side ioniser - J1105- : Overview of fitting locations
⇒ “11.1 Overview of fitting locations - air ionisation system”, page 323
– Remove dash panel ⇒ General body repairs, interior; Rep. gr. 70 ; Dash panel; Removing and installing
dash panel .

– Remove pine-tree clip and detach air distribution housing.

– Unplug electrical connectors and remove air distribution housing.

9 - Air duct (left-side)

10 - Air duct
❑ For control unit for head-up display
11 - Spreader rivet
❑ 2x
12 - Air duct/defroster intermediate piece
– Removing and installing ⇒ General body repairs, interior; Rep. gr. 70 ; Dash panel; Removing and
installing dash panel

– Remove spreader rivet and detach intermediate piece.

7. Air duct 287

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13 - Spreader rivet
14 - Air duct to dash panel vents (centre)
❑ Removing and installing
⇒ “7.3 Removing and installing air duct to dash panel vents (centre)”, page 294
15 - Air duct (right-side)
❑ Removing dash panel cross member ⇒ General body repairs, interior; Rep. gr. 70 ; Dash panel cross
member; Removing and installing dash panel cross member
16 - Bolt
❑ 1.5 Nm
17 - Air duct (outer right)
❑ Different versions ⇒ Electronic parts catalogue
❑ Equipment version with passenger side ioniser - J1106- Overview of fitting locations ⇒ page 323
– Remove dash panel ⇒ General body repairs, interior; Rep. gr. 70 ; Dash panel; Removing and installing
dash panel .

– Remove spreader rivet and unscrew bolt.

– Unplug electrical connectors and remove air distribution housing.

18 - Spreader rivet
19 - Front right chest vent temperature sensor - G386-
❑ Removing and installing
⇒ “10.3.2 Removing and installing front right chest vent temperature sensor G386 ”, page 318
20 - Spreader rivet
21 - Bolt
❑ 3 Nm
22 - Dash panel vent (centre)
❑ Removing and installing ⇒ General body repairs, interior; Rep. gr. 70 ; Dash panel; Exploded view -
dash panel
23 - Spreader rivet
24 - Footwell vent (front right)
❑ ⇒ “7.5 Removing and installing footwell vent (front passenger side)”, page 295

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7.1.2 Exploded view - air ducts and vents in rear passenger compartment

1 - Air duct to B-pillar air duct

(left-side)
2 - B-pillar air duct (left-side)
3 - B-pillar vent (left-side)
❑ Removing and installing
⇒ General body repairs,
interior; Rep. gr. 70 ;
Passenger compart‐
ment trim panels; Re‐
moving and installing B-
pillar trim
4 - Spreader rivet
❑ 3x
5 - Vent temperature sender
for rear left footwell - G637-
❑ Fitted depending on
equipment
❑ Removing and installing
⇒ “10.8 Removing and
installing vent tempera‐
ture sender for rear left
footwell G637 / vent
temperature sender for
rear right footwell G638
”, page 320
6 - Footwell vent (left-side) in
passenger compartment
7 - Crash pad
8 - Rear left chest vent temper‐
ature sender - G635- - vehicles
with PR number 9AU
❑ Checking ⇒ Vehicle di‐
agnostic tester
❑ Removing and installing
⇒ “10.7 Removing and installing rear left chest vent temperature sender G635 / rear right chest vent
temperature sender G636 ”, page 320
9 - Air duct (left-side) to footwell vent in passenger compartment
10 - Air duct
11 - Heater and air conditioning unit
❑ Different versions ⇒ Electronic parts catalogue
❑ Exploded view ⇒ “6.1 Exploded view - heater and air conditioning unit”, page 253
❑ Air intake, air outlet and routing of air flow in heater and air conditioning unit
⇒ “7.2.2 Routing of air flow in front heater and air conditioning unit”, page 292
12 - Air duct (right-side) to footwell vent in passenger compartment
13 - Air duct (rear)
❑ Removing and installing ⇒ “7.7 Removing and installing air duct (rear)”, page 296
14 - Rear right chest vent temperature sender - G636- - vehicles with PR number 9AU
❑ Checking ⇒ Vehicle diagnostic tester
❑ Removing and installing
⇒ “10.7 Removing and installing rear left chest vent temperature sender G635 / rear right chest vent
temperature sender G636 ”, page 320

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15 - Crash pad
16 - Footwell vent (right-side) in passenger compartment
17 - Vent temperature sender for rear right footwell - G638-
❑ Removing and installing
⇒ “10.8 Removing and installing vent temperature sender for rear left footwell G637 / vent temperature
sender for rear right footwell G638 ”, page 320
18 - Spreader rivet
❑ 3x
19 - B-pillar vent (right-side)
❑ Removing and installing ⇒ General body repairs, interior; Rep. gr. 70 ; Passenger compartment trim
panels; Removing and installing B-pillar trim
20 - B-pillar air duct (right-side)
21 - Air duct to B-pillar air duct (right-side)
22 - Rear vent in centre console
❑ Removing and installing ⇒ General body repairs, interior; Rep. gr. 68 ; Centre console; Removing and
installing centre console
23 - Air duct to rear vent
❑ Exploded view ⇒ “5.3 Exploded view - control motors (rear)”, page 211
❑ Removing and installing ⇒ “7.8 Removing and installing air duct for rear vent”, page 296

7.2 Air intake and air outlet openings

⇒ “7.2.1 Air intake and air outlet openings - front heater and air
conditioning unit”, page 290
⇒ “7.2.2 Routing of air flow in front heater and air conditioning
unit”, page 292

7.2.1 Air intake and air outlet openings - front

heater and air conditioning unit
The passenger compartment is ventilated via two ventilation
frames (on left and right of luggage compartment in area of bump‐
er)
⇒ “7.9 Removing and installing forced ventilation vents in pas‐
senger compartment”, page 297 .

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1 - Fresh air intake

❑ Air is drawn in from ple‐
num chamber
⇒ “7.11 Removing and
installing fresh air in‐
take”, page 298
2 - Air intake box
❑ Exploded view
⇒ “6.3 Exploded view -
air intake box of heater
and air conditioning
unit”, page 257
3 - Air intake from passenger
compartment (air recirculation
mode)
❑ Air is drawn in from front
passenger's footwell un‐
derneath glove box
4 - Air duct for glove box cool‐
ing
❑ Removing and installing
⇒ “7.6 Removing and in‐
stalling air duct for glove
box cooling”, page 296
❑ Vehicles without glove
box cooling (optional ex‐
tra): Connection is
sealed off with a cap
5 - Air outlet to dash panel
vents (right-side) and to wide
air outlet
❑ Air is directed to differ‐
ent vents, depending on
version of air condition‐
er
⇒ “7.1.1 Exploded view
- routing of air flow and air distribution in passenger compartment (front)”, page 286
6 - Condensation drain hose (right-side)
❑ ⇒ “6.13 Removing and installing condensation drain hose”, page 284
7 - Air outlet to footwell vent (front right)
8 - Condensation drain hose (left-side)
❑ Removing and installing ⇒ “6.13 Removing and installing condensation drain hose”, page 284
9 - Air outlet to air ducts beneath centre console (right-side)
❑ Different air temperatures are possible for the left and right sides depending on the setting
⇒ “7.2.2 Routing of air flow in front heater and air conditioning unit”, page 292
10 - Air outlet to air ducts beneath centre console (centre)
❑ Different air temperatures are possible for the left and right sides depending on the setting. The temper‐
ature reached in the centre is determined by the left and right temperature settings and the selected air
flow rate ⇒ “7.2.2 Routing of air flow in front heater and air conditioning unit”, page 292 .
❑ Depending on equipment version, this flap may also be separated
11 - Air outlet to air ducts beneath centre console (left-side)
❑ Different air temperatures are possible for the left and right sides depending on the setting
⇒ “7.2.2 Routing of air flow in front heater and air conditioning unit”, page 292
12 - Air outlet to dash panel vent (centre right)
❑ Different air temperatures are possible for the left and right sides depending on the setting
⇒ “7.2.2 Routing of air flow in front heater and air conditioning unit”, page 292

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13 - Air outlet to dash panel vent (centre left)

