Air Conditioning (coupe) (2 of 2) Audi A5 I

A/C COMPRESSOR - ENGINE CODE(S): CAUA

Special tools and workshop equipment required

1. Engine Support Bridge 10- 222 A
2. Engine Support Supplement Set T40093
3. Engine And Transmission Lifter V.A.G 1383 A

REMOVING

Turn the front wheels so that they are straight.

Switch off the ignition.

Disconnect the battery. Refer to Removal and Installation .

Remove the engine cover -arrows-.

Scheme 36

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Note. Depending on the allocation of the service connection an on the refrigerant line, and on the version of the vehicle, it may be necessary to remove the additional reinforcement on the left suspension strut dome so that the service coupling of the service station can be connected (for example, on the Audi Q5). Refer to Removal and Installation and Removal and Installation .

Disconnect the coolant hose -3- from the coolant overflow reservoir.

Scheme 37

Remove the bolts -arrows- and move the coolant overflow reservoir with the hoses still connected -1- and -2- to the side.

Drain the coolant. Refer to General Information .

Remove plenum chamber front wall -A-. Refer to Description and Operation .

Scheme 38

Disconnect the upper coolant hose -right arrow- from the engine.

Scheme 39

Note. This coolant hose is removed with the coolant pipe.

Remove the screw -2-.

Remove the bolt -arrows-.

Scheme 40

Remove the guide tube -1- for the oil dipstick from the upper part of the oil pan.

Install the 10- 222 A with adapters T40093/6 on the left and right suspension strut domes as shown in the illustration.

Scheme 41

Mount the spindles 10- 222 A /11 on the engine lifting eyes.

Pretension the engine with the spindles slightly.

Remove the left and right front wheels.

Remove the left and right wheelhouse liners. Refer to Removal and Installation

Remove the left and right drive axle from the transmission shaft. Refer to Removal and Installation .

Remove the bolt -arrow- for the power steering hydraulic oil pressure line. Refer to Removal and Installation .

Scheme 42

Remove bolt -arrow- and the steering intermediate shaft from the steering gear and push them upward. Refer to Removal and Installation .

Scheme 43

Remove the CV joint from the steering gear and push it all the way up.

Disconnect the vacuum hose -1- and free up the power steering hydraulic fluid hose -arrow- on the bracket. Refer to Removal and Installation .

Scheme 44

Remove the nuts -2- and remove the vacuum reservoir.

Disconnect the connector -1- on the steering gear and free it up.

Scheme 45

Note. Disregard -item 2-.

Free up the left power steering hydraulic oil hose on the subframe.

Free up the wires on the right side of the subframe.

Disconnect the ground wires -arrow- from the right longitudinal member.

Scheme 46

Remove the left and right bolts -1- and nuts -3- and the Lock Carrier Braces -2-. Refer to Lock Carrier with Attachments Overview in Description and Operation .

Scheme 47

Disconnect the electrical connector on the Left Front Level Control System Sensor -G78- and free up the electric line -arrow-.

Scheme 48

Disconnect the electrical connector -3- for the Left Electro-Hydraulic Engine Mount Solenoid Valve -N144-.

Scheme 49

Remove the bolt -4- for the left engine mount.

Note. Disregard -item 1, 2- and -arrows-.

Disconnect the electrical connector -2- for the Right Electro-Hydraulic Engine Mount Solenoid Valve -N145-.

Scheme 50

Remove the engine mount bolt. Refer to -1- Removal and Installation .

Note. Disregard -item 3, 4- and -arrows-.

Support the subframe using the Engine-/Gearbox Jack V.A.G 1383 A as shown in the illustration. Refer to Removal and Installation .

Scheme 51

Remove the left and right stabilizer bolts -3-. Refer to Removal and Installation .

Scheme 52

Remove the left and right nuts -1- and the suspension strut bolts -2- Removal and Installation .

Remove the left and right bolts -1 ••• 3- in stages.

Scheme 53

Carefully lower the subframe using the Engine-/Gearbox Jack V.A.G 1383 A; while doing this, pay attention to the clearance for the left hydraulic oil hoses and the right electrical wires. Refer to Removal and Installation .

Let the subframe hang on the lower transverse link.

Free up the electrical line on the lower left coolant pipe.

Remove the bolt -1- (and if still not done, the bolt -2-) and remove the left lower coolant pipe from the coolant hose -left arrow-.

Note. In order to remove the coolant pipe, it may be necessary, depending on the flange shaft bracket, to loosen the bracket from the transmission and then turn it (do not remove bracket).

Remove the coolant pipe. Removal and Installation

Remove the bolts -2- and remove the left engine support.

Scheme 54

Note. Depending on the engine version, it may be necessary to use a M12 socket (multi-point socket) with a ball head to remove the top bolts on the engine support.

Remove the left engine mount. Refer to Removal and Installation .

Open the spring clamp -3-, pull the clamp -2- slightly out and remove the coolant hose.

Scheme 55

Note. Disregard -item 1, 4-.

Remove the coolant pump housing. Refer to Removal and Installation

Remove the bolts -1- and -2-. Refer to A/C COMPRESSOR REFRIGERANT LINES .

Scheme 56

Remove refrigerant lines from A/C compressor.

Note. Close open lines and connections on A/C compressor using suitable caps (to prevent possible penetration of dirt and moisture).

Hold the compressor driveshaft -A- with a wrench and turn the compressor drive unit -B- in the direction of arrow -C-.

Scheme 57

Note. Do not turn the compressor driveshaft -A-. Compressor driveshaft -A- can be slid into drive wheel through boot -E- after loosening threaded connection.

Mark the electrical connector -1- for the A/C Compressor Regulator Valve -N280- (to prevent confusing it with other connectors which look identical).

Scheme 58

Note. The connector to A/C Compressor Regulator Valve and the connector to the electric engine mounts are identical in construction. If these connectors are interchanged, no entry appears in the event memory. However since the A/C compressor is continuously activated, the evaporator may ice up.

Disconnect the connector -1- for the A/C Compressor Regulator Valve from the bracket.

Remove the bolts -2- and remove the compressor.

Carefully push the subframe downward and them remove the A/C compressor to the rear (between the longitudinal member and the subframe).

INSTALLING

Installation is done is reverse order, observe the following

Note. There is an unspecified amount of refrigerant oil in the removed compressor so follow the information on replacing the compressor. Removal and Installation .

If necessary, install the compressor driveshaft -A- (in the engine drive wheel) and check the grommet -E- seating.

Note. A clamp on the power take-off flange keeps the grommet -E- from sliding off. Refer to Removal and Installation . The illustration shows the location of the components on a vehicle with a power steering pump. Only vehicles without electro-mechanical power steering have a power steering pump. Refer to Removal and Installation .

If necessary, remove the alignment sleeves -F- from the compressor.

Scheme 59

Thoroughly clean the A/C compressor and bracket surfaces.

Install the alignment sleeves -F- in the bracket or in the A/C compressor.

Before tightening the A/C compressor, check seating of both alignment bushings -A- in bracket or A/C compressor -B-.

Scheme 60

Note. The alignment sleeves -A- have different styles (different lengths), make sure to use the correct style. Ensure bushings -A- are properly seated and contact surfaces are clean. Sockets installed incorrectly and dirty or damaged contact surfaces -C- on the bracket or A/C compressor can lead to alignment irregularities between the A/C compressor and engine. Alignment irregularities over operating time can lead to damage to the drive unit or the A/C compressor.

Tighten the bolts -arrows-.

1. Tightening specification: 25 Nm.

Connect electrical connector -1- on A/C Compressor Regulator Valve.

Check the A/C compressor connections and the refrigerant lines for damage or dirt. Refer tot A/C COMPRESSOR REFRIGERANT LINES .

Connect the refrigerant lines to the compressor; bolt tightening specification -A-, for the O-ring dimensions -B- and -C- as well as additional information, refer to A/C COMPRESSOR REFRIGERANT LINES .

Note. Check refrigerant lines and their bracket for sufficient distances to other components. Coat the O-ring seals lightly with refrigerant oil prior to installation. Refer to REFRIGERANT CIRCUIT O-RINGS .

To prevent damaging the compressor the first time is it switched on, turn the compressor drive unit -B- on the compressor by hand 10 rotations in the direction of the arrow -C- before turning the compressor driveshaft -A-.

Note. Refrigerant oil can collect in the compressor compression chamber after removing the compressor or adding new oil (for example, by blowing through the refrigerant circuit). Rotating forces the refrigerant oil out of the compression chamber.

Hold the compressor driveshaft -A- with a wrench and turn the compressor drive unit -B- in the direction of arrow -D-.

1. Tightening specification: 60 Nm.

Note. Do not turn the compressor driveshaft -A- when tightening. After installing, check installation position of grommet -E- on drive wheel. After installing the driveshaft -A-, check the boot -E- installation position.

Install the left engine mount. Refer to Removal and Installation .

Install the lower left coolant pipe. Refer to Removal and Installation .

Install the subframe. Refer to Removal and Installation .

Connect the suspension strut to the control arm. Refer to Removal and Installation .

Install the stabilizer. Refer to Removal and Installation .

Connect the CV joint to the steering gear. Refer to Removal and Installation .

Install the power steering hydraulic oil pressure line. Refer to Removal and Installation .

Install the longitudinal braces. Refer to Description and Operation

Note. Replace the seal; the self-locking nuts and the O-ring for the oil dipstick guide tube.

Install the oil dipstick guide tube. Refer to Removal and Installation .

Fill with coolant and bleed the coolant circuit. Refer to General Information .

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Install the remaining removed components.

Check the Climatronic control module -J255- display and control head DTC memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Note. Note the information regarding operating the A/C system after filling. Refer to A/C Service Station in Description and Operation .

A/C COMPRESSOR - ENGINE CODE(S): CFSA

Special tools and workshop equipment required

1. Engine Support Bridge 10- 222 A
2. Engine and Transmission Lifter V.A.G 1383 A
3. Engine Support Supplement Set T40093

Turn the front wheels so that they are straight.

Switch off the ignition.

Disconnect the battery. Refer to [For engine(s) CAUA, CAEB, CALA] Removal and Installation .

Remove the engine cover -arrows-.

Scheme 61

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Left air filter housing, removing .

Remove the bolt -arrows-.

Scheme 62

Remove the guide pipe -1- for the oil dipstick.

Install the 10- 222 A with adapters T40093/6 on the left and right suspension strut domes as shown in the illustration.

Mount the spindles 10- 222 A /11 on the engine lifting eyes.

Pretension the engine with the spindles slightly.

Remove the noise insulation -1- and -2-. Refer to Description and Operation .

Scheme 63

Remove the left and right front wheels. Refer to Removal and Installation .

Remove the left and right front wheel housing liners. Refer to Removal and Installation .

Remove the left and right drive axles from the transmission flange shaft. Refer to Removal and Installation .

Drain the coolant.

Remove the left and right bolt -1- and nut -3- and then remove the brace -2-.

Scheme 64

Remove the nut -arrow- from the right longitudinal member and free up the ground cables.

Scheme 65

Disconnect the connector -1- from headlamp range control sensor 1 -G233- and free up the wire -arrow-.

Remove the left and right bolt -1- from the stabilizer bar.

Scheme 66

Note. Ignore -2 and 3-.

Loosen the safety catch -arrow-, push the release down and disconnect the connector -2- from the steering gear.

Scheme 67

Disconnect the connector -1-.

Free up the wiring harness.

Remove the steering intermediate shaft from the steering gear and push them upward. Refer to Removal and Installation .

Remove the bolt -arrow- from the ATF pipes.

Scheme 68

Remove the left and right bolts -arrows- and leave the heat shield -1- in its installed position.

Scheme 69

Disconnect the electrical connector -3- for the Left Electro-Hydraulic Engine Mount Solenoid Valve -N144-.

Note. The connector to A/C Compressor Regulator Valve -N280- and the connector to the electric engine mounts are identical in construction. If these connectors are interchanged, no entry appears in the event memory. However since the A/C compressor is continuously activated, the evaporator may ice up.

Remove the bolt -4- for the left engine mount.

Note. Disregard -item 1, 2- and -arrows-.

Disconnect the electrical connector -2- for the Right Electro-Hydraulic Engine Mount Solenoid Valve -N145-.

Remove the bolt -1- from the right engine mount.

Note. Disregard -item 3, 4- and -arrows-.

Support the subframe using the V.A.G 1383 A as shown in the illustration. .

Remove the left and right bolts -1 ••• 3- in stages.

Lower the subframe carefully using V.A.G 1383 A. While doing this, make sure there is enough clearance on the left side for the ATF pipes and on the right side for the electric wires. Refer to Removal and Installation .

Let the subframe hang on the lower transverse link.

Remove the bolts -2- and remove the left engine support.

Move the clamp -1- and open the clamp -2- and then remove the coolant hose.

Scheme 70

Move the coolant hose to the side.

Open the clamps -1 and 2- remove the coolant hoses.

Scheme 71

Move the coolant hoses to the side.

Remove the bolts -1- and -2-. Refer to A/C COMPRESSOR REFRIGERANT LINES .

Remove refrigerant lines from A/C compressor.

Note. Close open lines and connections on A/C compressor using suitable caps (to prevent possible penetration of dirt and moisture).

Hold the compressor driveshaft -A- with a wrench and turn the compressor drive unit -B- in the direction of arrow -C-.

Note. Do not turn the compressor driveshaft -A-. Compressor driveshaft -A- can be slid into drive wheel through boot -E- after loosening threaded connection.

Mark the electrical connector -1- for the A/C Compressor Regulator Valve -N280- (to prevent confusing it with other connectors which look identical).

Note. The connector to A/C Compressor Regulator Valve and the connector to the electric engine mounts are identical in construction. If these connectors are interchanged, no entry appears in the event memory. However since the A/C compressor is continuously activated, the evaporator may ice up.

Disconnect the connector -1- for the A/C Compressor Regulator Valve from the bracket.

Remove the bolts -2- and remove the compressor.

Carefully push the subframe downward and them remove the A/C compressor to the rear (between the longitudinal member and the subframe).

Installation is done is reverse order, observe the following

Note. There is an unspecified amount of refrigerant oil in the removed compressor so follow the information on replacing the compressor. Removal and Installation .

If necessary, install the compressor driveshaft -A- (in the engine drive wheel) and check the grommet -E- seating.

Note. A clamp on the power take-off flange keeps the grommet -E- from sliding off . The illustration shows the location of the components on a vehicle with a power steering pump. Only vehicles without electro-mechanical power steering have a power steering pump. Refer to Removal and Installation .

If necessary, remove the alignment sleeves -F- from the compressor.

Thoroughly clean the A/C compressor and bracket surfaces.

Install the alignment sleeves -F- in the bracket or in the A/C compressor.

Before tightening the A/C compressor, check seating of both alignment bushings -A- in bracket or A/C compressor -B-.

Note. The alignment sleeves -A- have different styles (different lengths), make sure to use the correct style. Ensure bushings -A- are properly seated and contact surfaces are clean. Sockets installed incorrectly and dirty or damaged contact surfaces -C- on the bracket or A/C compressor can lead to alignment irregularities between the A/C compressor and engine. Alignment irregularities over operating time can lead to damage to the drive unit or the A/C compressor.

Tighten the screws -arrows-.

1. Tightening specification: 25 Nm.

Connect electrical connector -1- on A/C Compressor Regulator Valve.

Check the A/C compressor connections and the refrigerant lines for damage or dirt. Refer to A/C COMPRESSOR REFRIGERANT LINES .

Connect the refrigerant lines to the compressor; bolt tightening specification -A-, for the O-ring dimensions -B- and -C- as well as additional information, refer to A/C COMPRESSOR REFRIGERANT LINES .

Note. Check refrigerant lines and their bracket for sufficient distances to other components. Coat the O-ring seals lightly with refrigerant oil prior to installation. Refer to REFRIGERANT CIRCUIT O-RINGS .

To prevent damaging the compressor the first time is it switched on, turn the compressor drive unit -B- on the compressor by hand 10 rotations in the direction of the arrow -C- before turning the compressor driveshaft -A-.

Note. Refrigerant oil can collect in the compressor compression chamber after removing the compressor or adding new oil (for example, by blowing through the refrigerant circuit). Rotating forces the refrigerant oil out of the compression chamber.

Hold the compressor driveshaft -A- with a wrench and turn the compressor drive unit -B- in the direction of arrow -D-.

1. Tightening specification: 60 Nm.

Note. Do not turn the compressor driveshaft -A- when tightening. After installing, check installation position of grommet -E- on drive wheel. After installing the driveshaft -A-, check the boot -E- installation position.

Install the left engine mount.

Install the subframe. Refer to Removal and Installation .

Install the stabilizer. Refer to Removal and Installation .

Connect the intermediate shaft joint to the steering gear. Refer to Removal and Installation .

Install the ATF pipes. Refer to REMOVAL AND INSTALLATION for 0B6 or REMOVAL AND INSTALLATION for 0BK .