❑ Different air temperatures are possible for the left and right sides depending on the setting
⇒ “7.2.2 Routing of air flow in front heater and air conditioning unit”, page 292
14 - Air outlet to footwell vent (front left)
❑ Different air temperatures are possible for the left and right sides depending on the setting
⇒ “7.2.2 Routing of air flow in front heater and air conditioning unit”, page 292
15 - Air outlet to dash panel vents (left-side)
❑ Different air temperatures are possible for the left and right sides depending on the setting
⇒ “7.2.2 Routing of air flow in front heater and air conditioning unit”, page 292
16 - Air distribution housing of front heater and air conditioning unit
❑ Different versions ⇒ Electronic parts catalogue
❑ Exploded view ⇒ “6.1 Exploded view - heater and air conditioning unit”, page 253
❑ Removing and installing ⇒ “6.8 Removing and installing heater and air conditioning unit”, page 270
17 - Air outlet to dash panel defroster vent (left-side)
❑ Different air temperatures are possible for the left and right sides depending on the setting
⇒ “7.2.2 Routing of air flow in front heater and air conditioning unit”, page 292
18 - Air outlet to dash panel defroster vent (right-side)
❑ Different air temperatures are possible for the left and right sides depending on the setting
⇒ “7.2.2 Routing of air flow in front heater and air conditioning unit”, page 292
19 - Evaporator housing
❑ Exploded view ⇒ “6.4 Exploded view - evaporator housing”, page 258
❑ Removing and installing ⇒ “6.8 Removing and installing heater and air conditioning unit”, page 270

7.2.2 Routing of air flow in front heater and air

conditioning unit
♦ To illustrate the routing of air flow in the air intake box and the
heater and air conditioning unit, the two components are
shown in the form of sectional views “A - A”, “B - B” and “C -
C”.
♦ There are different versions of the air conditioner depending
on the vehicle equipment. Pay attention to the correct version
and assignment of the different components ⇒ Electronic
parts catalogue .
♦ On vehicles with glove box cooling, the cooled air routed into
the glove box is tapped directly downstream of the evaporator
⇒ Item 11 (page 293) .
♦ The front heater and air conditioning unit is fitted with partitions
(not shown in detail here) so that the temperature of the air
from the front vents can be controlled separately.

292 Rep. gr.87 - Air conditioning system

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1 - Evaporator and air distribu‐

tion housing of front heater and
air conditioning unit
❑ Different versions ⇒
Electronic parts cata‐
logue
❑ Exploded view
⇒ “6.1 Exploded view -
heater and air condition‐
ing unit”, page 253
2 - Air intake box of front heater
and air conditioning unit
3 - Fresh air intake
❑ Air is drawn in from ple‐
num chamber
⇒ “7.11 Removing and
installing fresh air in‐
take”, page 298
4 - Air intake from passenger
compartment (air recirculation
mode)
❑ When air recirculation
flap is open, air is drawn
in beneath glove box
from passenger's foot‐
well
❑ Illustration shows air re‐
circulation flap in
“closed” position
5 - Fresh air blower - V2- with
fresh air blower control unit -
J126-
6 - Air outlet to left dash panel
vent (driver side)
7 - Air outlet to left footwell vent
(driver side)
8 - Air outlet to right dash panel vent (passenger side)
9 - Air outlet to right footwell vent (passenger side)
10 - Dust and pollen filter
❑ Different versions ⇒ Electronic parts catalogue
❑ Removing and installing ⇒ “6.10 Removing and installing dust and pollen filter”, page 275
11 - Evaporator
12 - Heat exchanger for heater
❑ Removing and installing ⇒ “6.12 Removing and installing heat exchanger”, page 277
13 - Zone divider or auxiliary air heater element - Z35-
❑ -Z35- is fitted on some equipment versions
⇒ “6.7 Removing and installing auxiliary air heater element Z35 ”, page 268
❑ A zone divider is fitted on vehicles without -Z35-
14 - Mixing chamber (front left) for heated and non-heated air (driver side)
❑ The various temperature flaps direct a certain volume of air through the heat exchanger (and the auxiliary
air heater element - Z35- or the zone divider) or past it
❑ Temperature flaps for front are not shown in illustration

7. Air duct 293

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15 - Partition between driver and passenger side

❑ Separates air duct to vents (left and right) and is necessary to allow different air outflow temperatures
(depending on position of corresponding temperature flaps)
16 - Air outlet for passenger compartment, rear left (driver side)
❑ Depending on setting, heated or cooled air can be directed to vents
❑ Temperature flap for rear passenger compartment not shown in illustration
17 - Air outlet (centre) for passenger compartment (rear)
❑ Depending on setting, heated or cooled air can be directed to vents
❑ Temperature flap for rear passenger compartment not shown in illustration
18 - Air outlet to passenger compartment, rear right (passenger side)
❑ Depending on setting, heated or cooled air can be directed to vents
❑ Temperature flap for rear passenger compartment not shown in illustration
19 - Mixing chamber (front right) for heated and non-heated air (passenger side)
❑ The various temperature flaps direct a certain volume of air through the heat exchanger (and the auxiliary
air heater element - Z35- or the zone divider) or past it
❑ Temperature flaps for front are not shown in illustration
20 - Connection for hose to air duct for glove box cooling
❑ On vehicles without glove box cooling as an optional extra, opening in heater and air conditioning unit is
sealed with a cover ⇒ “7.6 Removing and installing air duct for glove box cooling”, page 296
❑ Checking, removing and installing hose to air duct for glove box cooling
⇒ “7.6 Removing and installing air duct for glove box cooling”, page 296

7.3 Removing and installing air duct to dash

panel vents (centre)
Removing
– Remove dash panel ⇒ General body repairs, interior; Rep. gr.
70 ; Dash panel; Removing and installing dash panel .
– If fitted, remove control unit for air ionisation system - J897-
⇒ “11.8 Removing and installing ioniser control unit J897 ”,
page 331 .
– Remove bolt -C-.
– Release fasteners -A- and detach air duct -B-.
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ “7.1.1 Exploded view - routing of air flow and air distribution
in passenger compartment (front)”, page 286

7.4 Removing and installing footwell vent

(driver side)
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .

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All vehicles (continued)

– Switch off ignition.
– 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) .
– Depending on version: Remove knee airbag ⇒ General body
repairs, interior; Rep. gr. 69 ; Knee airbags; Removing and
installing knee airbag with igniter .
– Remove spreader rivet -A-.
– Remove footwell vent (left-side) -C- from heater and air con‐
ditioning unit -B-.
Installing
Installation is carried out in reverse order; note the following:
– Check footwell vent -C- and heater and air conditioning unit
-B- for damage. If connections are damaged or not assembled
properly, noise may occur during operation.

7.5 Removing and installing footwell vent

(front passenger side)
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Switch off ignition.
– Remove glove box ⇒ General body repairs, interior; Rep. gr.
68 ; Storage compartments/covers/trim panels; Removing and
installing glove box .

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– Remove bolt -B-.

– Depending on version: Remove knee airbag ⇒ General body
repairs, interior; Rep. gr. 69 ; Knee airbags; Removing and
installing knee airbag with igniter .
– Remove footwell vent -A- from heater and air conditioning unit.
Installing
Installation is carried out in reverse order; note the following:
– Check footwell vent -A- and heater and air conditioning unit for
damage. If connections are damaged or not assembled prop‐
erly, noise may occur during operation.
Tightening torques
♦ ⇒ “7.1.1 Exploded view - routing of air flow and air distribution
in passenger compartment (front)”, page 286

7.6 Removing and installing air duct for

glove box cooling
Removing
– Remove right footwell vent (passenger side)
⇒ “7.5 Removing and installing footwell vent (front passenger
side)”, page 295 .
– Unfasten and detach air duct at air intake box.
– To detach air duct for glove box cooling -A- from heater and
air conditioning unit, turn it clockwise -arrow-.
Installing
Installation is carried out in reverse sequence.

7.7 Removing and installing air duct (rear)

Removing
– Remove centre console and bracket (front) for centre console
⇒ General body repairs, interior; Rep. gr. 68 ; Centre console;
Removing and installing bracket for centre console .
– Vehicles with High version of air conditioner (PR no. 9AQ):
Detach crash pads -D, F- and unplug electrical connectors
-A-.
– Swivel air duct -C- upwards at rear -arrow E- and release it
from fastener at air distribution housing -arrow B-.
– Detach air duct (rear).
Installing
Installation is carried out in reverse sequence.

7.8 Removing and installing air duct for rear

vent
• Before removing control motors, note general information and
procedure for removing and installing control motors

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⇒ “5.4 General information and procedure for removing and

installing control motors”, page 211 .
Removing
– Remove centre console trim (rear) ⇒ General body repairs,
interior; Rep. gr. 68 ; Centre console; Exploded view - centre
console .
– Unplug electrical connectors -A, C-.
– Pull off air duct -B- for rear vent in centre console.
– If air duct is being renewed, the following control motors must
be removed on vehicles with High version of air conditioner
(PR no. 9AQ): right B-pillar and footwell shut-off flap control
motor - V211- and left B-pillar and footwell shut-off flap control
motor - V212-
⇒ “5.15 Removing and installing right B-pillar and footwell
shut-off flap control motor V211 / left B-pillar and footwell shut-
off flap control motor V212 ”, page 230 .
Installing
Installation is carried out in reverse order; note the following:
– Renew damaged or defective foam seals at air duct.

7.9 Removing and installing forced ventila‐

tion vents in passenger compartment
Removing
– Remove bumper cover (rear) ⇒ General body repairs, exteri‐
or; Rep. gr. 63 ; Bumper (rear); Removing and installing
bumper cover .
– Detach cover for luggage compartment side trim.
– Move insulation to one side.
– Release retaining clips -C- and press forced ventilation frame
-A- outwards out of body opening -D-.
Installing
Installation is carried out in reverse order; note the following:
– Check seal on ventilation frame -A- for damage.
– Fit ventilation frame -A- in correct position to make sure seal‐
ing lips -B- close properly.
– Push forced ventilation frame -A- into body opening -D- until
all retaining tabs -C- engage audibly.

7.10 Checking forced ventilation vents in

passenger compartment
♦ Ventilation openings -B, D, E- must not be closed or obstructed
as this could result in problems with passenger compartment
ventilation.

7. Air duct 297

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– Unclip covers -C, F- from luggage compartment side trim

-A, G- ⇒ General body repairs, interior; Rep. gr. 70 ; Luggage
compartment trim panels; Exploded view - luggage compart‐
ment side trim .
– Check that ventilation frame -H- (left and right) is not blocked.
• Sealing lips in ventilation frame -H- must move freely and close
automatically.
• Ventilation frames -H- must be installed on correct side.
• Ventilation frames -H- must not be obstructed.

7.11 Removing and installing fresh air intake

⇒ “7.11.1 Exploded view - fresh air intake of front heater and air
conditioning unit”, page 298
⇒ “7.11.2 Removing and installing drip rail for fresh air intake”,
page 299
⇒ “7.11.3 Removing and installing leaf grille”, page 300
⇒ “7.11.4 Removing and installing fresh air intake”, page 300

7.11.1 Exploded view - fresh air intake of front heater and air conditioning unit

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1 - Spreader rivet
❑ 2x
2 - Outer cover for fresh air in‐
take box (drip rail)
❑ Before installing, check
outer cover for damage
(water can enter heater
and air conditioning unit
through fresh air intake
duct if cover is dam‐
aged)
❑ When installing, make
sure fresh air intake is
positioned correctly. If
fresh air intake is not fit‐
ted correctly, water can
run into intake duct of
heater and air condition‐
ing unit
❑ Removing and installing
⇒ “7.11.2 Removing and
installing drip rail for
fresh air intake”,
page 299
3 - Leaf grille
❑ Removing and installing
⇒ “7.11.3 Removing and
installing leaf grille”,
page 300
4 - Nut
❑ 3.5 Nm
❑ Observe tightening se‐
quence
⇒ “7.11.4 Removing and
installing fresh air in‐
take”, page 300
5 - Fresh air intake
❑ Before installing, check that fresh air intake duct and corresponding seal are not damaged and are as‐
sembled correctly.
❑ Renew if damaged
❑ Removing and installing ⇒ “7.11.4 Removing and installing fresh air intake”, page 300
6 - Air quality sensor - G238- / external air quality and air humidity sensor - G935-
❑ Removing and installing
⇒ “10.1 Removing and installing air quality sensor G238 / external air quality and air humidity sensor
G935 ”, page 316

7.11.2 Removing and installing drip rail for

fresh air intake
Removing
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .

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– Remove spreader rivets -1-.

– Swivel drip rail -2- upwards and detach it from fresh air intake
duct -3-.
Installing
Installation is carried out in reverse sequence.

7.11.3 Removing and installing leaf grille

Removing
– Remove drip rail for fresh air intake
⇒ “7.11.2 Removing and installing drip rail for fresh air intake”,
page 299 .
– Remove air quality sensor - G238- / external air quality and air
humidity sensor - G935- and move to one side (do not unplug
electrical connector)
⇒ “10.1 Removing and installing air quality sensor G238 / ex‐
ternal air quality and air humidity sensor G935 ”, page 316 .
– Release retaining tabs -arrows-.
– Detach leaf grille -1- from intake duct -2-.
Installing
Installation is carried out in reverse sequence.

7.11.4 Removing and installing fresh air intake

Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Switch off ignition.
– Remove leaf grille
⇒ “7.11.3 Removing and installing leaf grille”, page 300 .

300 Rep. gr.87 - Air conditioning system

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– If fitted, remove windscreen washer pump control unit - J1100-

-5- and move it to one side (do not unplug electrical connector)
⇒ Electrical system; Rep. gr. 92 ; Windscreen washer system;
Exploded view - windscreen washer system .
– Unscrew nuts -3.4 and 6-.
– Take intake duct -1- out of plenum chamber.

Installing
Installation is carried out in reverse order; note the following:
– Check bonded seal -2- between intake duct and body for dam‐
age.
– First tighten nut -6- and then nuts -4- and -3-.
Tightening torques
♦ ⇒ “7.11.1 Exploded view - fresh air intake of front heater and
air conditioning unit”, page 298

7.12 Checking plenum chamber water drain

Procedure
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .
– Check plenum chamber and water drain openings -1,2,3,4- for
contamination.
– Check that water drain openings -1,2,3,4- are not blocked.
– Check plenum chamber for damage and then check that it is
installed correctly.

7.13 Cleaning plenum chamber water drain

Special tools and workshop equipment required
♦ Suction feed spray-gun - VAG 1538-
♦ Nylon probe - VAG 1538/2-
♦ Flexible picking tool
Procedure
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .
– Remove coarse dirt from plenum chamber and water drain
openings with a flexible picking tool.
– Remove fine dirt using suction-feed spray gun - V.A.G 1538-
and nylon probe - V.A.G 1538/2- or a thin water hose.

7. Air duct 301

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8 Coolant circuit
⇒ “8.1 Exploded view - high-voltage heater (PTC) Z115 ”,
page 302
⇒ “8.2 Incorporation of heater and air conditioning unit into engine
coolant circuit”, page 303
⇒ “8.3 Removing and installing high-voltage heater (PTC) Z115
(with high-voltage heater (PTC) control unit J848 )”, page 308

8.1 Exploded view - high-voltage heater (PTC) - Z115-

1 - Bracket
2 - Nuts
❑ 2x
❑ 8 Nm
3 - Nut
Tightening torque ⇒ Rep. gr.
93 ; Potential equalisation
lines; Overview of fitting loca‐
tions - potential equalisation
lines

4 - High-voltage heater (PTC)

- Z115-
❑ Removing and installing
⇒ “8.3 Removing and in‐
stalling high-voltage
heater (PTC) Z115 (with
high-voltage heater
(PTC) control unit
J848 )”, page 308
5 - Bracket
6 - Bolts
❑ 2x
❑ 8 Nm
7 - Guide sleeves
8 - Rubber bush
9 - Spacer
10 - Bolts
❑ 3x
❑ 8 Nm
11 - Bolt
❑ 8 Nm

302 Rep. gr.87 - Air conditioning system

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8.2 Incorporation of heater and air condi‐

tioning unit into engine coolant circuit
⇒ “8.2.1 Notes on incorporation of heater and air conditioning unit
into coolant circuit”, page 303
⇒ “8.2.2 Incorporation of heater and air conditioning unit into cool‐
ant circuit - vehicles without auxiliary heater and with 4-cyl. TDI
engine”, page 303
⇒ “8.2.3 Incorporation of heater and air conditioning unit into cool‐
ant circuit - vehicles without auxiliary heater and with V6 3.0 ltr.
TDI engine”, page 304
⇒ “8.2.5 Incorporation of heater and air conditioning unit into cool‐
ant circuit - vehicles without auxiliary heater and with V6 3.0 ltr.
FSI engine”, page 306
⇒ “8.2.4 Incorporation of heater and air conditioning unit into cool‐
ant circuit - vehicles without auxiliary heater and with 4-cyl. TFSI
engine”, page 305
⇒ “8.2.6 Incorporation of heater and air conditioning unit into cool‐
ant circuit - vehicles with auxiliary heater”, page 307
⇒ “8.2.7 Incorporation of heater and air conditioning unit into cool‐
ant circuit - vehicles with high-voltage system”, page 307

8.2.1 Notes on incorporation of heater and air

conditioning unit into coolant circuit
♦ Mark coolant hoses and coolant lines before removing them.
Interchanging coolant hoses or coolant lines during installation
can cause problems when bleeding heat exchanger in heater
and air conditioning units and with vehicle operation.
♦ Air in coolant lines, coolant hoses or heat exchangers in heater
and air conditioning units will cause noise in coolant circuit.