Install the longitudinal braces. Refer to Description and Operation

Note. Replace the seal; the self-locking nuts and the O-ring for the oil dipstick guide tube.

Install the oil dipstick guide tube. .

Fill with coolant and bleed the coolant circuit .

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Check the DTC memory and erase any displayed entries. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

Turn off the ignition.

Remove the front noise insulation. Refer to Removal and Installation .

Mark the direction of the operation of the ribbed belt.

Remove the ribbed belt. Refer to -A- Removal and Installation .

Disconnect the electrical connector -A-.

Scheme 72

Remove the A/C compressor bolt -B-.

Remove the A/C compressor and move it away from the engine only far enough without bending or pulling off the refrigerant hoses.

Fasten the A/C compressor to the vehicle (for example, with a wire) without pulling or bending the refrigerant pipes.

Note. If the A/C compressor cannot be swiveled away enough from the engine, then the A/C compressor must be removed. Refer to A/C COMPRESSOR .

Installation is done is reverse order, observe the following

Before tightening the A/C compressor, check seating of both alignment bushings -A- in bracket or A/C compressor -B-.

Note. The alignment sleeves -A- have different styles (different lengths), make sure to use the correct style. Ensure bushings -A- are properly seated and contact surfaces are clean. Sockets installed incorrectly and dirty or damaged contact surfaces -C- on the bracket or A/C compressor can lead to alignment irregularities between the A/C compressor and engine. Alignment irregularities over operating time lead to damage to the ribbed belt or A/C compressor.

Tighten the bolts -arrows- (tightening specification: 25 Nm).

Scheme 73

Connect electrical connector -1- on A/C Compressor Regulator Valve -N280-.

Mount the ribbed belt onto the ribbed belt pulley. Refer to Removal and Installation .

Note. After fastening the A/C compressor, check installation position of refrigerant lines, lines must be engaged in bracket (if installed, depending on engine). Check refrigerant lines and their bracket to ensure there is enough distance to the other components. Ensure there is also enough distance between belts, bracket and pulley.

Check the Climatronic control module -J255- memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

A/C COMPRESSOR - ENGINE CODE(S): CAEB

For vehicles without a high voltage system

Turn off the ignition.

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Note. Depending on the allocation of the service connection an on the refrigerant line, and on the version of the vehicle, it may be necessary to remove the additional reinforcement on the left suspension strut dome so that the service coupling of the service station can be connected (for example, on the Audi Q5). Refer to Removal and Installation and Description and Operation

Remove the front noise insulation. Refer to Removal and Installation

Remove the refrigerant lines from A/C compressor. Refer to A/C COMPRESSOR REFRIGERANT LINES .

Note. The sequence is different and depends on the engine and the power steering pump. Depending on the version of the power steering pump, the A/C compressor must first be removed from the bracket before the refrigerant lines can be removed. The power steering pump is installed only on vehicles with electro-mechanical power steering. Refer to Description and Operation .

Removing the A/C compressor from the bracket, refer to A/C COMPRESSOR REMOVING FROM BRACKET .

Installation is carried out in the reverse order while noting the following

Note. An uncertain quantity of refrigerant oil remains in a removed A/C compressor. Therefore, observe the notes for replacing the A/C compressor. Refer to Removal and Installation .

Before installing the A/C compressor, refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Turn the A/C compressor by hand 10 rotations before installing the ribbed belt on the pulley (to prevent damage to the compressor when it is first switched on).

Install the A/C compressor on the bracket. Refer to A/C COMPRESSOR REMOVING FROM BRACKET .

Attach the refrigerant lines to the A/C compressor. Refer to A/C COMPRESSOR REFRIGERANT LINES .

Note. Coat the O-ring seals lightly with refrigerant oil prior to installation. Refer to REFRIGERANT CIRCUIT O-RINGS . Rotating will prevent damage to the A/C compressor when starting the engine for the first from refrigerant oil that may be located in the compression chamber.

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Install the remaining removed components.

Switch on the ignition.

Check the Climatronic control module -J255- DTC memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Note. Note the information regarding operating the A/C system after filling. Refer to A/C Service Station in Description and Operation .

Switch off the ignition.

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Note. Depending on the allocation of the service connection an on the refrigerant line, and on the version of the vehicle, it may be necessary to remove the additional reinforcement on the left suspension strut dome so that the service coupling of the service station can be connected (for example, on the Audi Q5). Refer to Removal and Installation and Removal and Installation .

Remove front noise insulation. Refer to Description and Operation

Remove the bolts -1- and nuts -3- and then remove the left longitudinal brace -2-. Refer to Description and Operation .

Remove the left front wheel and the left front wheel housing liner. Refer to Removal and Installation .

Mark the direction of the operation of the ribbed belt -A-.

Scheme 74

Remove the ribbed belt -A-. Refer to Removal and Installation .

If equipped, clamp the supply line (suction hose) to the power steering pump -B- with hose clamps 3094. Refer to Removal and Installation .

Remove the pressure line -C- from the power steering pump -B-, if necessary. Refer to Steering .

Note. When swiveling the pressure line to the side, be sure not to bend, twist or pull the line to the vane pump. The power steering vane pump -B- is not removed from the bracket when removing the A/C compressor. The pressure line and power steering pump are installed only on vehicles without electro-mechanical power steering. Refer to Removal and Installation . The pressure line to the vane pump -C- (see illustration above) is secured to the A/C compressor by the bracket with the bolt -C- (see illustration below).

Remove the refrigerant lines from A/C compressor. Refer to A/C COMPRESSOR REFRIGERANT LINES .

Note. The refrigerant lines are removed from the top. On vehicles with a gasoline engine and dynamic steering (depending on where the intake hose is installed on the power steering pump), first loosen the A/C compressor from the bracket and then remove the refrigerant pipes from the A/C compressor. Refer to A/C COMPRESSOR REFRIGERANT LINES .

Disconnect the electrical connector -A-.

Scheme 75

Remove the bolt -B- (and bolt -C-) (tightening specification: 25 Nm).

Note. The bolt -C- (tightening specification: 25 Nm) was already removed on vehicles with a power steering pump when the pressure line to the power steering pump was loosened. The pressure line and power steering pump are installed only on vehicles without electro-mechanical power steering. Refer to Description and Operation . This illustration shows the A/C compressor in a vehicle equipped with an after-run coolant pump -V51- (not installed on all versions). Depending on the vehicle equipment level, it may be necessary to drain the coolant after-run coolant pump and remove the after-run coolant pump in order to remove the A/C compressor (draining the coolant and removing the After-Run Coolant Pump. Refer to Removal and Installation ). Depending on the version of the compressor and of the vehicle (different fans for the coolant, water cooler and hoses for the after-run coolant pump) it may also be necessary to bring the lock carrier in the service position (so that the A/C compressor can be swiveled downward). Refer to Description and Operation .

Information for the service position of the lock carrier

Scheme 76

1. When the bolts -A- are first removed, and after bolts -A- are removed, mark the position of the lock carrier -B-, for example with a water resistant marker on the longitudinal member -C- (through the left and right hole) so that it can be installed exactly in the same position.
2. When both bolts -D- are removed and then longer bolts -E- (for example bolts M10 x 100) are installed, the lock carried can be moved approximately 60 mm (2.4 in.) forward after the bolts -F- are removed.
3. Using the sleeves -G- (or a suitable pad approximately 60 mm (2.4 in.) long), secure the lock carrier -C- from sliding back.

Remove the bracket -D-.

Remove the bolt -E- (tightening specification 25 Nm).

Remove the A/C compressor -F- from the bracket, pull it forward and swivel it downward.

Installation is carried out in the reverse order while noting the following

Note. An uncertain quantity of refrigerant oil remains in a removed A/C compressor. Therefore, observe the notes for replacing the A/C compressor. Refer to Removal and Installation

Before installing the A/C compressor, refer to Removal and Installation .

Before tightening the A/C compressor, check seating of both alignment bushings -A- in bracket or A/C compressor -B-.

Note. The alignment sleeves -A- have different styles (different lengths), make sure to use the correct style. Ensure bushings -A- are properly seated and contact surfaces are clean. Sockets installed incorrectly and dirty or damaged contact surfaces -C- on the bracket or A/C compressor can lead to alignment irregularities between the A/C compressor and engine. Alignment irregularities over operating time lead to damage to the ribbed belt or A/C compressor.

Turn the A/C compressor by hand 10 rotations before installing the ribbed belt on the pulley (to prevent damage to the compressor when it is first switched on).

Install the pressure line to the power steering pump. Refer to Removal and Installation .

Install the ribbed belt -A-. Refer to Removal and Installation .

Attach the refrigerant lines to the A/C compressor. Refer to A/C COMPRESSOR REFRIGERANT LINES .

Note. Coat the O-ring seals lightly with refrigerant oil prior to installation. Refer to REFRIGERANT CIRCUIT O-RINGS . Rotating will prevent damage to the A/C compressor when starting the engine for the first from refrigerant oil that may be located in the compression chamber. After fastening the A/C compressor and installing the refrigerant line, check installation position of refrigerant lines, lines must be engaged in bracket (if installed, depending on engine). Check refrigerant lines and their bracket to ensure there is enough distance to the other components. Ensure there is also enough distance between belts, bracket and pulley.

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Install the remaining removed components.

Check the Climatronic control module -J255- display and control head DTC memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Note. Note the information regarding operating the A/C system after filling. Refer to A/C Service Station in Description and Operation .

A/C COMPRESSOR INPUT SHAFT, LOOSENING AND TIGHTENING

Note. Extensive preparatory work must be performed to be able to loosen A/C compressor input shaft. Refer to S5 A/C COMPRESSOR or RS5 A/C COMPRESSOR . The driveshaft can be checked and tightened without opening the refrigerant circuit. Refer to S5 A/C COMPRESSOR or RS5 A/C COMPRESSOR .

INPUT SHAFT, LOOSENING

Remove any parts that may be preventing access to the input shaft. Refer to S5 A/C COMPRESSOR or RS5 A/C COMPRESSOR .

Hold the A/C compressor input shaft -A- in place using a wrench and turn the drive unit -B- in direction of arrow -C-.

Note. Do not turn the driveshaft -A-. Input shaft -A- can be slid into drive wheel through the boot -E- after loosening threaded connection. After installing the driveshaft -A-, check the boot -E- installation position.

INPUT SHAFT, TIGHTENING

Hold the A/C compressor input shaft -A- in place using a wrench and turn the drive unit -B- in direction of arrow -D- (tightening specification: 60 Nm).

After tightening the A/C compressor input shaft, check the position of the grommet -E-.

REMOVE THE DRIVESHAFT

Remove the A/C compressor. Refer to S5 A/C COMPRESSOR or RS5 A/C COMPRESSOR ..

Remove the grommet -A-.

Scheme 77

Remove driveshaft -B- from splines of drive pinion -C

Note. A clamp on the engine toothed drive gear flange -C- prevents the boot -A- from slipping.

INSTALL THE DRIVESHAFT

Installation is carried out in the reverse order while noting the following

Check driveshaft -B-, splines must show no traces of wear and must be seated free of play in splines of drive wheel -C-.

Before installing, coat the driveshaft splines -B- for example with Grease, refer to the G 000 100.

Insert the input shaft -B- before installing A/C compressor and slide it into drive wheel -C- up to stop.

After installing A/C compressor, check the position of the grommet -A-.

Note. A clamp on the power take-off flange keeps the grommet -A- from sliding off. Refer to Removal and Installation .

DRIVE PLATE WITH OVERLOAD PROTECTION

Remove the A/C compressor. Refer to S5 A/C COMPRESSOR or RS5 A/C COMPRESSOR .

REMOVE THE DRIVE PLATE

Remove bolts -A-.

Scheme 78

Note. Use a commercially available band wrench (with webbed band) to counterhold at drive plate -C-.

INSTALLING DRIVE PLATE

Position drive plate with overload protection -B- onto drive plate -C-.

Install the bolts -A- and tighten by hand.

Check the drive plate run-out -B-. Refer to DRIVE PLATE WITH OVERLOAD PROTECTION, CHECKING RUN-OUT AND ADJUSTING .

Tighten the bolts -A- (torque specification: 10 Nm).

Check the drive plate run-out -B-. Refer to DRIVE PLATE WITH OVERLOAD PROTECTION, CHECKING RUN-OUT AND ADJUSTING .

A/C COMPRESSOR DRIVE PLATE

Remove the drive plate with overload protection. Refer to DRIVE PLATE WITH OVERLOAD PROTECTION .

Disconnect the drive plate -C- by turning using a conventional band wrench (with webbed band) in direction of arrow -D-, counterhold compressor shaft -A- using a retainer -B- on compressor shaft -A-.

Scheme 79

Note. Depending on the versions of the compressor (the A/C compressor shafts are different), a wrench or a socket wrench T10001/10 from the shock absorber set T10001 or retainer 3079 must be used to counterhold.

CONNECT THE DRIVE PLATE

Lightly coat the rubber elements -B- with soapy water (as a lubricant) to install.

Scheme 80

Insert rubber element -B- in the drive plate -A- according to illustration.

Insert drive plate -A- with rubber elements -B- onto drive plate -C- according to illustration until it makes contact with A/C compressor shaft.

Note. This illustration shows the rubber element -B- in version "1". Rubber elements -B- of version "2" are joined to each other at top.

Screw drive plate -C- onto compressor shaft -A- by rotating in direction of arrow -E-.

Tighten the drive plate -C- to 30 Nm by turning it in the direction of arrow -E- using a conventional band wrench (with webbed band); hold the compressor shaft -A- using a counter holder -B- on the compressor shaft -A-.

Note. Depending on the versions of the compressor (the A/C compressor shafts are different), a wrench or a socket wrench T10001/10 from the shock absorber set T10001 or retainer 3079 must be used to counterhold.

DRIVE PLATE WITH ANTI-FRICTION BEARING

Remove the drive plate from the compressor shaft. Refer to A/C COMPRESSOR DRIVE PLATE .

Remove the circlip -A-.

Scheme 81

Remove the drive plate -B-.

Note. Replace circlip -A-. Clean the A/C compressor flange before sliding on drive plate. When installing circlip -A-, note that it cannot be bent open more than is necessary for installation. Insert circlip -A- on correct side, the side with beveled insertion edge -C- faces away from A/C compressor (install flat side facing compressor).

ELECTRIC A/C COMPRESSOR

Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system, refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS and to GENERAL INFORMATION .

If it is necessary for the following procedure to work near high voltage components, perform a visual inspection of the high voltage components and cables for damage, refer to VISUAL INSPECTION OF HIGH-VOLTAGE COMPONENTS AND CABLES FOR DAMAGE and High Voltage System General Warnings. Refer to GENERAL INFORMATION .

It is necessary to work on the high voltage system for the following procedure. High voltage system, de-energizing, refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS , GENERAL INFORMATION and General Warnings When Working On The High Voltage System. Refer to GENERAL INFORMATION .

Switch off the ignition.

De-energize the high voltage system. Refer to GENERAL INFORMATION .

Disable the high voltage system

Note. Disable the high voltage system: Connect the vehicle diagnosis tester Select the Guided Fault Finding mode Using the GO TO button, select the following menu commands Functions/Component selection Body Electrical Equipment OBD-capable system 8C - Hybrid battery management -J840 8C - Hybrid battery management, functions 51 - Disable the high voltage system (Rep.Gr. 93)

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Note. Depending on the allocation of the service connection an on the refrigerant line, and on the version of the vehicle, it may be necessary to remove the additional reinforcement on the left suspension strut dome so that the service coupling of the service station can be connected. Refer to Removal and Installation and Removal and Installation .

Remove the engine cover -arrows-. Refer to [For engine(s) CAEB] Removal and Installation .

Scheme 82

Free up the attaching points -1- and -3- for the high voltage system cable on the engine -2- and electric wiring harness -4-.

Scheme 83

Unlock and disconnect the high voltage system connector -3- on the A/C compressor.

Pull the locking mechanism in the -direction of the arrow-.

Scheme 84

Remove the connector from the A/C compressor horizontally, and without turning.

Cover the high voltage cable connector and socket on the A/C compressor (such as with a clean plug from the engine bung set VAS 6122) to protect them from debris and damage.

Disconnect the connector -2- (for low voltage on the A/C compressor).

Scheme 85

Note. Ignore -1 and 4-.

Remove the refrigerant lines from A/C compressor. Refer to A/C COMPRESSOR REFRIGERANT LINES .

Removing the A/C compressor from the bracket. Refer to ELECTRIC A/C COMPRESSOR REMOVING FROM BRACKET .

Scheme 86

Installation is carried out in the reverse order while noting the following

Before installing the A/C compressor refer to A/C Service Station in Description and Operation .

Note. There is an unspecified amount of refrigerant oil in the removed compressor so follow the information on replacing the compressor. Refer to Removal and Installation .

Attach the A/C compressor to the bracket. Refer to ELECTRIC A/C COMPRESSOR REMOVING FROM BRACKET .

Install the A/C compressor refrigerant pipes. Refer to A/C COMPRESSOR REFRIGERANT LINES .

Note. Coat the O-ring seals lightly with refrigerant oil prior to installation. Refer to REFRIGERANT CIRCUIT O-RINGS . After the installation of the electric A/C compressor and the subsequent filling of the refrigerant circuit, start up the A/C compressor for the first time using the "compressor intake" function for the basic setting. The A/C compressor may otherwise become damaged if before installation, refrigerant oil was improperly stored in the A/C compressor compression chamber. Refer to the Vehicle diagnostic tester in "Guided Fault Finding" Function for A/C System and Battery Regulator. Only activate the electric A/C compressor when the refrigerant circuits is filled. Damage to the A/C compressor may occur if the A/C compressor is running while the refrigerant circuit is empty. Refer to the Vehicle diagnostic tester in "Guided Fault Finding" Function for A/C System and Battery Regulator.

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Insert and secure the electrical connection for the high voltage system on the A/C compressor.

Scheme 87

Inspect the connector for debris and damage.

Plug the connector into the A/C compressor.

1. The marks -1- and -2- on the connector and A/C compressor must line up with each other.

Secure the locking mechanism in the -direction of the arrow-.

Install the remaining removed parts in the opposite order.

De-energize the voltage supply to the high voltage system. Refer to GENERAL INFORMATION .

Restart the high voltage system

Note. Restart the high voltage system: Connect the vehicle diagnosis tester Select the Guided Fault Finding mode Using the GO TO button, select the following menu commands Functions/Component selection Body Electrical Equipment OBD-capable system 8C - Hybrid battery management -J840 8C - Hybrid battery management, functions 51 - High voltage restart (Rep.Gr. 93)

Switch on the ignition.

Check the Climatronic control module -J255- DTC memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

Operate the electric A/C compressor -V470- using the function "Compressor Cut-In". Refer to the Vehicle diagnostic tester in "Guided Fault Finding" Function for A/C System and Battery Regulator.

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Note. Note the information regarding operating the A/C system after filling. Refer to A/C Service Station in Description and Operation .

ELECTRIC A/C COMPRESSOR REMOVING FROM BRACKET

With high voltage systems (hybrid vehicles)

Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system, refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS and to GENERAL INFORMATION .

Note. With A/C compressor control module -J842- and electric A/C compressor -V470- The electric motor for the A/C compressor is powered with voltage from the electric drive power and control electronics system -JX1-. The A/C compressor control module, integrated in the A/C compressor, controls the rotation and thereby the output of the A/C compressor corresponding with the Data bus receiving requirements. Refer to the Vehicle diagnostic tester in "Guided Fault Finding" Function for the A/C System and the Battery Control. There is no A/C compressor regulator valve -N280- installed in the electric A/C compressor, the output of the A/C compressor is regulated via the exterior rotation of the A/C compressor. Refer to the appropriate SYSTEM WIRING DIAGRAMS information and the Vehicle diagnostic tester in "Guided Fault Finding" Function for the A/C System and the Battery Control. The electric A/C compressor functions according to the principle of a spiral charger (similar to a G-charger). The A/C compressor control module -J842- and the electric A/C compressor -V470- are components and are currently not able to be separated.

The following procedure requires working on the high voltage system. De-energize the high voltage system. Refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS , GENERAL INFORMATION and Read and follow the high voltage electrical system general warnings. Refer to GENERAL INFORMATION .

Note. You can remove and re-install the A/C compressor in vehicles with 4 cylinder engines. The compressor can be removed and installed at the bracket without opening the refrigerant lines. Do not discharge the refrigerant circuit to remove the bracket, do not remove refrigerant hoses and lines from A/C compressor. Do not unfasten refrigerant pipes and corresponding clamps. The cable for the high voltage system remains connected to the A/C compressor. Do not release the electrical connection for the high voltage system from the A/C compressor. After removing the A/C compressor, tie it to the vehicle with wire. Do not let it hang by the refrigerant lines. Different A/C compressors may be installed depending on engine and country variant.

The following procedure requires working on the high voltage system. De-energize the high voltage system. Refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS , GENERAL INFORMATION and Read and follow the high voltage electrical system general warnings. Refer to GENERAL INFORMATION .

Turn off the ignition.

De-energize the high voltage system. Refer to GENERAL INFORMATION .

Disable the high voltage system

Note. Disable the high voltage system: Connect the vehicle diagnosis tester Select the Guided Fault Finding mode Using the GO TO button, select the following menu commands Functions/Component selection Body Electrical Equipment OBD-capable system 8C - Hybrid battery management -J840 8C - Hybrid battery management, functions 51 - Disable the high voltage system (Rep.Gr. 93)

Remove the engine cover. Refer to [For engine(s) CAEB] Removal and Installation .

Loosen the clamps -arrows- and remove the air guide hose.

Scheme 88

Note. Ignore -1-.

Free up the high voltage system connector -3- on the engine.

Disconnect the connector -2- (for low voltage on the A/C compressor).

Note. Ignore -1 and 4-.

Remove the bolts -arrows- from the A/C compressor.

Remove the A/C compressor -A- and move it as far as possible away from the engine on the left side in such a way that the cable for the high voltage system -C- or the coolant hose are not kinked or bent.

Scheme 89

Secure the A/C compressor to the vehicle (for example, with a wire) without pulling or bending the high voltage system cable or the coolant hoses.

Note. If the A/C compressor cannot be swiveled away enough from the engine, then the A/C compressor must be removed. Refer to ELECTRIC A/C COMPRESSOR .

Installation is done is reverse order, observe the following

1. Check the bolting points of the A/C compressor and the bracket prior to installation. The contact surfaces must be clean and rust and grease-free. Otherwise, repair the contact surfaces with the contact surface cleaning set VAS 6410. Refer to «[For engine(s) CAUA, CAEB, CALA] Description and Operation»(/audi/a5/i-2007-2011/remont/wiring-system-data-link-connectors-pwr-dist-grnd-dist/#wiring-coupe) .

Note. After the installation of the electric A/C compressor and the subsequent filling of the refrigerant circuit, start up the A/C compressor for the first time using the "compressor intake" function for the basic setting. The A/C compressor may otherwise become damaged if before installation, refrigerant oil was improperly stored in the A/C compressor compression chamber, refer to ELECTRIC A/C COMPRESSOR OVERVIEW and the Vehicle Diagnostic Tester in "Guided Fault Finding" Function for A/C System and Battery Regulator.

Tighten the bolts -arrows- (tightening specification: 25 Nm).

Connect the connector to the electric system.

Note. After fastening the A/C compressor, check installation position of refrigerant lines, lines must be engaged in bracket (if installed, depending on engine). Check refrigerant lines and their bracket to ensure there is enough distance to the other components. Ensure there is also enough distance between belts, bracket and pulley.

Secure the electric high voltage system cable to the designated engine points.

Secure the clip -1- to the engine -2- and cable holder -3- on the wiring harness -4- as illustrated.

Install the air guide hoses with screw-type clamps. Refer to [For engine(s) CAEB] Removal and Installation .

Install the remaining removed components.

Energize the voltage to the high voltage system. Refer to GENERAL INFORMATION .

Restart the high voltage system

Note. Restart the high voltage system: Connect the vehicle diagnosis tester Select the Guided Fault Finding mode Using the GO TO button, select the following menu commands Functions/Component selection Body Electrical Equipment OBD-capable system 8C - Hybrid battery management -J840 8C - Hybrid battery management, functions 51 - High voltage restart (Rep.Gr. 93)

Switch on the ignition.

Check and, if necessary, erase the displayed faults in the DTC memory for the Climatronic control module -J255- and the A/C compressor control module -J842-. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

A/C COMPRESSOR BELT PULLEY

Note. At start of the production, 4 and 6 cylinder engines had A/C compressors manufactured by "Denso" (type "6 SEU 14") installed. Depending on engine and period of production, A/C compressors from other manufacturers or other versions may be installed at a later time. You can remove and re-install the A/C compressor in vehicles with a 4 cylinder engine. The 4 cylinder compressor can be removed and installed at the bracket without opening the refrigerant lines. Refer to A/C COMPRESSOR REMOVING FROM BRACKET . For vehicles 6 cylinders gasoline engines, the A/C compressor can be disconnected and removed from the bracket only if the refrigerant circuit is open. Refer to A/C COMPRESSOR .

PREPARATION FOR REPLACEMENT

Turn off the ignition.

Remove the front noise insulation. Refer to Description and Operation

Mark the direction of the operation of the ribbed belt (always refer to the Appropriate Repair Information for the routing of the ribbed belt for each engine). Refer to [For engine(s) CAEB] Removal and Installation or to [For engine(s) CALA] Removal and Installation .

Release the tension on the ribbed belt and then remove it. Refer to [For engine(s) CAEB] Removal and Installation or to [For engine(s) CALA] Removal and Installation

Note. Mark direction of rotation of ribbed belt using chalk or felt-tip marker before removing. Running a used belt in the opposite direction could destroy it.

Note. Observe notes on replacing belt pulley -E-. Refer to BELT PULLEY WITHOUT A/C CLUTCH OVERVIEW . The belt pulley is made of plastic and is sensitive to impact, therefore handle it with especial care. If the drive plate -C- overload protection activates, rotate the pulley -E- using the outer part of the drive plate -C- so that the compressor shaft -B- and the hexagon head on the drive plate -D- (inner part of the drive plate -C-) do not rotate.

Remove the cap -A-.

Scheme 90

Hold the A/C compressor input shaft -B- for example, with a 7 mm socket or wrench and turn the drive plate -C- together with the pulley -E- in the direction of the arrow -arrow-.

Note. The torque to drive the A/C compressor is transferred to the drive plate -C- via the threaded connection. If, while the A/C compressor is working, the drive plate -C- was attached to the A/C compressor shaft so tight, that it cannot be loosened then the A/C compressor must be replaced.

Remove the drive plate -C-.

Remove the circlip -A-.

Scheme 91

Remove the pulley -B-.

Note. Replace circlip -A-.

Clean A/C compressor flange before installing pulley -B-.

When installing circlip -A-, note that it cannot be bent open more than is necessary for installation.

Install the pulley -B-.

Insert circlip -A- on correct side, the side with beveled insertion edge -C- faces away from A/C compressor (install flat side facing A/C compressor).

Clean the compressor shaft thread.

Note. The thread of the new drive plate has already been greased with a specific amount of a grease by the manufacturer.

When installing drive plate, coat the rubber element -D- lightly with, for example, tire mounting paste or soap solution (as sliding compound).

Insert rubber element -D- in belt pulley -B- according to illustration.

Press the drive plate rubber element -C- far enough into the pulley -E- until the drive plate -C- until it contacts A/C compressor shaft -B-.

Attach the drive plate -C- to the compressor shaft -B- by turning it contrary to the direction of the arrow -arrow-.

Hold the A/C compressor input shaft -B- with a 7 mm socket or wrench and turn the drive plate -C- together with the belt pulley -E- opposite the direction of the arrow -arrow- (tightening specification 30 Nm).

A/C COMPRESSOR CLUTCH PLATE

Turn off the ignition.

Perform the preliminary work as for replacing the belt pulley. Refer to PREPARATION FOR REPLACEMENT .

Remove the cap -A-.

Scheme 92

Hold the A/C compressor input shaft -B- secure with a commercially available socket (7 mm) and turn the clutch plate -C- in direction of arrow -arrow-.

Note. The torque to drive the A/C compressor is transferred to the clutch plate -C- via the threaded connection. If, while the A/C compressor is working, the clutch plate -C- was attached to the A/C compressor shaft so tight, that it cannot be loosened (the 7 mm wrench cannot transmit the necessary torque) then the A/C compressor must be replaced.

Check the cap between the belt pulley and clutch plate. Refer to A/C COMPRESSOR BELT PULLEY AND CLUTCH PLATE GAP, CHECKING .

BELT PULLEY WITH A/C CLUTCH

Note. Remove the belt pulley -A- as described below if it (after removing the locking ring) will not come off the A/C compressor flange by hand (for example, due to dirt build-up). Mount the arms on the puller so that the outside of the belt pulley does not get bent if the belt pulley -A- is going to be used again.

Remove the belt pulley -A- with a 3-arm puller -B-.

Note. Do not support the puller spindle -B- on the A/C compressor shaft when removing the belt pulley -A-. Use a sleeve -C- (for example, VAG 1719/1 taken from A/C clutch set V.A.G 1719) to support the spindle on the arm puller -B- on the A/C compressor flange. Clean the flange on the A/C compressor thoroughly after removing the belt pulley -A-. It must possible to install the belt pulley -A- by hand.

CONDENSATION WATER DRAIN HOSE

Note. This vehicle is equipped with 2 condensate drains (left and right on the air conditioner or center tunnel). There is no valve or door present on the outlet opening -C- of the condensation water drain hose -B- ; the condensation water flows over the rubber seals. There are different versions of the condensation water hoses -B-. On version "1" (see illustration above), the condensation water drain -B- is inserted directly in the opening -D-. On version "2" the condensation water drain -B- is inserted into the bracket -A-. The bracket -A- is held in the opening -D- of the floor panel -C- with the tabs. After installing the bracket -A-, the condensation water drain -B- must be pushed into the floor panel -C- to prevent any condensation water coming out of the drain -B- into the passenger compartment. Seal the area between both parts with silicone adhesive D176 001 A3.

For complaints of moisture in passenger compartment, check the following as well as condensation water drain

Plenum chamber water drain, refer to PLENUM CHAMBER WATER DRAIN .

Check the cowl land the fresh air intake housing for proper installation and damage. Refer to FRESH AIR INTAKE .

Dust and pollen filter for soiling and correct installation. Refer to DUST AND POLLEN FILTER .

Forced air extraction vents in luggage compartment, refer to PASSENGER COMPARTMENT FORCED AIR EXTRACTION .

Back pressure door/fresh air door activation and function, refer to AIR FLOW DOOR MOTOR -V71 and recirculation door RECIRCULATION DOOR MOTOR -V113 for example, via the "output diagnostic test mode" of the Guided Fault Finding using the Vehicle diagnostic tester in "Guided Fault Finding"

1. If there are complaints regarding humidity in the passenger compartment which only appears when the A/C compressor is switched on and under certain climatic conditions, check the temperature of the air coming out of the vents from the evaporator as follows

Select "read measured values block" for Guided Fault Finding (using the measured value from the evaporator vent temperature sensor -G263-). Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

Check the output temperature of air at evaporator under conditions reported by the customer or at the following setting on the Climatronic control module -J255-, "Auto" operating mode, A/C compressor switched on (control light in the A/C button lights up), temperature setting "Cold", middle fresh air blower speed at a voltage of approximately 7 V on the Fresh Air Blower -V2-, fresh air mode (indicator light "recirculation button" does not light up) and open instrument panel vents, the air vent temperature at the evaporator.

The sensor measured value is too low (at an ambient temperature above 0 °C (32 °F), longer time if colder than 0 °C (32 °F)) or too high even though the A/C system is working correctly, above, for example, 10 °C (50 °F). Correct the cause of the difference and note the information for the cooling output test. Refer to A/C COOLING OUTPUT, CHECKING .

CONDENSATION WATER HOSE, REMOVING, CHECKING

Turn off the ignition.

Remove the glove compartment (for the right condensation water drain). Refer to Removal and Installation .

Remove storage compartment on driver's side (for the left condensation water drain). Refer to Removal and Installation .

Fold back the carpet near the condensation water drain (left or right) so that the condensation water drain is visible.

Check the condensation water drain hoses -B- that they are properly routed and for dirt. Correct, for example, if the hose is constricted.

Scheme 93

Cover the area under both openings -D- (for condensation water drain -C-) with absorbent paper (so that any water present does not get under the carpet).

Remove both condensation water drain hoses -B-.

Check both A/C condensation water drains -A- for soiling (for example, using a piece of wire).

Check the gap between the insulation mat installed in the center tunnel -E- and the end of the condensation water hose -C- above the openings -F- in the floor panel -D- ; the gap must be large enough so that the condensation water can flow out of the hose -B-.

Installation is carried out in the reverse order while observing the following.

Install both condensation water hoses -B- making sure they are not twisted or kinked (different styles for the left and right side).

Make sure the carpet does not push up against the condensation water drain hose -B- when installing.

If a condensation water drain hose -B- fits too loose on the A/C condenser water drain -A-, secure it with a clamp, for example, so that it cannot slide off.