8.2.2 Incorporation of heater and air condi‐

tioning unit into coolant circuit - vehicles
without auxiliary heater and with 4-cyl.
TDI engine
♦ Arrows show direction of coolant flow.
♦ The different colours in the illustration provide greater clarity.
♦ They do not correspond to the colours of the coolant hoses
fitted in the vehicle.

8. Coolant circuit 303

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1 - Leadthrough for coolant

lines through plenum chamber
partition panel
2 - Front heater and air condi‐
tioning unit
❑ Removing and installing
heat exchanger with
heater and air condition‐
ing unit installed
⇒ “6.12 Removing and
installing heat exchang‐
er”, page 277
❑ Removing and installing
heat exchanger with
heater and air condition‐
ing unit removed
⇒ “6.1 Exploded view -
heater and air condition‐
ing unit”, page 253
3 - Coolant hose (supply)
❑ In plenum chamber
4 - Coolant hose (return)
❑ In plenum chamber
5 - Connection piece for cool‐
ant supply from engine
❑ Incorporation of heater
and air conditioning unit
into engine coolant cir‐
cuit ⇒ Engine; Rep. gr.
19 ; Cooling system/
coolant; Connection di‐
agram - coolant hoses
6 - Connection piece for cool‐
ant return to engine
❑ Incorporation of heater
and air conditioning unit
into engine coolant circuit ⇒ Engine; Rep. gr. 19 ; Cooling system/coolant; Connection diagram - coolant
hoses

8.2.3 Incorporation of heater and air condi‐

tioning unit into coolant circuit - vehicles
without auxiliary heater and with V6 3.0
ltr. TDI engine
♦ Arrows show direction of coolant flow.
♦ The different colours in the illustration provide greater clarity.
♦ They do not correspond to the colours of the coolant hoses
fitted in the vehicle.

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1 - Coolant hose (supply)

❑ In plenum chamber
2 - Coolant hose (return)
❑ In plenum chamber
3 - Connection piece for cool‐
ant return to engine
❑ Incorporation of heater
and air conditioning unit
into engine coolant cir‐
cuit ⇒ Engine; Rep. gr.
19 ; Cooling system/
coolant; Connection di‐
agram - coolant hoses
4 - Connection piece for cool‐
ant supply from engine
❑ Incorporation of heater
and air conditioning unit
into engine coolant cir‐
cuit ⇒ Engine; Rep. gr.
19 ; Cooling system/
coolant; Connection di‐
agram - coolant hoses
5 - Leadthrough for coolant
lines through plenum chamber
partition panel
6 - Connection piece to coolant
expansion tank
7 - Front heater and air condi‐
tioning unit
❑ Removing and installing
heat exchanger with
heater and air condition‐
ing unit installed
⇒ “6.12 Removing and
installing heat exchang‐
er”, page 277
❑ Removing and installing heat exchanger with heater and air conditioning unit removed
⇒ “6.1 Exploded view - heater and air conditioning unit”, page 253

8.2.4 Incorporation of heater and air condi‐

tioning unit into coolant circuit - vehicles
without auxiliary heater and with 4-cyl.
TFSI engine
♦ Arrows show direction of coolant flow.
♦ The different colours in the illustration provide greater clarity.
♦ They do not correspond to the colours of the coolant hoses
fitted in the vehicle.

8. Coolant circuit 305

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1 - Connection piece for cool‐

ant return to engine
❑ Incorporation of heater
and air conditioning unit
into engine coolant cir‐
cuit ⇒ Engine; Rep. gr.
19 ; Cooling system/
coolant; Connection di‐
agram - coolant hoses
2 - Leadthrough for coolant line
(right-side) through body
3 - Front heater and air condi‐
tioning unit
❑ Removing and installing
heat exchanger with
heater and air condition‐
ing unit installed
⇒ “6.12 Removing and
installing heat exchang‐
er”, page 277
❑ Removing and installing
heat exchanger with
heater and air condition‐
ing unit removed
⇒ “6.1 Exploded view -
heater and air condition‐
ing unit”, page 253
4 - Coolant hose (supply)
❑ In plenum chamber
5 - Leadthrough for coolant line
(left-side) through body
6 - Connection piece for cool‐
ant supply from engine
❑ Incorporation of heater
and air conditioning unit
into engine coolant cir‐
cuit ⇒ Engine; Rep. gr. 19 ; Cooling system/coolant; Connection diagram - coolant hoses
7 - Coolant hose (return)
❑ In plenum chamber

8.2.5 Incorporation of heater and air condi‐

tioning unit into coolant circuit - vehicles
without auxiliary heater and with V6 3.0
ltr. FSI engine
♦ Arrows show direction of coolant flow.
♦ The different colours in the illustration provide greater clarity.
♦ They do not correspond to the colours of the coolant hoses
fitted in the vehicle.

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1 - Coolant hose (return)

❑ In plenum chamber
2 - Coolant hose (supply)
❑ In plenum chamber
3 - Connection piece for cool‐
ant supply from engine
❑ Incorporation of heater
and air conditioning unit
into engine coolant cir‐
cuit ⇒ Engine; Rep. gr.
19 ; Cooling system/
coolant; Connection di‐
agram - coolant hoses
4 - Connection piece for cool‐
ant return to engine
❑ Incorporation of heater
and air conditioning unit
into engine coolant cir‐
cuit ⇒ Engine; Rep. gr.
19 ; Cooling system/
coolant; Connection di‐
agram - coolant hoses
5 - Leadthrough for coolant
lines through plenum chamber
partition panel
6 - Front heater and air condi‐
tioning unit
❑ Removing and installing
heat exchanger with
heater and air condition‐
ing unit installed
⇒ “6.12 Removing and
installing heat exchang‐
er”, page 277
❑ Removing and installing
heat exchanger with heater and air conditioning unit removed
⇒ “6.1 Exploded view - heater and air conditioning unit”, page 253

8.2.6 Incorporation of heater and air condi‐

tioning unit into coolant circuit - vehicles
with auxiliary heater
For incorporation of heater and air conditioning unit into coolant
circuit on vehicles with auxiliary heater, refer to ⇒ Auxiliary/sup‐
plementary heater; Rep. gr. 82 ; Coolant circuit with auxiliary/
supplementary heater; Connection diagram - coolant hoses .

8.2.7 Incorporation of heater and air condi‐

tioning unit into coolant circuit - vehicles
with high-voltage system
♦ Arrows show direction of coolant flow.
♦ The different colours in the illustration provide greater clarity.
♦ They do not correspond to the colours of the coolant hoses
fitted in the vehicle.