AIR FLOW DOOR MOTOR -V71

Note. Perform Basic Setting of A/C system after installing the control motor. Refer to the Vehicle diagnostic tester in "Guided Fault Finding". Using the functions "Output diagnostic test mode" and "Basic setting", the activation of A/C system electrical components can be tested if necessary (for example allocation test). Refer to the Vehicle diagnostic tester in "Guided Fault Finding" function. Currently in this vehicle, all motors are identical in construction. During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM . After installing new positioning motor, check activation through the Climatronic Control Module -J255- and check function (correct position of recirculation door and back pressure/fresh air door). Refer to the Vehicle diagnostic tester in "Guided Fault Finding". Air flow door motor function, refer to BACK PRESSURE DOOR MOTOR -V71-, FUNCTION .

Move the passenger seats as far back as possible.

Turn off the ignition.

Remove the air intake housing. Refer to A/C UNIT AIR INTAKE HOUSING .

Remove the air intake housing from the air intake manifold. Refer to AIR INTAKE DUCT, REMOVING FROM AIR INTAKE HOUSING .

Remove bolts -B-.

Scheme 94

Counter hold on the cam plate -A- and disconnect the control motor -C- from the cam plate -A-.

Installation is carried out in the reverse order while observing the following.

Check the lever for the back pressure door -D- and for the fresh air door -E- ; they must fit correctly in the cam plate -A-.

Install the control motor shaft -C- into the cam plate bracket -A-.

Note. The control motor does not have a stop; the control motor shaft -C- can be inserted into the cam plate mount -A- at any position

Install bolts -B-.

Install the removed parts in the opposite order.

Perform a basic setting and the output Diagnostic Test Mode (DTM) on the A/C system using the Vehicle diagnostic tester in "Guided Fault Finding".

Note. On this vehicle, the control motors are equipped with electronics, during the first basic setting, a new control motor learns its position on the air conditioner and can then be controlled by the Climatronic Control Module -J255- (currently all control motors are identical). Refer to the Vehicle diagnostic tester in "Guided Fault Finding". During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM .

Check the Climatronic Control Module -J255- DTC memory and erase any displayed malfunction if necessary using the Vehicle diagnostic tester in "Guided Fault Finding" function.

RECIRCULATION DOOR MOTOR -V113

Note. Perform Basic Setting of A/C system after installing the control motor. Refer to the Vehicle diagnostic tester in "Guided Fault Finding". Using the functions "Output diagnostic test mode" and "Basic setting", the activation of A/C system electrical components can be tested if necessary (for example allocation test). Refer to the Vehicle diagnostic tester in "Guided Fault Finding" function. In the event of problems with moisture in passenger compartment, additionally check recirculated-air door (must close completely).

Move the passenger seats as far back as possible.

Turn off the ignition.

Remove the glove compartment. Refer to Removal and Installation .

Loosen the wiring harness -E- from the air intake housing.

Scheme 95

Remove bolts -B-.

Disconnect the control motor shaft -C- from the air recirculation door shaft -D-.

Mark the connector -A- if necessary (to rule out an interchange in the event several connectors are disconnected at the same time).

Disconnect connector -A-.

Installation is carried out in the reverse order while observing the following.

Connect connector -A-.

Insert the control motor shaft -C- into the air recirculation door shaft -D-.

Note. The control motor does not have a stop; therefore the control motor shaft -C- can be inserted into the air recirculation door shaft -D- at any position.

Install the bolts -B-.

Install the wiring harness -E- so that it cannot come in contact with any moving parts (e.g. the actuating arm).

Install the removed parts in the opposite order.

Perform a basic setting and the output Diagnostic Test Mode (DTM) on the A/C system using the Vehicle diagnostic tester in "Guided Fault Finding".

Note. On this vehicle, the control motors are equipped with electronics. During the first basic setting, a new control motor learns its position on the air conditioner and can then be controlled by the Climatronic Control Module -J255- (currently all control motors are identical). Refer to the Vehicle diagnostic tester in "Guided Fault Finding". During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM .

Switch on the ignition.

Check the Climatronic Control Module -J255- DTC memory and erase any displayed malfunction if necessary using the Vehicle diagnostic tester in "Guided Fault Finding" function.

TEMPERATURE REGULATOR DOOR MOTOR -V68- AND REAR TEMPERATURE DOOR MOTOR -V137

The temperature regulator door motor is installed on vehicles equipped with the "Basis" A/C system.

The rear temperature door motor is installed on the "Comfort" A/C system.

Note. Different designations and functions, depending on the A/C version. Refer to AIR ROUTING AND DISTRIBUTION IN PASSENGER COMPARTMENT . On a vehicle equipped with a "Comfort" A/C system, the Rear Temperature door Motor actuates the temperature doors for the rear footwell vents and the rear center console vents (not installed in the "Basis" A/C system). On a vehicle equipped with the "Basis" A/C system, the Temperature Regulator door Motor actuates the temperature doors for the left and right side. Currently in this vehicle, all motors are identical in construction. During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM . Depending on the production date, there are different versions of the levers and connections on the A/C unit. Refer to AIR CONDITIONER, LEVERS AND CONNECTING ELEMENTS .

Move the driver seat as far back as possible.

Turn off the ignition.

Remove the storage compartment under the dash panel on the driver side. Refer to Removal and Installation .

Note. The control motor is installed on the left side, on the air conditioner, near the center tunnel. Refer to A/C UNIT AND AIR INTAKE HOUSING COMPONENTS .

Remove bolts -B-.

Scheme 96

Remove the control motor and its bracket -H- in the direction of the arrow -arrow- from the brackets -C- and -D-.

Mark the connector -A- if necessary (to prevent confusing it with other connectors, in the event several connectors are disconnected at the same time).

Disconnect connector -A-.

Loosen the connecting rod -E- from the toothed segment -F-.

Remove the motor and its bracket.

Remove the screws -G- and separate the control motor from the bracket -H-.

Loosen the toothed segment -A- from the control motor shaft -B-.

Scheme 97

Installation is carried out in the reverse order while observing the following.

Install the control motor -B- in the bracket -D-.

Install the screws -G-.

Mount the toothed segment -A- on to the control motor shaft -B- as shown in the illustration.

Note. The control motor does not have a stop, therefore the toothed segment -A- can be mounted on the control motor shaft at any position. To assure the function, the toothed segment -A- must be in the correct position to the marking on the bracket after assembling.

Check the position of the toothed segment -A- ; the first tooth must meet up with the marking -C- as shown.

Note. If a new control motor is delivered as a replacement part, the shaft must always be positioned so that the toothed segment -A- can be mounted as shown. If, when installing the toothed segment -A- on the control motor shaft and the first tooth does not meet up with the marking -C- as shown, (for example on a motor that was already once installed), then you must connect the motor to the vehicle's electric system, and with the ignition switched on, change the temperature setting on the Climatronic Control Module -J255- so that the control motor changes its position and that the toothed segment -A- moves into the correct position. Applying voltage does not make the control motor move; it moves only if it is actuated by the Climatronic Control Module. On the toothed segment -A- (see illustration above) mounted on the control motor shaft, there is a larger tooth present; when in use, this tooth must touch the lower tooth interval on the toothed segment -D- which is on the temperature door shaft. There are different toothed segments -A- (different connecting element for the right temperature door connecting rod) depending on the date of production. Refer to AIR CONDITIONER, LEVERS AND CONNECTING ELEMENTS .

Secure the temperature door toothed segment -D- with a pin -A- (4 mm diameter) over the guide -B- and bracket -C-.

Clip the connecting rod -E- to the toothed segment -F-.

Connect connector -A-.

Remove the control motor and its bracket -H- in the direction of the arrow -arrow- from the brackets -C- and -D-.

Install the wiring harness -A- so that it cannot come in contact with any moving parts, for example, the actuating arm.

Install the bolts -B-.

Install the removed parts in the opposite order.

Switch on the ignition.

Perform a basic setting and the output Diagnostic Test Mode (DTM) on the A/C system using the Vehicle diagnostic tester in "Guided Fault Finding".

Note. On this vehicle, the control motors are equipped with electronics, during the first basic setting, a new control motor learns its position on the air conditioner and can then be controlled by the Climatronic Control Module -J255- (currently all control motors are identical). Refer to the Vehicle diagnostic tester in "Guided Fault Finding". During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM .

Check the Climatronic Control Module DTC memory and erase any displayed malfunction if necessary using the Vehicle diagnostic tester in "Guided Fault Finding".

CENTER VENT ADJUSTMENT MOTOR -V102

Note. The Center Vent Adjustment Motor is installed only on vehicles equipped with the "Basis" A/C system. Currently in this vehicle, all motors are identical in construction. During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM .

Move the passenger seats as far back as possible.

Turn off the ignition.

Remove the glove compartment. Refer to Removal and Installation .

Remove the right (passenger) footwell vent. Refer to RIGHT FOOTWELL VENT .

Remove bolts -A-.

Scheme 98

Remove the air guide channel -B- leading to the right instrument panel vent (passenger side).

Mark the connector -A- if necessary (to rule out an interchange in the event several connectors are disconnected at the same time).

Scheme 99

Disconnect connector -A-.

Remove bolts -B-.

Remove the shaft -D- of the control motor -C- from the center vent door shaft -E-.

Installation is carried out in the reverse order while observing the following.

Insert the shaft -D- of the control motor -C- into the center vent door shaft -E-.

Note. The control motor does not have a stop; therefore the control motor shaft can be inserted into the center vent door shaft -E- at any position.

Install the bolts -B-.

Connect connector -A-.

Install the wiring harness so that it cannot come in contact with any moving parts (e.g. the actuating arm).

Install the removed parts in the opposite order.

Switch on the ignition.

Perform a basic setting and the output Diagnostic Test Mode (DTM) on the A/C system using the Vehicle diagnostic tester in "Guided Fault Finding".

Note. On this vehicle, the control motors are equipped with electronics. During the first basic setting, a new control motor learns its position on the air conditioner and can then be controlled by the Climatronic Control Module -J255- (currently all control motors are identical). Refer to the Vehicle diagnostic tester in "Guided Fault Finding". During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM .

Check the Climatronic Control Module DTC memory and erase any displayed malfunction if necessary using the Vehicle diagnostic tester in "Guided Fault Finding".

RIGHT FOOTWELL DOOR MOTOR -V109

Note. The Right Footwell Door Motor is installed only on vehicles equipped with the "Comfort" A/C system. Currently in this vehicle, all motors are identical in construction. During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM . Right Footwell Door Motor and Right Center Vent Motor -V111- removing and installing, refer to RIGHT RETAINING PLATE WITH RIGHT FOOTWELL DOOR MOTOR -V109- AND RIGHT CENTER VENT MOTOR -V111 .

Move the passenger seats as far back as possible.

Turn off the ignition.

Remove the glove compartment. Refer to Removal and Installation .

Remove the right (passenger) footwell vent. Refer to RIGHT FOOTWELL VENT .

Mark the connector -A- if necessary (to rule out an interchange in the event several connectors are disconnected at the same time).

Scheme 100

Disconnect connector -A-.

Remove bolts -B-.

Remove the shaft -D- of the control motor -C- from the cam plate -E-.

Installation is carried out in the reverse order while observing the following.

Insert the shaft -D- of the control motor -C- into the cam plate -E-.

Note. The control motor does not have a stop; therefore the control motor shaft can be inserted into the cam plate -E- at any position.

Install the bolts -B-.

Connect the connector -A-.

Install the wiring harness so that it cannot come in contact with any moving parts (e.g. the actuating arm).

Install the removed parts in the opposite order.

Switch on the ignition.

Perform a basic setting and the output Diagnostic Test Mode (DTM) on the A/C system using the Vehicle diagnostic tester in "Guided Fault Finding"

Note. On this vehicle, the control motors are equipped with electronics. During the first basic setting, a new control motor learns its position on the air conditioner and can then be controlled by the Climatronic Control Module -J255- (currently all control motors are identical). Refer to the Vehicle diagnostic tester in "Guided Fault Finding". During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform to the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM .

Check the Climatronic Control Module DTC memory and erase any displayed malfunction if necessary using the Vehicle diagnostic tester in "Guided Fault Finding".

RIGHT CENTER VENT MOTOR -V111

Note. The Right Center Vent Motor is installed only on vehicles equipped with the "Comfort" A/C system. Currently in this vehicle, all motors are identical in construction. During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM . Right Footwell Door Motor mounting plate -V109- and Right Center Vent Motor removing and installing, refer to RIGHT RETAINING PLATE WITH RIGHT FOOTWELL DOOR MOTOR -V109- AND RIGHT CENTER VENT MOTOR -V111 .

Move the passenger seats as far back as possible.

Turn off the ignition.

Remove the glove compartment. Refer to Removal and Installation .

Remove bolts -A-.

Remove the air guide channel -B- leading to the right instrument panel vent (passenger side).

Remove the air intake housing. Refer to A/C UNIT AIR INTAKE HOUSING .

Mark the connector -A- if necessary (to rule out an interchange in the event several connectors are disconnected at the same time).

Scheme 101

Disconnect connector -A-.

Remove bolts -B-.

Remove the shaft -D- of the control motor -C- from the cam plate -E-.

Installation is carried out in the reverse order while observing the following.

Insert the shaft -D- of the control motor -C- into the cam plate -E-.

Note. The control motor does not have a stop; therefore the control motor shaft can be inserted into the cam plate -E- at any position.

Install the bolts -B-.

Connect connector -A-.

Install the wiring harness so that it cannot come in contact with any moving parts (such as the actuating arm).

Install the removed parts in the opposite order.

Switch on the ignition.

Perform a basic setting and the output Diagnostic Test Mode (DTM) on the A/C system using the Vehicle diagnostic tester in "Guided Fault Finding".

Note. On this vehicle, the control motors are equipped with electronics. During the first basic setting, a new control motor learns its position on the air conditioner and can then be controlled by the Climatronic Control Module -J255- (currently all control motors are identical.) Refer to the Vehicle diagnostic tester in "Guided Fault Finding". During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM .

Check the Climatronic Control Module DTC memory and erase any displayed malfunction if necessary using the Vehicle diagnostic tester in "Guided Fault Finding".

RIGHT RETAINING PLATE WITH RIGHT FOOTWELL DOOR MOTOR -V109- AND RIGHT CENTER VENT MOTOR -V111

Note. The mounting plate with the Right Footwell Door Motor and the Right Center Vent Motor is installed only on vehicles equipped with the "Comfort" A/C system. Right Footwell Door Motor mounting plate and Right Center Vent Motor disassembling and assembling, refer to RIGHT RETAINING PLATE WITH RIGHT FOOTWELL DOOR MOTOR -V109- AND RIGHT CENTER VENT MOTOR -V111 . Currently in this vehicle, all motors are identical in construction. During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM .

Move the passenger seats as far back as possible.

Turn off the ignition.

Remove the glove compartment. Refer to Removal and Installation .

Remove bolts -A-.

Loosen the air duct for the right instrument panel vent from the instrument panel crossmember, but do not remove it.

Note. The air guide from the air guide channel -B- is attached to the right instrument panel vent with two screws. To loosen, remove the screw which is installed at the bottom and is accessible.

Remove the air guide channel -B- leading to the right instrument panel vent (passenger side).

Remove the air intake housing. Refer to A/C UNIT AIR INTAKE HOUSING .

Mark the connector -A- (to the Right Center Vent Motor) and -B- (Right Footwell Door Motor) (to prevent confusion).

Scheme 102

Disconnect the connector -A- and -B-.

Disconnect the connector from the Evaporator Vent Temperature Sensor -G263-. Refer to EVAPORATOR VENT TEMPERATURE SENSOR -G263 .

Loosen the wiring harness -D- from the mounting points on the mounting plate -J-.

Carefully loosen the different connecting rods (from -E- to -H-) from each door.

Note. The connecting rods (from -E- through -H-) are clipped on to the levers; unclip them carefully so that the lever does not get damaged. Depending on the production date, there are different versions of the levers and connections on the A/C unit. Refer to AIR CONDITIONER, LEVERS AND CONNECTING ELEMENTS .

Remove the screws -C-.

Remove the mounting plate -J- (together with the control motors, the lever, the cam plate and the connector rods) from the A/C unit.

Installation is carried out in the reverse order while observing the following.

Apply a small quantity of grease G 000 150 to the cam plate guides as well as to the pins at the door levers.

Make sure the levers, cam plates and connector rod mounting plates -J- are assembled correctly. Refer to RIGHT RETAINING PLATE WITH RIGHT FOOTWELL DOOR MOTOR -V109- AND RIGHT CENTER VENT MOTOR -V111 .

When installing the mounting plate -J- pay attention to the lever pin -K- and the cam plate guide -L-.

Note. Make sure the curved washer stop -M- is inserted between both stops on the A/C -N- and -O- (the cam plate must be able to move across the range marked with the arrow).

Install the screws -C-.

Connect the connector -A- and -B- according to the markings.

Mount the wiring harness -D- into the mounting points on the mounting plate -J-.

Install the wiring harness -D- so that it cannot come in contact with any moving parts (such as the actuating arm).

Install the removed parts in the opposite order

Perform a basic setting and the output Diagnostic Test Mode (DTM) on the A/C system using the Vehicle diagnostic tester in "Guided Fault Finding".