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1 - Heater and air conditioning

unit
❑ Removing and installing
heat exchanger with
heater and air condition‐
ing unit installed
⇒ “6.12 Removing and
installing heat exchang‐
er”, page 277
❑ Removing and installing
heat exchanger with
heater and air condition‐
ing unit removed
⇒ “6.1 Exploded view -
heater and air condition‐
ing unit”, page 253
2 - Coolant hose (supply)
❑ From high-voltage heat‐
er (PTC) - Z115- to heat‐
er and air conditioning
unit
❑ In plenum chamber
3 - Coolant hose (return)
❑ In plenum chamber
4 - Coolant temperature send‐
er 2 for thermal management -
G903-
❑ Exploded view ⇒ 4-cyl‐
inder direct injection en‐
gine (2.0 ltr. 4-valve
TFSI, EA 888 Gen. III);
Rep. gr. 19 ; Cooling
system/coolant; Over‐
view of fitting locations -
cooling system
5 - Leadthrough for coolant
lines through plenum chamber partition panel
6 - Connection piece for coolant supply from engine to high-voltage heater (PTC) - Z115-
❑ Incorporation of heater and air conditioning unit into engine coolant circuit ⇒ Engine; Rep. gr. 19 ; Cooling
system/coolant; Connection diagram - coolant hoses
7 - Connection piece for coolant return to engine
❑ Incorporation of heater and air conditioning unit into engine coolant circuit ⇒ Engine; Rep. gr. 19 ; Cooling
system/coolant; Connection diagram - coolant hoses
8 - High-voltage heater (PTC) - Z115-
❑ Exploded view ⇒ “8.1 Exploded view - high-voltage heater (PTC) Z115 ”, page 302
❑ Removing and installing
⇒ “8.3 Removing and installing high-voltage heater (PTC) Z115 (with high-voltage heater (PTC) control
unit J848 )”, page 308

8.3 Removing and installing high-voltage

heater (PTC) - Z115- (with high-voltage
heater (PTC) control unit - J848- )
Special tools and workshop equipment required

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♦ Hose clamps up to 25 mm - 3094-

♦ Engine bung set - VAS 6122-

♦ Cooling system tester - V.A.G 1274 B-

♦ Spring-type clip pliers - VAS 5024A-

♦ Five-point star bit (TS30H) with centre hole (commercially

available)
Removing
Working with ignition switched on or high-voltage system active

8. Coolant circuit 309

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– Switch off (deactivate) auxiliary air conditioner function ⇒

Owner's Manual .

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or electric
arcs.
– Have an Audi high-voltage technician (HVT) or an Audi high-
voltage expert (HVE) de-energise the high-voltage system.

– De-energise high-voltage system ⇒ Rep. gr. 93 ; De-ener‐

gising high-voltage system .
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .

CAUTION
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.

– Drain coolant for engine coolant circuit ⇒ 4-cylinder direct in‐

jection engine (2.0 ltr. 4-valve TFSI, EA 888 Gen. III); Rep. gr.
19 ; Cooling system/coolant; Draining and filling cooling sys‐
tem .
– Release hose clips -D- with pliers -VAS 5024A- and detach
coolant hoses from connections to high-voltage heater (PTC)
- Z115- -F-.
– Seal off connections on high-voltage heater (PTC) - Z115-
-F- with plugs (e.g. from engine bung set - VAS 6122- ) and
use absorbent paper to clean up any coolant which has esca‐
ped.
– Unscrew nut -H- and detach potential equalisation line -A-
from high-voltage heater (PTC) - Z115- -F- ⇒ Rep. gr. 93 ;
Potential equalisation lines; Overview of fitting locations - po‐
tential equalisation lines .
– Loosen high-voltage wire -G- from bracket for high-voltage
heater (PTC) - Z115- -F-.
– Release and unplug electrical connectors -I- (for low voltage)
and -G- (high-voltage wire) ⇒ Rep. gr. 93 ; High-voltage wires;
Overview of fitting locations - high-voltage wires .
– Cover electrical connector -G- of high-voltage wire and mating
plug at high-voltage heater (PTC) - Z115- -F- to prevent dam‐
age and contamination (e.g. with clean plugs from engine
bung set - VAS 6122- ).
– Unscrew nuts -C- and bolt -B-, and remove high-voltage heat‐
er (PTC) - Z115- with bracket -F-.

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– Unscrew bolts -A- and detach bracket -B-.

– Remove bolts -C- and detach high-voltage heater (PTC) -

Z115- -B- from bracket -A-.

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Installing
Installation is carried out in reverse order; note the following:
– Plug in electrical connectors -I- (for low voltage) and -G- (high-
voltage wire) at high-voltage heater (PTC) - Z115- ⇒ Rep. gr.
93 ; High-voltage wires; Overview of fitting locations - high-
voltage wires .
– Check and, if necessary, clean potential equalisation line -A-
and connection point for potential equalisation line at high-
voltage heater (PTC) - Z115- -F- before securing ⇒ Rep. gr.
93 ; Potential equalisation lines .
– Secure potential equalisation line -A- to high-voltage heater
(PTC) - Z115- -F- with nut -H- and perform potential equalisa‐
tion measurement ⇒ Rep. gr. 93 ; Potential equalisation lines;
Overview of fitting locations - potential equalisation lines .
– Fit coolant hoses at connections to high-voltage heater (PTC)
- Z115- -F-, making sure they are the right way round, and
secure them with hose clips -D-.
– Fill up coolant for engine coolant circuit and bleed coolant cir‐
cuit ⇒ 4-cylinder direct injection engine (2.0 ltr. 4-valve TFSI,
EA 888 Gen. III); Rep. gr. 19 ; Cooling system/coolant; Drain‐
ing and filling cooling system .

WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or electric
arcs.
– Have an Audi high-voltage technician (HVT) or an Audi high-
voltage expert (HVE) re-energise the high-voltage system.

– Re-energise high-voltage system ⇒ Rep. gr. 93 ; Re-ener‐

gising high-voltage system .
Tightening torques
♦ ⇒ “8.1 Exploded view - high-voltage heater (PTC) Z115 ”, page
302
♦ ⇒ Rep. gr. 93 ; Potential equalisation lines; Overview of fitting
locations - potential equalisation lines

312 Rep. gr.87 - Air conditioning system

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9 Operating and display unit

⇒ “9.1 Overview - operating and display unit”, page 313
⇒ “9.2 Removing and installing operating and display unit”, page
314

9.1 Overview - operating and display unit

⇒ “9.1.1 Overview - operating and display unit, rest-of-world ver‐
sion”, page 313
⇒ “9.1.2 Overview - operating and display unit, version for China”,
page 314

9.1.1 Overview - operating and display unit, rest-of-world version

1 - Display unit for front infor‐

mation display and operating
unit control unit - J685-
❑ Removing and installing
⇒ Communication;
Rep. gr. 91 ; Infotain‐
ment system; Removing
and installing infotain‐
ment system display
2 - Display unit 2 for front infor‐
mation display and operating
unit control unit - J1060-
❑ Removing and installing
⇒ Communication;
Rep. gr. 91 ; Infotain‐
ment system; Removing
and installing infotain‐
ment system display
3 - Operating and display unit
for rear air conditioning system
- E265-
❑ Fitted depending on
equipment
❑ Removing and installing
⇒ “9.2 Removing and in‐
stalling operating and
display unit”, page 314

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9.1.2 Overview - operating and display unit, version for China

1 - Display unit 2 for front infor‐

mation display and operating
unit control unit - J1060-
❑ Removing and installing
⇒ Communication;
Rep. gr. 91 ; Infotain‐
ment system; Removing
and installing infotain‐
ment system display
2 - Display unit for front infor‐
mation display and operating
unit control unit - J685-
❑ Removing and installing
⇒ Communication;
Rep. gr. 91 ; Infotain‐
ment system; Removing
and installing infotain‐
ment system display
3 - Wireless operating unit 1 -
E859-
❑ Fitted depending on
equipment
❑ Removing and installing
⇒ Communication;
Rep. gr. 91 ; Infotain‐
ment system; Overview
of fitting locations - info‐
tainment system
4 - Additional display and op‐
erating unit 1 - E857-
❑ Fitted depending on
equipment
❑ Removing and installing
⇒ Communication;
Rep. gr. 91 ; Infotain‐
ment system; Overview
of fitting locations - info‐
tainment system

9.2 Removing and installing operating and

display unit
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Switch off ignition.
– Remove centre console trim (rear) ⇒ General body repairs,
interior; Rep. gr. 68 ; Centre console; Removing and installing
centre console trim (rear) .

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– Remove bolts -arrows-.

– Remove operating and display unit -A-.
Installing
Installation is carried out in reverse order; note the following:
• If the operating and display unit for rear air conditioning system
- E265- is being renewed, the test plan for renewing the oper‐
ating and display unit for rear air conditioning system - E265-
must be performed ⇒ Vehicle diagnostic tester.
Procedure
– Connect ⇒ Vehicle diagnostic tester.
– Select Diagnosis mode and begin diagnosis.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 0009 - Electronic central electrics - J519
♦ 0009 - Electronic central electrics, functions
♦ 0009 - E265 - Operating and display unit for rear air condi‐
tioning system
♦ ⇒ Renew control unit
Component Tight‐
ening
torque
Operating and display unit for rear air conditioning sys‐ 2 Nm
tem

9. Operating and display unit 315

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10 Further control components

⇒ “10.1 Removing and installing air quality sensor G238 / external
air quality and air humidity sensor G935 ”, page 316
⇒ “10.2 Removing and installing ambient temperature sensor G17
”, page 317
⇒ “10.3 Removing and installing front chest vent temperature
sensor G385 / G386 ”, page 317
⇒ “10.4 Removing and installing left footwell vent temperature
sender G261 ”, page 318
⇒ “10.5 Removing and installing right footwell vent temperature
sender G262 ”, page 319
⇒ “10.6 Removing and installing evaporator output temperature
sender G263 ”, page 319
⇒ “10.7 Removing and installing rear left chest vent temperature
sender G635 / rear right chest vent temperature sender G636 ”,
page 320
⇒ “10.8 Removing and installing vent temperature sender for rear
left footwell G637 / vent temperature sender for rear right footwell
G638 ”, page 320
⇒ “10.9 Removing and installing dash panel temperature sensor
G56 ”, page 321
⇒ “10.10 Removing and installing humidity sender G355 ”,
page 321
⇒ “10.11 Removing and installing thermal management control
unit J1024 ”, page 321

10.1 Removing and installing air quality sen‐

sor - G238- / external air quality and air
humidity sensor - G935-
Removing
– Switch off ignition.
– Remove cover on right side of plenum chamber cover ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 50 ; Bulkhead; Exploded
view - plenum chamber cover .
– Unplug electrical connector -A-.
– Release catch -D-, turn air quality sensor - G238- / external air
quality and air humidity sensor - G935- -C- approx. 90° in di‐
rection of -arrow- and remove it from leaf grille -B-.
Installing
Installation is carried out in reverse sequence.

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10.2 Removing and installing ambient tem‐

perature sensor - G17-
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Switch off ignition.
– Remove lock carrier cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Bumper (front) .
– Unclip ambient temperature sensor - G17- -B- from retainer
-A- -arrow-.
– Unplug connector -C- from temperature sensor -B- and re‐
move temperature sensor -B-.
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ General body repairs, exterior; Rep. gr. 63 ; Bumper (front)

10.3 Removing and installing front chest vent

temperature sensor - G385- / -G386-
⇒ “10.3.1 Removing and installing front left chest vent tempera‐
ture sensor G385 ”, page 317
⇒ “10.3.2 Removing and installing front right chest vent temper‐
ature sensor G386 ”, page 318

10.3.1 Removing and installing front left chest

vent temperature sensor - G385-
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Switch off ignition.
– Remove storage compartment (driver side) ⇒ General body
repairs, interior; Rep. gr. 68 ; Storage compartments/covers/
trim panels; Exploded view - dash panel cover (driver side) .

10. Further control components 317

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– Turn vent temperature sender -A- anti-clockwise and pull it out

of mounting.
– Unplug electrical connector -B-.
Installing
Installation is carried out in reverse order; note the following:
– Check seal for damage and make sure it is seated correctly.

10.3.2 Removing and installing front right chest

vent temperature sensor - G386-
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Switch off ignition.
– Remove glove box ⇒ General body repairs, interior; Rep. gr.
68 ; Storage compartments/covers/trim panels; Removing and
installing glove box .
– Turn vent temperature sender -A- anti-clockwise and pull it out
of mounting.
– Unplug electrical connector -B-.
Installing
Installation is carried out in reverse order; note the following:
– Check seal for damage and make sure it is seated correctly.

10.4 Removing and installing left footwell

vent temperature sender - G261-
Removing
– 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) .
– Turn vent temperature sender -2- anti-clockwise and pull it out
of mounting.
– Unplug electrical connector -1-.
Installing
Installation is carried out in reverse order; note the following:
– Check seal -3- for damage and make sure it is seated correct‐
ly.

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10.5 Removing and installing right footwell

vent temperature sender - G262-
Removing
– Remove glove box ⇒ General body repairs, interior; Rep. gr.
68 ; Storage compartments/covers/trim panels; Removing and
installing glove box .
– Turn vent temperature sender -2- anti-clockwise and pull it out
of mounting.
– Unplug electrical connector -1-.
Installing
Installation is carried out in reverse order; note the following:
– Check seal -3- for damage and make sure it is seated correct‐
ly.

10.6 Removing and installing evaporator out‐

put temperature sender - G263-
On right-hand drive vehicles, the evaporator output temperature
sender - G263- is installed from the left of the evaporator housing
of the heater and air conditioning unit (in the area behind the
coolant pipes to the heat exchanger).
Removing
Vehicles with high-voltage system
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
All vehicles (continued)
– Switch off ignition.
– Remove glove box ⇒ General body repairs, interior; Rep. gr.
68 ; Storage compartments/covers/trim panels; Removing and
installing glove box .
– If fitted, remove air duct for glove box cooling
⇒ “7.6 Removing and installing air duct for glove box cooling”,
page 296 .
– Remove footwell vent (passenger side)
⇒ “7.5 Removing and installing footwell vent (front passenger
side)”, page 295 .
– Detach evaporator output temperature sender - G263- -A-
(with connector -B- plugged in) from evaporator housing on
heater and air conditioning unit -arrow- and remove.
– Release catch -C- and unplug connector -B-.
Installing
Installation is carried out in reverse order; note the following:
– Insert evaporator output temperature sender - G263- -A- in
mounting of evaporator housing -D- in correct position and
check that it is seated securely.

10. Further control components 319

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10.7 Removing and installing rear left chest

vent temperature sender - G635- / rear
right chest vent temperature sender -
G636-
Vehicles with “Low” version of air conditioner (PR no. 9AK) are
not fitted with rear chest vent temperature senders.
Vehicles with “Mid” version of air conditioner (PR no. KH5) are
only fitted with a rear chest vent temperature sender on the driver
side.
Removing
– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing centre con‐
sole .
– Detach crash pad -C-.
– Unplug electrical connector -A-.
– Turn vent temperature sender -B- anti-clockwise and pull it out
of mounting.
Installing
Installation is carried out in reverse order; note the following:
– Check seal for damage and make sure it is seated correctly.

10.8 Removing and installing vent tempera‐

ture sender for rear left footwell - G637- /
vent temperature sender for rear right
footwell - G638-
Vehicles with “Low” version of air conditioner (PR no. 9AK) are
not fitted with rear footwell vent temperature senders.
Vehicles with “Mid” version of air conditioner (PR no. KH5) are
only fitted with a rear footwell vent temperature sender on the
driver side.
Removing
– Remove front seat ⇒ General body repairs, seats; Rep. gr.
72 ; Front seats; Removing and installing front seat .
– Lift floor covering in vicinity of connector point.
– Turn vent temperature sender -A- anti-clockwise and pull it out
of mounting.
– Unplug electrical connector -B-.
Installing
Installation is carried out in the reverse order; note the following:
– Check seal for damage and make sure it is seated correctly.

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10.9 Removing and installing dash panel

temperature sensor - G56-
Removing
– Remove steering column trim (bottom) ⇒ General body re‐
pairs, interior; Rep. gr. 68 ; Storage compartments/covers/trim
panels; Removing and installing steering column trim (bot‐
tom) .
– Release retaining tabs -2- -arrows-.
– Detach dash panel temperature sensor - G56- -1-.
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ General body repairs, interior; Rep. gr. 68 ; Storage com‐
partments/covers/trim panels; Exploded view - steering col‐
umn trim

10.10 Removing and installing humidity send‐

er - G355-
The humidity sender - G355- is part of the rain and light sensor -
G397- and cannot be renewed separately ⇒ Electrical system;
Rep. gr. 92 ; Windscreen wiper system; Removing and installing
rain and light sensor .