Note. On this vehicle, the control motors are equipped with electronics. During the first basic setting, a new control motor learns its position on the air conditioner and can then be controlled by the Climatronic Control Module -J255- (currently all control motors are identical). Refer to the Vehicle diagnostic tester in "Guided Fault Finding". During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM .

Check the Climatronic Control Module DTC memory and erase any displayed malfunction if necessary using the Vehicle diagnostic tester in "Guided Fault Finding".

Switch on the ignition.

Adjust and check the air flow direction on the different air ducts via Climatronic control module, if the quantity of air actually changes at each setting.

RIGHT TEMPERATURE DOOR MOTOR -V159

Note. The Right Temperature Door Motor is installed only on vehicles equipped with the "Comfort" A/C system. Currently in this vehicle, all motors are identical in construction. During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM .

Switch on the ignition.

Adjust the air flow direction from the instrument panel vents, driver and passenger side, on the Climatronic control module -J255-.

Note. In the "air to the dash panel vents" setting, the Right Center Vent Motor -V111- -B- moves the cam plate -A- in a position so that the screw -C- is accessible. If the Right Center Vent Motor -B- does not move the cam plate -A- into the desired position, then remove the control motor if necessary. Refer to RIGHT CENTER VENT MOTOR -V111 and move the curved washer by hand.

Move the passenger seats as far back as possible.

Turn off the ignition.

Remove the air intake housing. Refer to A/C UNIT AIR INTAKE HOUSING .

Mark the connector -D- (to prevent confusing it with other connectors).

Disconnect the connector -D-.

Remove the screws -C- and -E-.

Loosen the pin -A- (on the control motor bracket -C-) from the toothed segment -B- (temperature door shaft) and remove the bracket -C- (with the control motor) in the direction of the arrow.

Scheme 103

Remove the screws -A- and separate the control motor -B- from the bracket -D-.

Scheme 104

Remove the toothed gear -C- from the control motor shaft -D-.

Installation is carried out in the reverse order while observing the following.

Mount the toothed gear -C- on the shaft -E- of the control motor -B-.

Note. The control motor does not have a stop, therefore the toothed gear -C- can be mounted on the control motor shaft at any position.

Turn the toothed gear -B- (in the temperature door shaft) all the way to the stop into the shown position (by turning in the direction of the arrow).

Insert the guide -D- (on the bracket -C- with the control motor) into the bracket -E- (on the A/C unit).

Push the bracket -C- opposite the direction of the arrow to the toothed segment -B- and insert the pin -A- (on the control motor bracket) into the toothed segment -B- (temperature door shaft).

Note. The control motor and the toothed gear -C- do not have a stop; therefore the toothed gear -C- can be joined to the toothed segment -B- (temperature door shaft) in any position.

Remove the screws -C- and -E-.

Scheme 105

Connect the connector -D-.

Install the wiring harness so that it cannot come in contact with any moving parts (such as the actuating arm).

Install the removed parts in the opposite order.

Switch on the ignition.

Perform a basic setting and the output Diagnostic Test Mode (DTM) on the A/C system using the Vehicle diagnostic tester in "Guided Fault Finding".

Note. On this vehicle, the control motors are equipped with electronics. During the first basic setting, a new control motor learns its position on the air conditioner and can then be controlled by the Climatronic Control Module -J255- (currently all control motors are identical). Refer to the Vehicle diagnostic tester in "Guided Fault Finding". During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM .

Check the Climatronic Control Module DTC memory and erase any displayed malfunction if necessary using the Vehicle diagnostic tester in "Guided Fault Finding".

DEFROSTER DOOR MOTOR -V107

Note. Currently in this vehicle, all motors are identical in construction. During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform with the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM .

Move the driver seat as far back as possible.

Turn off the ignition.

Remove the storage compartment under the dash panel on the driver's side. Refer to Removal and Installation .

Remove the left footwell vent (driver side). Refer to LEFT FOOTWELL VENTS .

Remove the accelerator pedal module. Refer to Removal and Installation .

Mark the connector -D- if necessary (to rule out an interchange in the event several connectors are disconnected at the same time).

Scheme 106

Disconnect the connector -D-.

Remove the screws -C-.

Note. To remove the screw -C- use ratchet wrench T40083.

Loosen the shaft -A- (on the motor -B-) from the actuating arm -E- and remove the motor.

Installation is carried out in the reverse order while observing the following.

Check the position of the actuating arm -E- in the A/C guide -F- ; when doing this, pay attention to both stops -G-.

Insert the shaft -A- (on the motor -B-) into the actuating arm -E-.

Note. The control motor does not have a stop; therefore the shaft -A- can be inserted into the actuating arm -E- in any position.

Install the screws -C-.

Connect the connector -D-.

Install the wiring harness so that it cannot come in contact with any moving parts (such as the actuating arm).

Install the removed parts in the opposite order.

Switch on the ignition.

Perform a basic setting and the output Diagnostic Test Mode (DTM) on the A/C system using the Vehicle diagnostic tester in "Guided Fault Finding".

Note. On this vehicle, the control motors are equipped with electronics. During the first basic setting, a new control motor learns its position on the air conditioner and can then be controlled by the Climatronic Control Module -J255- (currently all control motors are identical). Refer to the Vehicle diagnostic tester in "Guided Fault Finding" During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM .

Check the Climatronic Control Module DTC memory and erase any displayed malfunction if necessary using the Vehicle diagnostic tester in "Guided Fault Finding".

LEFT CENTER VENT MOTOR -V110

Note. The Left Center Vent Motor is installed only on vehicles equipped with the "Comfort" A/C system. Currently in this vehicle, all motors are identical in construction. During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM (A/C control motors block diagram) Left Footwell Door Motor -V108- and Left Center Vent Motor removing and installing, refer to LEFT RETAINING PLATE WITH LEFT FOOTWELL DOOR MOTOR -V108- AND LEFT CENTER VENT MOTOR -V110 . Depending on the production date, there are different versions of the levers and connections on the A/C unit. Refer to AIR CONDITIONER, LEVERS AND CONNECTING ELEMENTS .

Move the driver seat as far back as possible.

Turn off the ignition.

Remove the storage compartment under the dash panel on the driver's side. Refer to Removal and Installation .

Remove the left footwell vent (driver side). Refer to LEFT FOOTWELL VENTS .

Remove the accelerator pedal module. Refer to Removal and Installation .

Note. The following illustrations show the arrangement of the control motors and their mounting plates on the left side of the A/C with the air channel leading to the left dash panel vent -A- removed for clarity. The air guide channel leading the left instrument panel vent -A- is secured by an expanding clip or a screw -B- onto the instrument panel crossmember -C- ; the expanding clip or the screw can only be removed when the outer instrument panel shell is removed.

Carefully loosen the air guide channel leading to the left instrument panel vent -A- from the A/C vent.

Mark the connector -D- if necessary (to rule out an interchange in the event several connectors are disconnected at the same time).

Scheme 107

Disconnect the connector -D-.

Remove the screws -C-.

Note. To remove the screw -C- use ratchet wrench T40083.

Press the cam plate -E- toward the A/C and remove the shaft -A- (control motor -B-) from the cam plate -E-.

Note. The Left Center Vent Motor actuates the connector rod -F- via the cam plate -E- (and with it the door for the left indirect ventilation) and via the lever -G- and via the door left center dash panel vent. If the pin -G- comes out of the cam plate guiding groove -E- while removing the control motor, the left center dash panel vent door will not actuate. On RHD vehicles, the cam plate -E- is not driven directly by the control motor shaft -B- ; on these vehicles, the cam plate -E- is actuated by two additional toothed gears -A- and -C-. In MY 2008, revised toothed gears -A- and a new bracket were installed as a running change (a revised collar on the toothed gear and a revised hole). Make sure the correct toothed wheel and bracket are installed (these parts are supplied together as a replacement part). The connector rod -F- actuates the left door in the center vent

Installation is carried out in the reverse order while observing the following.

Check the lever pin -G- and the connector rod pin -F- for correct fit in each guiding groove in the cam plate -E-.

Insert the shaft -D- of the control motor -B- into the cam plate -E-.

Note. The control motor does not have a stop; therefore the control motor shaft can be inserted into the cam plate -E- at any position.

Install the screws -C-.

Connect the connector -D-.

Install the wiring harness so that it cannot come in contact with any moving parts (such as the actuating arm).

Install the removed parts in the opposite order.

Switch on the ignition.

Perform a basic setting and the output Diagnostic Test Mode (DTM) on the A/C system using the Vehicle diagnostic tester in "Guided Fault Finding".

Note. On this vehicle, the control motors are equipped with electronics. During the first basic setting, a new control motor learns its position on the air conditioner and can then be controlled by the Climatronic Control Module -J255- (currently all control motors are identical). Refer to the Vehicle diagnostic tester in "Guided Fault Finding". During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM .

Check the Climatronic Control Module DTC memory and erase any displayed malfunction if necessary using the Vehicle diagnostic tester in "Guided Fault Finding".

FOOTWELL DOOR MOTOR -V261- AND LEFT FOOTWELL DOOR MOTOR -V108

The Footwell Door Motor is installed on vehicles equipped with the "Basis" A/C system.

The Left Footwell Door Motor is installed on the "Comfort" A/C system.

Note. Different designations and functions, depending on the A/C version. Refer to AIR ROUTING AND DISTRIBUTION IN PASSENGER COMPARTMENT . On vehicles equipped with the "Comfort" A/C system, the left footwell door motor actuates the doors for the left instrument panel vent, the left footwell vent and the left rear footwell vent (under the driver seat). On vehicles with the "Basis" A/C system, the footwell door motor actuates the doors for the left and right instrument panel vents, the left and right footwells and the left and right rear footwells (under the front seats). The different doors for the left and right side are connected with each other in the A/C by connector rods. Currently in this vehicle, all motors are identical in construction. During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM . Retaining plate for the Footwell Door Motor removing and installing, refer to LEFT RETAINING PLATE WITH FOOTWELL DOOR MOTOR -V261 . Left Footwell Door Motor with the control motors and Left Center Vent Motor -V110- removing and installing, refer to LEFT RETAINING PLATE WITH LEFT FOOTWELL DOOR MOTOR -V108- AND LEFT CENTER VENT MOTOR -V110 .

Move the driver seat as far back as possible.

Turn off the ignition.

Remove the storage compartment under the dash panel on the driver side. Refer to Removal and Installation .

Remove the left footwell vent (driver side). Refer to LEFT FOOTWELL VENTS .

Remove the accelerator pedal module. Refer to Removal and Installation .

Mark the connector -D- if necessary (to rule out an interchange in the event several connectors are disconnected at the same time).

Scheme 108

Disconnect the connector -D-.

Remove the screws -C-.

Note. To remove the screw -C- use ratchet wrenchT40083.

Loosen the shaft -A- (on the motor -B-) from the curved washer -E- and remove the motor.

Installation is carried out in the reverse order while observing the following.

Insert the shaft -A- (on the control motor -B-) into the cam plate mount -E-.

Note. The control motor does not have a stop; therefore the shaft -A- can be inserted into the cam plate mount -E- in any position.

Install the screws -C-.

Connect the connector -D-.

Install the wiring harness so that it cannot come in contact with any moving parts (such as the actuating arm).

Install the removed parts in the opposite order.

Switch on the ignition.

Perform a basic setting and the output Diagnostic Test Mode (DTM) on the A/C system using the Vehicle diagnostic tester in "Guided Fault Finding".

Note. On this vehicle, the control motors are equipped with electronics. During the first basic setting, a new control motor learns its position on the air conditioner and can then be controlled by the Climatronic Control Module -J255- (currently all control motors are identical). Refer to the Vehicle diagnostic tester in "Guided Fault Finding". During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM .

Check the Climatronic Control Module DTC memory and erase any displayed malfunction if necessary using the Vehicle diagnostic tester in "Guided Fault Finding".

LEFT RETAINING PLATE WITH FOOTWELL DOOR MOTOR -V261

The Footwell Door Motor is installed on vehicles equipped with the "Basis" A/C system.

Note. The mounting plate with the Footwell Door Motor is installed only on vehicles equipped with the "Basis" A/C system. Mounting plate Footwell Door Motor, disassembling and assembling, refer to LEFT RETAINING PLATE WITH FOOTWELL DOOR MOTOR -V261 . Currently in this vehicle, all motors are identical in construction. During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform with the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM . Depending on the production date, there are different versions of the levers and connections on the A/C unit. Refer to AIR CONDITIONER, LEVERS AND CONNECTING ELEMENTS .

Move the driver seat as far back as possible.

Turn off the ignition.

Remove the storage compartment under the dash panel on the driver side. Refer to Removal and Installation .

Remove the left footwell vent (driver side). Refer to LEFT FOOTWELL VENTS .

Remove the accelerator pedal module. Refer to Removal and Installation .

Mark the connector -A- (to the Defroster Door Motor -V107-) and -B- (Footwell Door Motor) and -C- (Temperature Regulator Door Motor -V68-) (to prevent confusion).

Scheme 109

Disconnect the connector -A-, -B- and -C-.

Loosen the wiring harness -D- from the mounting points on the mounting plate -E-.

Carefully disconnect the connector rods -A-, -B- and -C- from the levers on each door.

Scheme 110

Note. The connecting rods (-A- through -C-) are clipped on to the levers; unclip them carefully so that the lever does not get damaged. Depending on the production date, there are different versions of the levers and connections on the A/C unit. Refer to AIR CONDITIONER, LEVERS AND CONNECTING ELEMENTS .

Remove screws -D-.

Remove the mounting plate -E- (together with the control motor -F-, the lever, the cam plate and the connector rods) from the A/C.

Installation is carried out in the reverse order while observing the following.

Apply a small quantity of grease G 000 150 to the cam plate guides as well as to the pins at the door levers.

Make sure the levers, cam plates and connector rod mounting plates -A- are assembled correctly. Refer to LEFT RETAINING PLATE WITH FOOTWELL DOOR MOTOR -V261 .

When installing the mounting plate -A- correctly insert the mounting plate pin -B- and the cam plate -C- into the A/C bracket.

Scheme 111

Install the screws -D-.

Connect the various connector rods -A-, -B- and -C- from the levers on each door.

Connect the connector -A- through -C- according to the markings.

Mount the wiring harness -D- into the mounting points on the mounting plate -E-.

Check the wiring harness routing -D- so that it cannot come in contact with any moving parts (such as levers).

Install the removed parts in the opposite order.

Switch on the ignition.

Perform a basic setting and the output Diagnostic Test Mode (DTM) on the A/C system using the Vehicle diagnostic tester in "Guided Fault Finding".

Note. On this vehicle, the control motors are equipped with electronics. During the first basic setting, a new control motor learns its position on the air conditioner and can then be controlled by the Climatronic Control Module -J255- (currently all control motors are identical). Refer to the Vehicle diagnostic tester in "Guided Fault Finding". During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM .

Check the Climatronic Control Module DTC memory and erase any displayed malfunction if necessary using the Vehicle diagnostic tester in "Guided Fault Finding".

LEFT RETAINING PLATE WITH LEFT FOOTWELL DOOR MOTOR -V108- AND LEFT CENTER VENT MOTOR -V110

The Left Footwell Door Motor and the Left Center Vent Motor are installed in the "Comfort" A/C system.

Note. The mounting plate with the Left Footwell Door Motor and the Left Center Vent Motor is installed only on vehicles equipped with the "Comfort" A/C system. Right Footwell Door Motor mounting plate and Right Center Vent Motor disassembling and assembling, refer to LEFT RETAINING PLATE WITH LEFT FOOTWELL DOOR MOTOR -V108- AND LEFT CENTER VENT MOTOR -V110 . Currently in this vehicle, all motors are identical in construction. During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform with the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM . Depending on the production date, there are different versions of the levers and connections on the A/C unit. Refer to AIR CONDITIONER, LEVERS AND CONNECTING ELEMENTS .

Move the driver seat as far back as possible.

Turn off the ignition.

Remove the storage compartment under the dash panel on the driver side. Refer to Removal and Installation .

Remove the left footwell vent (driver side). Refer to LEFT FOOTWELL VENTS .

Remove the steering column. Refer to Removal and Installation .

Remove the pedal assembly and accelerator pedal module. Refer to Removal and Installation and Removal and Installation .

Note. The following illustrations show the arrangement of the control motors and their mounting plates on the left side of the A/C with the air channel leading to the left dash panel vent -A- removed for clarity. The air guide channel leading the left instrument panel vent -A- is secured by an expanding clip or a screw -B- onto the instrument panel crossmember -C- ; the expanding clip or the screw can only be removed when the outer instrument panel shell is removed.

Mark the connector -A- (to the Left Center Vent Motor), -B- (to the Defroster Door Motor -V107-), -C- (to the Left Footwell Door Motor) and -D- (to the Rear Temperature Door Motor -V137-) (to prevent confusing them).