10.11 Removing and installing thermal man‐

agement control unit - J1024-
Thermal management control unit - J1024- is located in rack in
front of luggage compartment.
• If thermal management control unit - J1024- is being renewed,
test plan for renewal of thermal management control unit -
J1024- must be started before control unit is removed ⇒ Ve‐
hicle diagnostic tester.
Removing
– Switch off (deactivate) auxiliary air conditioner function ⇒
Owner's Manual .
– Switch off ignition.
– Remove frame for loading aid ⇒ General body repairs, interior;
Rep. gr. 70 ; Luggage compartment trim panels; Exploded
view - luggage compartment floor .

10. Further control components 321

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– Remove bolt -A- and lift rack in direction of -arrow B-.

– Release fastener -C- and remove thermal management con‐
trol unit - J1024- -F- from rack in direction of -arrow E-.
– Release and unplug electrical connector -D-.
Installing
Installation is carried out in reverse order; note the following:
– Check that bracket -G- and control units fitted are installed
correctly.
– If thermal management control unit - J1024- is being renewed,
complete test plan ⇒ Vehicle diagnostic tester.
Tightening torques
⇒ General body repairs, interior; Rep. gr. 70 ; Luggage com‐
partment trim panels; Exploded view - luggage compartment floor

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11 Air ionisation system

⇒ “11.1 Overview of fitting locations - air ionisation system”, page
323
⇒ “11.2 Exploded view - fragrance diffuser system”, page 325
⇒ “11.3 Removing and installing control unit for fragrance diffuser
system J1101 with blower for fragrance diffuser system V686 ”,
page 326
⇒ “11.4 Removing and installing function unit for fragrance dif‐
fuser system GX43 ”, page 327
⇒ “11.5 Removing and installing control motor for fragrance dif‐
fuser system V687 ”, page 328
⇒ “11.6 Removing and installing temperature sensor for fragrance
diffuser system G1056 ”, page 330
⇒ “11.7 Removing and installing hoses for fragrance diffuser sys‐
tem”, page 330
⇒ “11.8 Removing and installing ioniser control unit J897 ”, page
331
⇒ “11.9 Removing and installing driver side ioniser J1105 ”, page
332
⇒ “11.10 Removing and installing passenger side ioniser J1106
”, page 333
⇒ “11.11 Removing and installing air conditioner sensor for fine
particle concentration G930 ”, page 334

11.1 Overview of fitting locations - air ionisation system

11. Air ionisation system 323

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1 - Driver side ioniser - J1105-

❑ Removing and installing
⇒ “11.9 Removing and
installing driver side ion‐
iser J1105 ”, page 332
2 - Hose to air duct (left-side)
❑ Removing and installing
⇒ “11.7 Removing and
installing hoses for fra‐
grance diffuser system”,
page 330
3 - Hose to control unit for fra‐
grance diffuser system -
J1101- with blower for fra‐
grance diffuser system - V686-
❑ Removing and installing
⇒ “11.7 Removing and
installing hoses for fra‐
grance diffuser system”,
page 330
4 - Control unit for fragrance
diffuser system - J1101- with
blower for fragrance diffuser
system - V686-
❑ Removing and installing
⇒ “11.3 Removing and
installing control unit for
fragrance diffuser sys‐
tem J1101 with blower
for fragrance diffuser
system V686 ”,
page 326
❑ Exploded view
⇒ “11.2 Exploded view -
fragrance diffuser sys‐
tem”, page 325
5 - Function unit for fragrance
diffuser system - GX43-
❑ Removing and installing
⇒ “11.4 Removing and installing function unit for fragrance diffuser system GX43 ”, page 327
❑ Exploded view ⇒ “11.2 Exploded view - fragrance diffuser system”, page 325
❑ Includes the following components:
♦ Control motor for fragrance diffuser system - V687-
♦ Temperature sensor for fragrance diffuser system - G1056-
♦ Fragrance vial 1
♦ Fragrance vial 2
6 - Hose to air duct (left-side)
❑ Removing and installing
⇒ “11.7 Removing and installing hoses for fragrance diffuser system”, page 330
7 - Air conditioner sensor for fine particle concentration - G930-
❑ Removing and installing
⇒ “11.11 Removing and installing air conditioner sensor for fine particle concentration G930 ”,
page 334
❑ Fitted depending on equipment
8 - Passenger side ioniser - J1106-
❑ Removing and installing ⇒ “11.10 Removing and installing passenger side ioniser J1106 ”, page 333

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9 - Wiring harness
❑ From ioniser control unit - J897- to driver side ioniser - J1105- and passenger side ioniser - J1106-
10 - Ioniser control unit - J897-
❑ Removing and installing ⇒ “11.8 Removing and installing ioniser control unit J897 ”, page 331

11.2 Exploded view - fragrance diffuser system

1 - Plug
❑ 2x
❑ In dash panel cross
member
2 - Bolt
❑ 2x
❑ 1.5 Nm
3 - Bracket
4 - Bolt
❑ 2x
❑ 1.5 Nm
5 - Control unit for fragrance
diffuser system - J1101- with
blower for fragrance diffuser
system - V686-
❑ Integrated as one unit
and cannot be separa‐
ted from each other
❑ Removing and installing
⇒ “11.3 Removing and
installing control unit for
fragrance diffuser sys‐
tem J1101 with blower
for fragrance diffuser
system V686 ”,
page 326
6 - Wiring harness
7 - Bolt
❑ 3x
❑ 1.1 Nm
8 - Control motor for fragrance
diffuser system - V687-
❑ Removing and installing
⇒ “11.5 Removing and installing control motor for fragrance diffuser system V687 ”, page 328
9 - Temperature sensor for fragrance diffuser system - G1056-
❑ Removing and installing
⇒ “11.6 Removing and installing temperature sensor for fragrance diffuser system G1056 ”, page 330
10 - Seal
❑ Check this component before installing temperature sensor for fragrance diffuser system - G1056-
11 - Fragrance vial 1
❑ Removing and installing:
♦ A6 ⇒ Maintenance ; Booklet 501
♦ A7 ⇒ Maintenance ; Booklet 450

11. Air ionisation system 325

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❑ Different versions ⇒ Electronic parts catalogue

12 - Fragrance vial 2
❑ Removing and installing:
♦ A6 ⇒ Maintenance ; Booklet 501
♦ A7 ⇒ Maintenance ; Booklet 450
❑ Different versions ⇒ Electronic parts catalogue
13 - Function unit for fragrance diffuser system - GX43-
❑ Removing and installing
⇒ “11.4 Removing and installing function unit for fragrance diffuser system GX43 ”, page 327
14 - Hose
15 - Bolt
❑ 20 Nm

11.3 Removing and installing control unit for

fragrance diffuser system - J1101- with
blower for fragrance diffuser system -
V686-
Removing
– Remove function unit for fragrance diffuser system - GX43- ,
but do not detach it from bracket
⇒ “11.4 Removing and installing function unit for fragrance
diffuser system GX43 ”, page 327 .
– Unplug connector -2-.
– Disconnect hose -1- from control unit for fragrance diffuser
system - J1101- -5-.
– Unscrew bolts -3- and detach control unit for fragrance diffuser
system - J1101- -5-.
Installing
Installation is carried out in reverse order; note the following:
– If control unit for fragrance diffuser system - J1101- with blower
for fragrance diffuser system - V686- is renewed, work through
corresponding test plan.
Procedure
– Connect ⇒ Vehicle diagnostic tester.
– Select Diagnosis mode and begin diagnosis.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 0009 - Electronic central electrics - J519
♦ 0009 - Electronic central electrics, functions
♦ 0009 - J1101 Replace aroma system control unit
Tightening torques
♦ ⇒ “11.2 Exploded view - fragrance diffuser system”,
page 325

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11.4 Removing and installing function unit for

fragrance diffuser system - GX43-
Removing
– Remove footwell cover (driver side) ⇒ General body repairs,
interior; Rep. gr. 68 ; Storage compartments/covers/trim pan‐
els; Exploded view - dash panel cover (driver side) .
– Press catch -8- in direction of -arrow A- and at the same time
disconnect hose -7-.
– Unplug connector -6-.

CAUTION
Risk of fragrance escaping if function unit for fragrance diffuser
system - GX43- is tilted.
– If the control unit for fragrance diffuser system - J1101- , the
function unit for fragrance diffuser system - GX43- or the
control motor for fragrance diffuser system - V687- is defec‐
tive, the valves on the fragrance vials may be open.
– If any components of the fragrance system are defective,
remove the two fragrance vials before removing the bracket.

– Remove bolt -2-.

– Slide bracket -4- in direction of -arrow B- until pins -5- are clear
and then remove bracket.

– Disconnect hose -3- from function unit for fragrance diffuser

system - GX43- -1-.
– Unplug connector -5-.
– Unscrew bolts -2- and detach function unit for fragrance dif‐
fuser system - GX43- -1-.

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Installing
Installation is carried out in reverse order; note the following:
– Check that plug -1- is seated correctly in bracket -3-.
– If function unit for fragrance diffuser system - GX43- is re‐
newed, basic setting for control motor for fragrance diffuser
system - V687- must be performed.
Procedure
– Connect ⇒ Vehicle diagnostic tester.
– Select Diagnosis mode and begin diagnosis.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 0009 - Electronic central electrics - J519
♦ 0009 - Electronic central electrics, functions
♦ 0009 - Basic setting for AC functions
♦ ⇒ Basic setting 6: Adapt limit stops of control motor for fra‐
grance diffuser system - V687-
– If fragrance vials are renewed, these must also be adapted:
♦ A6 ⇒ Maintenance ; Booklet 501
♦ A7 ⇒ Maintenance ; Booklet 450
Tightening torques
♦ ⇒ “11.2 Exploded view - fragrance diffuser system”,
page 325

11.5 Removing and installing control motor

for fragrance diffuser system - V687-
Removing
– Remove function unit for fragrance diffuser system - GX43- ,
but do not detach it from bracket
⇒ “11.4 Removing and installing function unit for fragrance
diffuser system GX43 ”, page 327 .

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– Unplug connector -5-.

– Remove bolts -2-.
– Detach control motor for fragrance diffuser system - V687-
-1-; counterhold shaft -4- while doing so.
Installing
Installation is carried out in reverse order; note the following:
– Check that line -3- is routed correctly.
– If control motor for fragrance diffuser system - V687- -1- is re‐
newed, perform basic setting.
Procedure
– Connect ⇒ Vehicle diagnostic tester.
– Select Diagnosis mode and begin diagnosis.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 0009 - Electronic central electrics - J519
♦ 0009 - Electronic central electrics, functions
♦ 0009 - Basic setting for AC functions
♦ ⇒ Basic setting 6: Adapt limit stops of control motor for fra‐
grance diffuser system - V687-
Tightening torques
♦ ⇒ “11.2 Exploded view - fragrance diffuser system”,
page 325
♦ ⇒ General body repairs, interior; Rep. gr. 68 ; Storage com‐
partments/covers/trim panels; Exploded view - dash panel
cover (driver side)

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11.6 Removing and installing temperature

sensor for fragrance diffuser system -
G1056-
Removing
– Switch off ignition.
– Remove footwell cover (driver side) ⇒ General body repairs,
interior; Rep. gr. 68 ; Storage compartments/covers/trim pan‐
els; Exploded view - dash panel cover (driver side) .
– Release fragrance vial -2- in direction of -arrow- and detach.
– Unplug connector -3-.
– Turn temperature sensor for fragrance diffuser system -
G1056- -4- 90° in direction of -arrow- and pull it out of function
unit for fragrance diffuser system - GX43- -1-.
Installing
Installation is carried out in reverse order; note the following:
– Check seal -5- for damage and make sure it is seated correct‐
ly.
– Install fragrance vial -2-; note installation position while doing
so:
♦ A6 ⇒ Maintenance ; Booklet 501
♦ A7 ⇒ Maintenance ; Booklet 450
Tightening torques
♦ ⇒ General body repairs, interior; Rep. gr. 68 ; Storage com‐
partments/covers/trim panels; Exploded view - dash panel
cover (driver side)

11.7 Removing and installing hoses for fra‐

grance diffuser system
Removing
– Remove storage compartment (driver side) ⇒ General body
repairs, interior; Rep. gr. 68 ; Storage compartments/covers/
trim panels; Exploded view - dash panel cover (driver side) .

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Hose to air duct (left-side):

– Press pull release -B- into plug-in connector -A- -arrow- and
disconnect hose -C- from plug-in connector.
Hose to control unit for fragrance diffuser system - J1101- with
blower for fragrance diffuser system - V686- :
– Press pull release -B- into plug-in connector -A- -arrow- and
disconnect hose -D- from plug-in connector.
– Carefully guide out and detach hose.
Hose to air duct (right-side):
– Remove dash panel ⇒ General body repairs, interior; Rep. gr.
70 ; Dash panel; Removing and installing dash panel .
– Remove right footwell vent (passenger side)
⇒ “7.5 Removing and installing footwell vent (front passenger
side)”, page 295 .
– Depending on equipment version: Remove control unit for
head-up display ⇒ Electrical system; Rep. gr. 90 ; Dash panel
insert; Removing and installing control unit for head-up dis‐
play .

– Remove spreader rivet -B-, move air duct -A- clear and detach
it.

– Press pull release -B- into plug-in connector -C- -arrow- and
disconnect hose -A- from plug-in connector.
– Carefully guide out and detach hose.
Installing
Installation is carried out in reverse order; note the following:
• Connect plug-in connectors and hoses as far as stop.

11.8 Removing and installing ioniser control

unit - J897-
Removing
– Remove infotainment system display ⇒ Communication; Rep.
gr. 91 ; Infotainment system; Removing and installing info‐
tainment system display .

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– Remove bolts -arrows-.

– Detach ioniser control unit - J897- -B- and unplug electrical
connectors -A, C, D-.
Installing
Installation is carried out in reverse order; note the following:
Tightening torques
Component Tight‐
ening
torque
Control unit for air ionisation system 1.5
Nm

11.9 Removing and installing driver side ion‐

iser - J1105-
Special tools and workshop equipment required
♦ Wiring harness repair set - VAS 1978 B-

Removing
– Remove storage compartment (driver side) ⇒ General body
repairs, interior; Rep. gr. 68 ; Storage compartments/covers/
trim panels; Exploded view - dash panel cover (driver side) .
– Turn ioniser -A- clockwise and pull it out of air duct -B-.

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– Mark assignment of electrical wiring to connector housing for

re-installation.
– Release fasteners and open flaps -B, D- on connector housing
-C-.
– Use release tool -VAS 1978- to eject pins from connector
housing ⇒ Electrical system; Rep. gr. 97 ; Releasing and
dismantling connector housings .
Installing
Installation is carried out in reverse order; note the following:
– Slide pins -A, E- into correct side of connector housing (refer
to markings).
• The open side of the connector must face the outside of the
ioniser.

11.10 Removing and installing passenger side

ioniser - J1106-
Special tools and workshop equipment required
♦ Wiring harness repair set - VAS 1978 B-

Removing
– Remove glove box ⇒ General body repairs, interior; Rep. gr.
68 ; Storage compartments/covers/trim panels; Removing and
installing glove box .
– Turn ioniser -A- clockwise and pull it out of air duct -B-.

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– Mark assignment of electrical wiring to connector housing for

re-installation.
– Release fasteners and open flaps -B, D- on connector housing
-C-.
– Use release tool -VAS 1978- to eject pins from connector
housing ⇒ Electrical system; Rep. gr. 97 ; Releasing and
dismantling connector housings .
Installing
Installation is carried out in reverse order; note the following:
– Slide pins -A, E- into correct side of connector housing (refer
to markings).
• The open side of the connector must face the outside of the
ioniser.

11.11 Removing and installing air conditioner

sensor for fine particle concentration -
G930-
Removing
– Remove glove box ⇒ General body repairs, interior; Rep. gr.
68 ; Storage compartments/covers/trim panels; Removing and
installing glove box .
– Remove plugs -A-.
– Unfasten and detach insulating mat -B- from air intake box of
heater and air conditioning unit.

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– Unplug electrical connector -C-.

– Unscrew bolts -A-.
– Release fasteners -B- and move sensor -D- to one side.
– Release fastener -arrow- and disengage connection -E-.
– Detach sensor -D-.
Installing
Installation is carried out in reverse order; note the following:
– Check seal on connection -E- for damage.
– Press connection -E- on until it engages audibly.
Tightening torques
Component Tight‐
ening
torque
Air conditioner sensor for fine particle concentration 1.5
Nm

11. Air ionisation system 335