Scheme 112

Disconnect the connectors -A- up to -D-.

Loosen the wiring harness -E- from the mounting points on the mounting plate -F-.

Carefully disconnect the connector rods -A- through -D- from the levers on each door.

Scheme 113

Note. The connecting rods -A- through -D- are clipped on to the levers; unclip them carefully so that the lever does not get damaged. Depending on the production date, there are different versions of the levers and connections on the A/C unit. Refer to AIR CONDITIONER, LEVERS AND CONNECTING ELEMENTS .

Remove bolts -E-.

Remove the mounting plate -F- (together with the control motors, the levers, the cam plates and the connector rods) from the A/C.

Installation is carried out in the reverse order while observing the following.

Apply a small quantity of grease G 000 150 to the cam plate guides as well as to the pins at the door levers.

Make sure the levers, cam plates and connector rod mounting plates -A- are assembled correctly. Refer to LEFT RETAINING PLATE WITH LEFT FOOTWELL DOOR MOTOR -V108- AND LEFT CENTER VENT MOTOR -V110 .

Scheme 114

When installing the mounting plate -A-, insert the mounting plate pins -B- into the brackets -C- and the cam plate pins -D- and -F- into the brackets -E-.

When installing the mounting plate -A- insert the lever pins -G- into the guiding groove on the cam plates -F-.

Note. When inserting, make sure that the cam plate stop -C- is not in area -F- (between both stops on the A/C -D- and -E-). The cam plate -A- actuates the door for the left indirect ventilation (driver's side) via the lever -B-.

Install the screws -E-.

Carefully connect the various connector rods -A- through -D- to the lever of each door.

Route the wiring harness -E- as shown and secure it at the mounting points to the mounting plate -F-.

Connect the connectors -A- through -D- according to the markings.

Check the wiring harness routing -E- so that it cannot come in contact with any moving parts (for example, levers).

Install the removed parts in the opposite order.

Switch on the ignition.

Perform a basic setting and the output Diagnostic Test Mode (DTM) on the A/C system using the Vehicle diagnostic tester in "Guided Fault Finding".

Note. On this vehicle, the control motors are equipped with electronics. During the first basic setting, a new control motor learns its position on the air conditioner and can then be controlled by the Climatronic Control Module -J255- (currently all control motors are identical). Refer to the Vehicle diagnostic tester in "Guided Fault Finding". During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM .

Check the Climatronic Control Module DTC memory and erase any displayed malfunction if necessary using the Vehicle diagnostic tester in "Guided Fault Finding".

Adjust and check the air flow direction on the different air ducts via Climatronic control module, if the quantity of air actually changes at each setting.

LEFT TEMPERATURE DOOR MOTOR -V158

Note. The Left Temperature Door Motor is installed only on vehicles equipped with the "Comfort" A/C system. Currently in this vehicle, all motors are identical in construction. During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform with the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM . Depending on the production date, there are different versions of the levers and connections on the A/C unit. Refer to AIR CONDITIONER, LEVERS AND CONNECTING ELEMENTS .

Switch on the ignition.

Move the driver seat as far back as possible.

Adjust the air flow to the footwells on both the driver and passenger side on the Climatronic control module -J255-.

Note. In the "air to the footwell vents" setting, the Defroster Door Motor -V107- moves the connector rod -A- in a position so that the screw -B- is accessible. If the Defroster Door Motor does not move the connector rod -A- into the desired position, remove the control motor if necessary. Refer to DEFROSTER DOOR MOTOR -V107 .

Turn off the ignition.

Remove the storage compartment under the dash panel on the driver side. Refer to Removal and Installation .

Remove the left footwell vent (driver side). Refer to LEFT FOOTWELL VENTS .

Remove the steering column. Refer to Removal and Installation .

Remove the pedal assembly and accelerator pedal module. Refer to Removal and Installation and Removal and Installation .

Remove the left center vent motor -V110- -B-. Refer to LEFT CENTER VENT MOTOR -V110 .

Mark the connector -C- (to prevent confusing it with other connectors).

Scheme 115

Disconnect the connector -C-.

Remove bolts -B-.

Loosen the pin -D- (on the control motor bracket -E-) from the toothed segment -F- (temperature door shaft) and remove the bracket -E- (with the control motor) in the direction of the arrow.

Remove the screws -A- and separate the control motor -B- from the bracket -D-.

Scheme 116

Remove the toothed gear -C- from the control motor shaft -D-.

Installation is carried out in the reverse order while observing the following.

Mount the toothed gear -C- on the shaft -E- of the control motor -B-.

Note. The control motor does not have a stop, therefore the toothed gear -C- can be mounted on the control motor shaft at any position.

Bring the toothed gear -F- (in the temperature door shaft) all the way to the stop into the shown position (by turning in the direction of the arrow).

Insert the guide -G- (on the bracket -E- with the control motor) into the bracket -H- (on the A/C unit).

Push the bracket -E- opposite the direction of the arrow to the toothed segment -F- and insert the pin -D- (on the control motor bracket -E-) into the toothed segment -F- (temperature door shaft).

Note. The control motor and the toothed gear -J- do not have a stop; therefore the toothed gear -J- can be joined to the toothed segment -F- (temperature door shaft) in any position.

Install the bolts -B-.

Connect the connector -C-.

Install the wiring harness so that it cannot come in contact with any moving parts (such as the actuating arm).

Install the removed parts in the opposite order.

Switch on the ignition.

Perform a basic setting and the output Diagnostic Test Mode (DTM) on the A/C system using the Vehicle diagnostic tester in "Guided Fault Finding".

Note. On this vehicle, the control motors are equipped with electronics. During the first basic setting, a new control motor learns its position on the air conditioner and can then be controlled by the Climatronic Control Module -J255- (currently all control motors are identical). Refer to the Vehicle diagnostic tester in "Guided Fault Finding". During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM .

Check the Climatronic Control Module DTC memory and erase any displayed malfunction if necessary using the Vehicle diagnostic tester in "Guided Fault Finding".

DUST AND POLLEN FILTER

Note. Dust and pollen filter change interval, refer to Maintenance, Diagnosis . There are different versions of the dust and pollen filter (without and with filter insert with activated charcoal) On vehicles equipped with the "Comfort" A/C system, there is currently a dust and pollen filter with an activated charcoal filter element installed; on vehicles equipped with the "Basis" A/C system, there is a dust and pollen filter without the activated charcoal filter element installed. Clean the surrounding area of the dust and pollen filter in heating & A/C unit shaft before installing a new filter. In model year 2012, vehicles with a "Comfort" A/C system will have a modified dust and pollen filter with an activated charcoal filter element installed as a running change. This filter with an improved interception rate for fine particulates has approximately the same air resistance values as the filter installed prior to the change, and for this reason will be in installed in vehicles built up to the change. If the customer requests it, it is permitted the exchange a dust and pollen filter without an activated charcoal filter element that came with the vehicle from the manufacturer for a dust and pollen filter with an activated charcoal filter element so long as the vehicle has the "Basis" A/C system. Depending on the version, for some countries with high dust levels, a filter is installed instead of fresh air intake grille. Check and replace these if necessary, refer to FRESH AIR INTAKE .

Move the passenger seats as far back as possible.

Turn off the ignition.

Remove the screw clips -A- and remove the insulation mat -B-.

Scheme 117

Cover floor carpet in area beneath dust and pollen filter with paper.

Disengage the catches -B-, slide the cover -A- in the direction of the arrow -arrow- and remove the cover.

Scheme 118

Note. If the cover -A- can no longer be held by the catches -B-, secure it with screws -D- on the mounting points -C-.

Remove the dust and pollen filter -A- from the A/C shaft -B-.

Scheme 119

Installation is carried out in the reverse order while observing the following.

Clean the A/C unit via the shaft -B- (for example, using a vacuum cleaner) after removing the dust and pollen filter -A-.

Install the dust and pollen filter -A- on the correct side (the angle -C- on the side facing the fresh air blower -D-)

Note. There are different versions of the dust and pollen filter, without and with a filter insert with activated charcoal; make sure the correct version is installed.

FRESH AIR BLOWER CONTROL MODULE -J126

Note. There are different versions of the replacement fresh air blower control module (for example, versions -A- and -B-). Pay attention to the correct allocation. From start of production through MY 12, version -A- was installed. From MY 12, version -A- was changed to version -B- (the time when the change-over took place depends on the version of the vehicle). Version -B- also has a seal -C-. From MY 12, (introduction depends on the version of the vehicle) a revised fresh air blower control module -B- (and fresh air blower -V2-, Climatronic control module -J255- and A/C unit with part number "8T_ 820 005") are being used. The air intake manifold, along with the fresh air blower control module and the A/C unit is also revised. Be sure to use the correct version and allocation. Refer to the Vehicle diagnostic tester in "Guided Fault Finding". The fresh air blower control module does not control the fresh air blower if the Climatronic control module allocation or adaptation to fresh air blower module (part number 8K0 820 521 or 8T0 820 521) is not according to the specification. In this case a fault is not always stored in the DTC memory even though the fresh air blower activation is not OK. Make sure the Climatronic control module adaptation is correct. Refer to the Vehicle diagnostic tester in "Guided Fault Finding". There is a label -A- on the outside of the A/C unit with a part -B- that tells which version is installed. The part number -B- on the decal -A- can be read when the CD changer is removed (depending on the vehicle equipment level). Refer to Removal and Installation . When the ignition is on and the fresh air blower -V2- is set at "Plus", the fresh air blower control module interconnects (for example, on version -A-) from contact "4" on terminal -C- to contact "1" on connector -B-. Fresh Air Blower speed is regulated by Fresh Air Blower Control Module via the ground connection between terminal "2" connector -B- and terminal "3" of connector -C-. Refer to the Vehicle diagnostic tester in "Guided Fault Finding" and the appropriate SYSTEM WIRING DIAGRAMS information. As a running change in MY 10, gasoline engines that can run on bioethanol (Flex Fuel Vehicles) were introduced, which currently have an auxiliary heater heating element -Z35-. Refer to AUXILIARY HEATER HEATING ELEMENT -Z35-, TESTING . Currently an auxiliary air heater heating element is installed for vehicles with a high voltage system (hybrid vehicles) and a gasoline engine. Refer to AUXILIARY HEATER HEATING ELEMENT -Z35-, TESTING . The activation of the auxiliary heater heating element occurs for vehicles with a gasoline engine from the Climatronic control module -J255- via the local Data bus (controlled using the same outlet and also using the fresh air blower control module -J126-) on the auxiliary air heater control module -J604-. Check the fresh air blower control module or the fresh air blower and also the auxiliary air heater control module when complaints arise for these vehicles. Refer to the Vehicle diagnostic tester in "Guided Fault Finding" and the appropriate SYSTEM WIRING DIAGRAMS information. Make sure the auxiliary air heater heating element is working. Refer to AUXILIARY HEATER HEATING ELEMENT -Z35-, TESTING .

Move the passenger seats as far back as possible.

Turn off the ignition.

Remove the glove compartment. Refer to Removal and Installation .

Disconnect the connector -A- and -B-.

Scheme 120

Remove the screws -C-.

Remove the Fresh Air Blower Control Module -D- from the air intake housing.

Installation is carried out in the reverse order while observing the following.

Switch on the ignition.

Check the Climatronic control module -J255- DTC memory and erase any displayed malfunctions if necessary using the Vehicle diagnostic tester in "Guided Fault Finding".

To check the function, perform an output Diagnostic Test Mode (DTM) on the A/C system using the Vehicle diagnostic tester in "Guided Fault Finding".

FRESH AIR BLOWER -V2

Note. The fresh air blower as a replacement part is available in different versions, make sure of the correct application. As a running change, the fresh air blower -A- has an additional foam sheathing -B- (as a noise insulation) from 08.2007. As a running change in MY 2009, a fresh air blower -A- with a revised housing with an optimized motor and motor mount, is being used. With the use of the new fresh air blower, the foam jacket on the house -B- is discontinued because the larger motor mount has a new insulation mat (see -B- in the next illustration). From MY 12 (depending on the version of the vehicle) revised fresh air blower control module -J126-, fresh air blower, Climatronic control module -J255- and A/C units are being used. Be sure to use the correct version and allocation. Refer to the Vehicle diagnostic tester in "Guided Fault Finding". There is a label -A- on the outside of the A/C unit with a part -B- that tells which version is installed. The part number -B- on the decal -A- can be read when the CD changer is removed (depending on the vehicle equipment level). Refer to Removal and Installation . As a running change in MY 10, gasoline engines that can run on bioethanol (Flex Fuel Vehicles) were introduced, which currently have an auxiliary heater heating element -Z35-. Refer to AUXILIARY HEATER HEATING ELEMENT -Z35-, TESTING . Currently an auxiliary air heater heating element is installed for vehicles with a high voltage system (hybrid vehicles) and a gasoline engine. Refer to AUXILIARY HEATER HEATING ELEMENT -Z35-, TESTING . The activation of the auxiliary heater heating element occurs for vehicles with a gasoline engine from the Climatronic control module via the local Data bus (controlled using the same outlet and also using the fresh air blower control module -J126-) on the auxiliary air heater control module -J604-. Check the fresh air blower control module or the fresh air blower and also the auxiliary air heater control module when complaints arise for these vehicles. Refer to the Vehicle diagnostic tester in "Guided Fault Finding" and the appropriate SYSTEM WIRING DIAGRAMS information. From MY 12 (introduction depending on the vehicle version) a revised fresh air blower control module (and fresh air blower, Climatronic control module and A/C units with part number "8T_ 820 005") are being used. The air intake manifold, along with the fresh air blower control module and the A/C unit is also revised. Be sure to use the correct version and allocation. Refer to the Vehicle diagnostic tester in "Guided Fault Finding". The fresh air blower control module does not control the fresh air blower if the Climatronic control module allocation or adaptation to fresh air blower module (part number 8K0 820 521 or 8T0 820 521) is not according to the specification. There may not always be an entry in the DTC memory even though the activation of the fresh air blower is not OK. Make sure the Climatronic control module adaptation is correct. Refer to the Vehicle diagnostic tester in "Guided Fault Finding". Make sure the auxiliary air heater heating element is working. Refer to AUXILIARY HEATER HEATING ELEMENT -Z35-, TESTING .

Remove the screw clips -A- and remove the insulation mat -B-.

Remove the fresh air blower control module -J126- (version -A-). Refer to FRESH AIR BLOWER CONTROL MODULE -J126 .

Scheme 121

Note. A revised fresh air blower control module -J126- -B- and fresh air blower -V2- are being installed as a running change (depending on the version of the vehicle) from MY 12. It is not always necessary to remove the fresh air blower control module in order to remove the fresh air blower on the revised version -B-.

Loosen the locking mechanism -A- and turn the fresh air blower -B- housing in the direction of the arrow.

Scheme 122

Installation is carried out in the reverse order while observing the following.

If the locking mechanism -A- breaks or can no longer hold, secure the fresh air blower -B- to the air intake housing with a screw -C-.

Make sure the fresh air blower -B- fits securely in the air intake housing when installing it.

Switch on the ignition.

Check the Climatronic control module -J255- DTC memory and erase any displayed malfunctions if necessary using the Vehicle diagnostic tester in "Guided Fault Finding".

To check the function, perform an output Diagnostic Test Mode (DTM) on the A/C system using the Vehicle diagnostic tester in "Guided Fault Finding".

FRESH AIR INTAKE

Note. Depending on the version, for some countries with high dust levels, a filter -C- is installed in the filter mount -B- instead of the fresh air intake grille -A-. The dust filter -C- prevents pollen and sand from getting sucked into the fresh air blower -V2-. Make sure when removing the dust filter -C- that contaminates do not fall into the A/C intake shroud. The dust filter -C- is held in the filter mount -B- with the retaining strap -D-. Note the replacement interval for the dust filter -C-. Refer to Maintenance, Diagnosis . Clean the air intake shroud and the area around the dust filter -C- in the plenum chamber before installing a new filter. Pay attention to the air flow direction -arrows- when installing the dust filter -C-.

PREPARATORY WORK

Turn off the ignition.

With high voltage systems (hybrid vehicles)

Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system, refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS and to GENERAL INFORMATION .

If it is necessary for the following procedure to perform work in the vicinity of high voltage components, perform a visual inspection of the high voltage components and cables for damages, refer to VISUAL INSPECTION OF HIGH-VOLTAGE COMPONENTS AND CABLES FOR DAMAGE and always follow the warnings when working on the high voltage system. Refer to GENERAL INFORMATION .

Remove the rubber seal -A- and the plenum chamber cover -B- (there are different versions). Refer to Removal and Installation .

Scheme 123

1. Inspect the high voltage components -D- (the electric drive power and control electronics -JX1-) and the high voltage cables -E- after removing the plenum chamber cover -B-. Refer to «VISUAL INSPECTION OF HIGH-VOLTAGE COMPONENTS AND CABLES FOR DAMAGE»(/audi/a5/i-2007-2011/remont/automatic-hvac-system/#air-conditioning-coupe-1-of-2__visual-inspection-of-high-voltage-components-and) and GENERAL INFORMATION .

1. Be careful not to damage any high voltage components -D- or the high voltage cables -E-. Refer to GENERAL INFORMATION .
2. Inspect the high voltage components -D- and high voltage cables -E- after completing the work procedure and before installing the plenum chamber cover -B-. Refer to GENERAL INFORMATION .

Note. Remove the cowl panel -C- if it is necessary to clean the water drains. Refer to Description and Operation .

For vehicles without a high voltage system

Remove the plenum chamber cover and/or the cowl panel (there are different versions). Refer to Description and Operation .

Note. The following illustrations show the location of the components on an Audi A5 Coupe; an Audi A5 Sportback, Audi A4, Audi Q5 etc., the location of the components varies slightly. The description of the components is not different; removing, installing and checking is performed in the same way as on the Audi A5 Coupe. The fresh air intake shaft -A- may have an additional cover with a rain water drain channel -B- depending on the vehicle version and the plenum chamber cover installed.

Remove both windshield wiper arms (only on vehicles where the cowl and the fresh air intake cover on the cowl -A- are one piece). Refer to Removal and Installation .

Scheme 124

Pull the left rubber seal -B- as far as necessary Removal and Installation .

Remove the fresh air intake cover on the wind cowl -A- or the wind cowl (different styles). Refer to Removal and Installation .

Note. Loosen the cowl panel trim from the windshield crossmember -C-. Refer to Removal and Installation .

All vehicles

Checking

Check the cowl -A- for proper installation and damage. Refer to Removal and Installation .

Check the seals between the fresh air intake cover -A-, the cowl and the windshield cross member -C- for damage and proper fit. This seals prevent water from entering between window cross member and cover and running into A/C unit air intake shroud. Refer to Removal and Installation .

REMOVING AND INSTALLING

Note. Depending on the version, for some countries with high dust levels (for example China), a dust filter installed instead of intake air grille -A-, which prevents dust and sand from entering the fresh air blower.

Perform the preparatory work PREPARATORY WORK .

Disconnect the connector -B- from the air quality sensor -G238- / humidity sensor in fresh air intake duct -G657- (there are different locations).

Scheme 125

Note. There are different versions of the air intake shroud for the fresh air intake -C- (with and without a mount for the for the air quality sensor / humidity sensor in fresh air intake duct -A-, in the front or on the side).

Remove the screws -C- (tightening specification: 3 Nm) and cover with the water channel -B-.

Scheme 126

Remove the screws -B-.

Scheme 127

Remove the fresh air intake -C-.

Installation is done is reverse order, observe the following

1. Pay attention to the tightening sequence for the nuts -B- when installing them.

Tighten the nuts -B- lightly by hand in the following sequence.

1. Tighten the inner lying nut -B- (in the right illustration).
2. Tighten the outer lying nut -B- (top left in the illustration).
3. Tighten the outer lying nut -B- (bottom left in the illustration).

Tighten the nuts -B- which correspond to the tightening sequence at the top (tightening specification: 3.5 Nm).

Note. Check for damage prior to installing the fresh air intake -C- and the bonded seal; if there is damage, replace the seal or fresh air intake -C-. When installing, make sure the fresh air intake -C- and seal are seated correctly; if the fresh air intake -C- is not installed correctly, water can seep into the A/C unit intake shroud through the sealing surface -D-. Prior to installing the cowl cover -A- (there are different versions), check the cowl and the seals for the cover -A- and the window cross member -C- for damage; if the cover, the cowl or the seal are damaged, water can seep into the fresh air intake and also into the A/C intake shroud.

HEATER CORE PREPARING FOR REMOVAL

Special tools and workshop equipment required

1. Hose Clamps up to 25 mm 3094 or Hose Clamps up to 40 mm 3093
2. Commercial compressed-air gun with rubber end piece
3. Cooling System Tester V.A.G 1274 (and corresponding adapter)

Switch on the ignition.

Set the air flow direction to "DEF" on the Climatronic control module -J255-.

Move the passenger seats as far back as possible.

Turn off the ignition.

With high voltage systems (hybrid vehicles)

Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system. Refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS and refer to GENERAL INFORMATION .

The following procedure requires working on the high voltage system. De-energize the high voltage system. Refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS , GENERAL INFORMATION and Read and follow the high voltage electrical system general warnings. Refer to GENERAL INFORMATION .

De-energize the high voltage system. Refer to GENERAL INFORMATION .

Disable the high voltage system

Note. Disable the high voltage system: Connect the vehicle diagnosis tester Select the Guided Fault Finding mode Using the GO TO button, select the following menu commands Functions/Component selection Body Electrical Equipment OBD-capable system 8C - Hybrid battery management -J840 8C - Hybrid battery management, functions 51 - Disable the high voltage system (Rep.Gr. 93)

Disconnect the ground cable from the battery. Refer to Removal and Installation .

Remove the rubber seal -A- and the plenum chamber cover -B- (there are different versions). Refer to Removal and Installation .

1. Inspect the high voltage components -D- (the electric drive power and control electronics -JX1-) and the high voltage cables -E- after removing the plenum chamber cover -B-. Refer to «VISUAL INSPECTION OF HIGH-VOLTAGE COMPONENTS AND CABLES FOR DAMAGE»(/audi/a5/i-2007-2011/remont/automatic-hvac-system/#air-conditioning-coupe-1-of-2__visual-inspection-of-high-voltage-components-and) and GENERAL INFORMATION .

Remove the cowl panel -C-. Refer to Description and Operation .

Loosen the power distribution panel -1- and move it toward the windshield with the wires. Refer to REMOVAL AND INSTALLATION .

Scheme 128

Remove the high voltage cables leading to the electric A/C compressor -V470- and from the traction battery -A2- and electric drive power and control electronics -JX1-. Refer to DESCRIPTION AND OPERATION .

Cover the electric drive power and control electronics -JX1- and wires to prevent them getting damaged and to protect them from dirt. Refer to DESCRIPTION AND OPERATION .

Note. Use clean 20 mm bungs -B-, taken from engine bung set VAS 6122, to seal off the connection on the electric drive power and control electronics -JX1- -A-.

1. Be careful not to damage any high voltage components -D- or the high voltage cables -E-. Refer to GENERAL INFORMATION .
2. Inspect the high voltage components -D- and high voltage cables -E- after completing the work procedure and before installing the plenum chamber cover -B-. Refer to GENERAL INFORMATION .

For vehicles without a high voltage system

Remove the plenum chamber cover (not always necessary, there are different versions). Refer to Removal and Installation .

Disconnect the ground cable from the battery. Refer to Removal and Installation .

Note. Disconnect the battery ground connection so that it cannot short circuit when the jumper cable post -C- is removed.

Remove the jumper cable post cover -C-.

Remove the jumper cable post -C- from the strut dome and lay it to the side. Refer to Removal and Installation .

All vehicles

Remove the air intake housing. Refer to A/C UNIT AIR INTAKE HOUSING .

Disconnect the connector from the Evaporator Vent Temperature Sensor -G263-. Refer to EVAPORATOR VENT TEMPERATURE SENSOR -G263 .

Note. From 01.2008, A/C units which have an additional connection for the glove compartment cooling are being installed, refer to GLOVE COMPARTMENT COOLING TO AIR INTAKE MANIFOLD CONNECTION . Make sure the correct right heater core housing and air intake hosing (different versions) are installed. The activation of the temperature doors and with it the right heater core housing is different between vehicles equipped with "Comfort" and "Basis" A/C systems. Refer to A/C UNIT AND AIR INTAKE HOUSING COMPONENTS . To maintain the A/C stability, only one heater core housing (the left or right side) may be removed with the A/C installed. Depending on the production date, there are different versions of the levers and connections on the A/C unit. Refer to AIR CONDITIONER, LEVERS AND CONNECTING ELEMENTS . Vehicles with the "Comfort" A/C system can have the right heater core housing and the mounting plate installed/removed for the motors removed/installed. Vehicles with the "Basis" A/C system do not have this mounting plate.

1. Right heater core housing, removing and installing (vehicles with "Basis" A/C system and vehicles with "Comfort" A/C system, where the right mounting plate and motors and the right heater core housing must be removed one after the other), refer to «RIGHT HEATER CORE HOUSING, MOTOR MOUNTING PLATE REMOVED»(/audi/a5/i-2007-2011/remont/automatic-hvac-system/#air-conditioning-coupe-2-of-2__right-heater-core-housing-motor-mounting) .
2. Right heater core housing together with the right mounting plate and motors, removing and installing (only on vehicles with "Comfort" A/C system), refer to «RIGHT HEATER CORE HOUSING AND RIGHT MOTOR MOUNTING PLATE»(/audi/a5/i-2007-2011/remont/automatic-hvac-system/#air-conditioning-coupe-2-of-2__right-heater-core-housing-and-right) .

1. Heater core, removing, refer to «HEATER CORE REMOVING AND INSTALLING»(/audi/a5/i-2007-2011/remont/automatic-hvac-system/#air-conditioning-coupe-2-of-2__heater-core-removing-and-installing) .

HEATER CORE REMOVING AND INSTALLING

Note. Due to space limitation when the instrument panel is installed, it is not possible to install the factory-installed heater core and clamps -B- and -C- again. If a factory installed heater core (Original part) must be installed again, remove the instrument panel and the air guide leading to the "Defrost" vent. Coat the O-rings with coolant (as described for installing a replacement heater core) on the coolant pipes -D- and -E- and then push the coolant pipes -D- and -E- (with the O-ring) from the top into the connections in the heater core -A-. Hold the coolant pipes -D- and -E- in the heater core and install the clamps -B- and -C-. Further assembly is performed as described for installing a replacement part - heater core.

Perform the preparation work for removing the heater core. Refer to HEATER CORE PREPARING FOR REMOVAL .

Release pressure in cooling circuit by opening cap on coolant expansion tank. [For engine(s) CAUA] General Information or to [For engine(s) CAEB] General Information or to [For engine(s) CALA] General Information .

Mark the arrangement of coolant hoses -A- (supply to cylinder head) and -B- (return to coolant pump).

Scheme 129

Note. The heater core is designed for a specific coolant flow direction. Therefore, coolant hoses must be connected on the correct sides. Bleed the coolant circuit. Refer to [For engine(s) CAUA] General Information or to [For engine(s) CAEB] General Information or to [For engine(s) CALA] General Information .

Clamp the coolant hoses -A- and -B- with hose clamps.

Cover the area beneath connections for coolant hoses -A- and -B- for example with absorbent paper.

Remove coolant hoses -A- and -B- from connections to heater core.

Insert one section each of hose -A- and -B- on to both connections to heater core.

Scheme 130

Place a container -B- under the other end of the hose -C-.

Using a compressed air gun -D-, carefully blow coolant out of heater core (into container -B-) via hose -A-.

Remove the clamps -B- and -C- from the heater core connectors -A-.

Scheme 131

Loosen both coolant pipes -D- and -E- from the heater core connectors -A-.

Remove the heater core -A- in the direction of the arrow -arrow-.

Note. The upper illustration shows a heater core with connectors as it is installed in production. If the heater core was already exchanged once, then both coolant pipes are held in the replacement heater core with a bracket -A-. Remove the screw -B- in this heater core. Install a longer screw -C- (with a M5 thread) all the way to the end as shown in the illustration and with this screw, loosen the bracket -A- from the connection.

Installation is carried out in the reverse order while noting the following

Depending on the A/C version, cover the heater core with the foam seal provided -A- through -D-.

Scheme 132

1 - Heater core for a vehicle equipped with a "Basis" A/C system with left- or right-hand drive.

2 - Heater core for a vehicle equipped with a "Comfort" A/C system.

Check the seals on the heater core; only install a heater core with seals that are not damaged and are secured glued on.

Note. If the vehicle has the "Comfort" A/C system, then there are different temperature settings for the right and left sides as well as for the rear. The seals -C- and -D- separate the air guides in the air conditioner from each other. Refer to AIR ROUTING IN AIR INTAKE HOUSING AND A/C UNIT . The heater core has a color mark that shows where to affix the seal -C-. The seal -D- must be applied to the center of the heater core as illustrated. The seal -C- may have different lengths (a short version as illustrated or a long version which reaches all the way around the heater core). If the heater core is delivered with the longer seal -C-, then attach it all the way around the heater core. Seal may curl up on insertion if not correctly bonded on. If the seal is damaged or installed incorrectly, cold air can flow over the heater core; on vehicles equipped with the "Comfort" A/C system, it is possible that there is no clear separation between the various areas.

Check the A/C unit and the evaporator -F- with the heater core removed -A- (via heater core opening) for dirt.

Remove any dirt or coolant which has leaked out of the A/C unit (for example, after removing a leaking heater core).

Check both connections -A- and -B- on the heater core -C- for damage and dirt.

Scheme 133

Grease both connections -A- and -B- on the heater core -C- with silicone grease.

Note. The silicone grease part number is G 000 405 A2.

Lightly moisten the seals -D- (contained in the heater core delivery) with coolant (or lightly with silicone grease).

Scheme 134

Install the new seals -D- on both heater core coolant pipes -E- and -F-.

Push the heater core -A- into the A/C unit.

Scheme 135

Support the heater core -A-, for example, with a plastic wedge -B- on the center tunnel -C- so that it cannot slip down when attaching the coolant pipes.

Install a longer screw -G- (with a M5 thread) all the way to the stop in the bracket -C- as shown in the illustration.

Install and push both coolant pipes -E- and -F- with each seal -D- into the heater core connector flange all the way. -H-.

Note. Do not bend the coolant pipes -D- and -E- when pushing them into the connections on the heater core.

Make sure the seals -C- between the coolant pipes -D- and -E- and the flange connection -B- on the heater core -A- fit securely.

Secure both coolant pipes -E- and -F- with the bracket -C- on the heater core flange -H-.

Note. The screw -G- is used to help with the installation and must be removed after the bracket is installed.

Insert the screw -A- and the washer -B- and tighten the screw -A-.

Screw tightening specification -A- 2.5 Nm.

Remove the screw -G-.

Make sure the grommet -H- fits correctly in the back of the plenum chamber.

Properly connect the coolant hoses to the heater core, pay attention to the marking.

A - Supply hose from cylinder head

B - Return to the coolant pump

Connect the coolant hose -A- to the heater core coolant pipe (pay attention to the marking) and secure it with the clamp -D-.

Attach the coolant hose for the heater core -B- onto the coolant pipe -F- just far enough as to not cover the bleed hole -G-.

Remove the hose clamp from the coolant hose -A-.

Fill the coolant expansion tank with coolant. Refer to [For engine(s) CAUA] General Information or to [For engine(s) CAEB] General Information or to [For engine(s) CALA] General Information .

Carefully force the coolant out of the coolant overflow reservoir into the heater core using, for example, the hand pump from the Cooling System Tester V.A.G 1274/.

As soon as the coolant comes out the ventilation hole -G-, install the coolant hose -B- on to the coolant pipe -F- at the marking.

Secure the coolant hose -B- with the clamp -E- on the marked location.

Remove the hose clamp from the coolant hose -D-.

If necessary, add more coolant to the coolant expansion tank. Refer to [For engine(s) CAUA] General Information or to [For engine(s) CAEB] General Information or to [For engine(s) CALA] General Information .

Note. This procedure completely bleeds the cooling system. If, for some other reason, there is still some air in the cooling system, install all removed components and bleed the system once again. Refer to [For engine(s) CAUA] General Information or to [For engine(s) CAEB] General Information or to [For engine(s) CALA] General Information .

Check the connections at the heater core for leaks as follows

Carefully increase the pressure in the coolant circuit by using, for example, the hand pump of the cooling system tester V.A.G 1274/.

Check coolant circuit for leaks, pay particular attention to the connection between coolant hoses and heater core. Refer to [For engine(s) CAUA] Diagnosis and Testing or to [For engine(s) CAEB] Diagnosis and Testing or to [For engine(s) CALA] Diagnosis and Testing .

Scheme 136

Note. When bleeding coolant circuit, take special care to ensure complete bleeding of heater cores. If there are still air bubbles in the heater core, it may cause the customer to complain of insufficient heating performance in winter or different air temperature from vents at same setting in regulated mode. Refer to HEAT OUTPUT AND TEMPERATURE DOOR ACTIVATION, CHECKING . Depending on vehicle equipment and on engine, heat insulation has been applied to coolant hoses, these must not be damaged and must be re-applied after installing.

Install all the components in reverse sequence, refer to HEATER CORE PREPARING FOR REMOVAL .

With high voltage systems (hybrid vehicles)

Install the cowl panel -C-. Refer to Removal and Installation .

Make sure the electric drive power and control electronics -JX1- -D- and wires -D- are installed correctly. Refer to GENERAL INFORMATION .

Energize the voltage to the high voltage system. Refer to GENERAL INFORMATION

Restart the high voltage system

Note. Restart the high voltage system: Connect the vehicle diagnosis tester Select the Guided Fault Finding mode Using the GO TO button, select the following menu commands Functions/Component selection Body Electrical Equipment OBD-capable system 8C - Hybrid battery management -J840 8C - Hybrid battery management, functions 51 - High voltage restart (Rep.Gr. 93)

For vehicles without a high voltage system

Reconnect the battery ground connection; when doing this, pay attention to the notes regarding reconnecting the battery. Refer to Removal and Installation .

All vehicles

Switch on the ignition.

Perform a basic setting and the output Diagnostic Test Mode (DTM) on the A/C system using the Vehicle diagnostic tester in "Guided Fault Finding".

Note. On this vehicle, the control motors are equipped with electronics. During the first basic setting, a new control motor learns its position on the air conditioner and can then be controlled by the Climatronic Control Module -J255- (currently all control motors are identical). Refer to the Vehicle diagnostic tester in "Guided Fault Finding". During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM (A/C control motors block diagram).

Switch on the ignition.

Check the Climatronic Control Module DTC memory and erase any displayed malfunction if necessary using the Vehicle diagnostic tester in "Guided Fault Finding".

Adjust and check the air flow direction on the different air ducts via Climatronic control module, if the quantity of air actually changes at each setting.

LEFT HEATER CORE HOUSING WITH TEMPERATURE DOORS

Note. The activation of the temperature doors and with it the heater core housing with the left temperature doors is different between vehicles equipped with "Comfort" and "Basis" A/C systems. Refer to AIR DISTRIBUTOR HOUSING DOORS AND PARTITIONS . To maintain the A/C stability, only one heater core housing (the left or right side) may be removed with the A/C installed. Depending on the production date, there are different versions of the levers and connections on the A/C unit. Refer to AIR CONDITIONER, LEVERS AND CONNECTING ELEMENTS .

Switch on the ignition.

Move the driver seat as far back as possible.

Turn off the ignition.

Remove the storage compartment under the dash panel on the driver side. Refer to Removal and Installation .

Remove the left footwell vent (driver side). Refer to LEFT FOOTWELL VENTS .

Remove the steering column. Refer to Removal and Installation .

Remove the pedal assembly and accelerator pedal module. Refer to Removal and Installation and Removal and Installation .

On a vehicle equipped with the "Comfort" A/C system, remove the retaining plate together with the left footwell door motor -V108- and the left center vent motor -V110- as well as the left temperature door motor -V158-. Refer to LEFT RETAINING PLATE WITH LEFT FOOTWELL DOOR MOTOR -V108- AND LEFT CENTER VENT MOTOR -V110 and LEFT TEMPERATURE DOOR MOTOR -V158 .

On a vehicle equipped with the "Basis" A/C system, remove the retaining plate together with the Footwell Door Motor -V261-. Refer to LEFT RETAINING PLATE WITH FOOTWELL DOOR MOTOR -V261 .

Remove the glove compartment. Refer to Removal and Installation .

Remove the right (passenger) footwell vent. Refer to RIGHT FOOTWELL VENT .

Carefully disconnect the connector rod -B- (so the lever does not get damaged) from the lever on the right temperature door -A-.

Scheme 137

Loosen the bolt -C-.

Loosen or remove the bolt -F- (installed beginning 07.2007, different versions).

Scheme 138

Note. At the start of production, A/C units were installed, where the left and right side of the heater core housing -D- and -E- were bolted together on the underside with the bolt -C-. Beginning 07.2007 as a running change, A/C units are being installed, where both heater core housings -D- and -E- are bolted together with the bolt -F-. From 07.2007 through 09.2007 and screw -F- and nut -G- was installed on the left heater core housing -D-. The left heater core housing -D- has a single hole and not a threaded connection. To remove and install the bolt -F- and the nut -G- on this control motor version, the Temperature Regulator Door Motor -V68- or the Rear Temperature Door Motor -V137- must be removed. Refer to TEMPERATURE REGULATOR DOOR MOTOR -V68- AND REAR TEMPERATURE DOOR MOTOR -V137 . You can place a catch on the holes on the right side of the heater core housing -E- which will prevent the bolt -C- (and the bolt -F-) from falling in the hole after being loosened.

Carefully disconnect the connector rod -A- (so the lever does not get damaged) from the lever on the defrost door -B-.

Scheme 139

Remove the screw -C-.

Remove the left heater core housing -D- (together with the Defroster door Motor -V107- and Temperature regulator door motor -V68- or the Rear temperature door motor -V137-) from the A/C. When doing this, pay attention to the lever on the defrost door -B- (and the lever on the door for the left center dash panel vent -E- on vehicles equipped with the "Comfort") A/C system).

Installation is carried out in the reverse order while observing the following.

Check the groove -A- on the left heater core housing -F- and the spring on the A/C -B- for damage.

Scheme 140

Note. If the groove -A- on the left heater core housing -F- or the spring on the A/C unit -B- are damaged, seal these with, for example, Silicone Adhesive D176 001 A3.

Check the heater core -C- and evaporator -D- for dirt; clean if necessary.

Check the foam seals on the heater core -C- and on the Auxiliary Air Heater Heating Element -Z35- (or on the honey comb on vehicles without an Auxiliary Air Heater Heating Element) for damage.

Insert the grooves -A- on the left heater core housing -F- into the springs on the A/C unit -B- and push the left heater core housing -F- into the A/C unit.

Note. Pay attention to the connector rod to the right temperature door -E- and the lever on the defroster door -G- (and the lever on the door for the left center dash panel vent on vehicles equipped with the "Comfort" A/C system).

Install the removed parts in the opposite order.

Switch on the ignition.

Perform a basic setting and the output Diagnostic Test Mode (DTM) on the A/C system using the Vehicle diagnostic tester in "Guided Fault Finding".

Note. On this vehicle, the control motors are equipped with electronics. During the first basic setting, a new control motor learns its position on the air conditioner and can then be controlled by the Climatronic Control Module -J255- (currently all control motors are identical). Refer to the Vehicle diagnostic tester in "Guided Fault Finding". During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM .

Check the Climatronic Control Module DTC memory and erase any displayed malfunction if necessary using the Vehicle diagnostic tester in "Guided Fault Finding".

RIGHT HEATER CORE HOUSING, MOTOR MOUNTING PLATE REMOVED

Note. From 01.2008, A/C units which have an additional connection for the glove compartment cooling are being installed GLOVE COMPARTMENT COOLING TO AIR INTAKE MANIFOLD CONNECTION . Make sure the correct right radiator housing and air intake hosing (different versions) are installed. The activation of the temperature doors and with it the right radiator housing is different between vehicles equipped with "Comfort" and "Basis" A/C systems. Refer to A/C UNIT AND AIR INTAKE HOUSING COMPONENTS . To maintain the A/C stability, only one radiator housing (the left or right side) may be removed with the A/C installed. Depending on the production date, there are different versions of the levers and connections on the A/C unit. Refer to AIR CONDITIONER, LEVERS AND CONNECTING ELEMENTS . Vehicles with the "Comfort" A/C system can have the right radiator housing and the mounting plate installed/removed for the motors removed/installed. Vehicles with the "Basis" A/C system do not have this mounting plate.

1. Vehicles with "Basis" A/C system (no motor mounting plate).
2. Vehicles with "Comfort" A/C system where the right mounting plate and motors and the right heater core housing must be removed one after the other.

Switch on the ignition.

Set the air flow direction to "DEF" on the Climatronic control module -J255-.

Move the passenger seats as far back as possible.

Turn off the ignition.

Remove the air intake housing. Refer to A/C UNIT AIR INTAKE HOUSING .

Vehicles with "Comfort" A/C system

Remove the right footwell door motor -V109- and right center vent motor -V111-. Refer to RIGHT RETAINING PLATE WITH RIGHT FOOTWELL DOOR MOTOR -V109- AND RIGHT CENTER VENT MOTOR -V111 .

Vehicles with "Basis" A/C system.

Remove the center vent adjustment motor -V102-. Refer to CENTER VENT ADJUSTMENT MOTOR -V102 .

All vehicles

Disconnect the connector from the Evaporator Vent Temperature Sensor -G263-. Refer to EVAPORATOR VENT TEMPERATURE SENSOR -G263 .

Carefully disconnect the connector rod -B- (so the lever does not get damaged) from the lever on the right temperature door -A-.

Note. Depending on the production date, there are different versions of the levers and connections on the A/C unit. Refer to AIR CONDITIONER, LEVERS AND CONNECTING ELEMENTS .

Loosen the bolt -C-.

Loosen or remove the bolt -F- (installed beginning 07.2007, different versions).

Note. At the start of production, A/C units were installed, where the left and right side of the heater core housing -D- and -E- were bolted together on the underside with the bolt -C-. Beginning 07.2007 as a running change, A/C units are being installed, where both heater core housings -D- and -E- are bolted together with the bolt -F-. From 07.2007 through 09.2007 and screw -F- and nut -G- was installed on the left heater core housing -D-. The left heater core housing -D- has a single hole and not a threaded connection. To remove and install the bolt -F- and the nut -G- on this control motor version, the Temperature Regulator Door Motor -V68- or the Rear Temperature Door Motor -V137- must be removed. Refer to TEMPERATURE REGULATOR DOOR MOTOR -V68- AND REAR TEMPERATURE DOOR MOTOR -V137 . You can place a catch on the holes on the right side of the heater core housing -E- which will prevent the bolt -C- (and the bolt -F-) from falling in the hole after being loosened.

On a vehicle equipped with the "Comfort" A/C system, mark the connector -A- (to prevent confusing it with other connectors) and remove.

Scheme 141

Note. The Right Temperature Door Motor -V159- is installed only on vehicles equipped with the "Comfort" A/C system.

Remove the screw -B-.

Remove the screw -C-.

Note. The bolt -C-, on vehicles equipped with the "Comfort" A/C system, was already moved when the Right Footwell Door Motor -V109- and the Right Center Vent Motor -V111- were removed.

Remove screws -D-.

On vehicles equipped with an auxiliary air heater heating element -Z35- loosen the cables -G- from the right heater core housing -E-. Refer to AUXILIARY AIR HEATER HEATING ELEMENT -Z35- / HONEY COMB .

Disconnect the right heater core housing -E- (together with the Right Temperature door Motor -V159-) from the A/C unit; when doing this, pay attention to the lever on the door for the dash panel vents -F- ("right center" on vehicles equipped with the "Comfort" A/C system, or "center" on vehicles equipped with the "Basis" A/C system).

Installation is carried out in the reverse order while observing the following.

Check the heater core -A- and evaporator -B- for dirt; clean if necessary.

Scheme 142

Check the foam seals on the heater core -A- and on the Auxiliary Air Heater Heating Element -Z35- -C- (or on the honey comb on vehicles without an Auxiliary Air Heater Heating Element) for damage.

Check the springs on the A/C unit - B- and the grooves -A- on the right heater core housing -C- for damage.

Scheme 143

Note. If the groove -A- on the right heater core housing -C- or the spring on the A/C unit -B- are damaged, seal these with, for example, Silicone Adhesive D176 001 A3.

Insert the grooves -A- on the right heater core housing into the springs on the A/C unit -B- and push the right heater core housing -C- into the A/C unit.

Note. On vehicles equipped an Auxiliary Air Heater Heating Element pay attention to the wiring -D- when installing the housing -C-. Pay attention to the lever on the door for the dash panel vents -F- ("right center" on vehicles equipped with the "Comfort" A/C system or "center" on vehicles equipped with the "Basis" A/C system).

Install the bolts -B- and -C-.

Install the removed parts in the opposite order

Switch on the ignition.

Perform a basic setting and the output Diagnostic Test Mode (DTM) on the A/C system using the Vehicle diagnostic tester in "Guided Fault Finding".

Note. On this vehicle, the control motors are equipped with electronics, during the first basic setting, a new control motor learns its position on the air conditioner and can then be controlled by the Climatronic Control Module -J255- (currently all control motors are identical). Refer to the Vehicle diagnostic tester in "Guided Fault Finding". During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM .

Check the Climatronic Control Module DTC memory and erase any displayed malfunction if necessary using the Vehicle diagnostic tester in "Guided Fault Finding".

RIGHT HEATER CORE HOUSING AND RIGHT MOTOR MOUNTING PLATE

Note. From 01.2008, A/C units which have an additional connection for the glove compartment cooling are being installed GLOVE COMPARTMENT COOLING TO AIR INTAKE MANIFOLD CONNECTION . Make sure the correct right radiator housing and air intake hosing (different versions) are installed. The activation of the temperature doors and with it the right radiator housing is different between vehicles equipped with "Comfort" and "Basis" A/C systems. Refer to A/C UNIT AND AIR INTAKE HOUSING COMPONENTS . To maintain the A/C stability, only one radiator housing (the left or right side) may be removed with the A/C installed. Depending on the production date, there are different versions of the levers and connections on the A/C unit. Refer to AIR CONDITIONER, LEVERS AND CONNECTING ELEMENTS . Vehicles with the "Comfort" A/C system can have the right radiator housing and the mounting plate installed/removed for the motors removed/installed. Vehicles with the "Basis" A/C system do not have this mounting plate.

1. The right motor mounting plate is installed only on vehicles with the "Comfort" A/C system.

Switch on the ignition.

Set the air flow direction to "DEF" on the Climatronic control module -J255-.

Move the passenger seats as far back as possible.

Turn off the ignition.

Remove the air intake housing. Refer to A/C UNIT AIR INTAKE HOUSING .

Remove the 2 screws -B- and remove the bracket -A-.

Scheme 144

Carefully disconnect the connector rod -B- (so the lever does not get damaged) from the lever on the right temperature door -A-.

Note. Depending on the production date, there are different versions of the levers and connections on the A/C unit. Refer to AIR CONDITIONER, LEVERS AND CONNECTING ELEMENTS .

Loosen the bolt -C-.

Loosen or remove the bolt -F- (installed beginning 07.2007, different versions).

Note. At the start of production, A/C units were installed, where the left and right side of the heater core housing -D- and -E- were bolted together on the underside with the bolt -C-. Beginning 07.2007 as a running change, A/C units are being installed, where both heater core housings -D- and -E- are bolted together with the bolt -F-. From 07.2007 through 09.2007 and screw -F- and nut -G- was installed on the left heater core housing -D-. The left heater core housing -D- has a single hole and not a threaded connection. To remove and install the bolt -F- and the nut -G- on this control motor version, the Temperature Regulator Door Motor -V68- or the Rear Temperature Door Motor -V137- must be removed. Refer to TEMPERATURE REGULATOR DOOR MOTOR -V68- AND REAR TEMPERATURE DOOR MOTOR -V137 . You can place a catch on the holes on the right side of the heater core housing -E- which will prevent the bolt -C- (and the bolt -F-) from falling in the hole after being loosened.

Disconnect the connector -A- from the evaporator vent temperature sensor -G263-. Refer to EVAPORATOR VENT TEMPERATURE SENSOR -G263 .

Scheme 145

Mark the connectors -B- (for the Right Footwell Door Motor -V109-), -C- (for the Right Center Vent Motor -V111-) and -D- (for the Right Temperature Door Motor -V159-) to avoid confusion.

Disconnect the connectors -B-, -C- and -D- from the motor.

Loosen the wiring harness -E- from the mounting points on the mounting plate.

Carefully loosen the different connecting rods (from -A- to -D-) from each door.

Scheme 146

Note. The connecting rods (from -A- through -D-) are clipped on to the levers; unclip them carefully so that the lever does not get damaged. Depending on the production date, there are different versions of the levers and connections on the A/C unit. Refer to AIR CONDITIONER, LEVERS AND CONNECTING ELEMENTS .

Remove bolts -E-.

On vehicles with an auxiliary air heater heating element, loosen the wiring from the right heater core housing. Refer to t AUXILIARY AIR HEATER HEATING ELEMENT -Z35- / HONEY COMB .

Pull the right heater core housing -A- (together with the mounting plate, motors and levers, curved washers and connecting rods) from the A/C unit.

Scheme 147

Installation is carried out in the reverse order while observing the following.

Check the heater core -A- and evaporator -B- for dirt; clean if necessary.

Check the foam seals on the heater core -A- and on the Auxiliary Air Heater Heating Element -C- (or on the honey comb on vehicles without an Auxiliary Air Heater Heating Element) for damage.

Check the springs on the A/C unit - B- and the grooves -A- on the right heater core housing -C- for damage.

Note. If the groove -A- on the right heater core housing -C- or the spring on the A/C unit -B- are damaged, seal these with, for example, Silicone Adhesive D176 001 A3.

Insert the grooves -A- on the right heater core housing into the springs on the A/C unit -B- and push the right heater core housing -C- just a little into the A/C unit.

Note. On vehicles with an auxiliary air heater heating element pay attention when pushing the housing -C- onto the wiring. Pay attention to the door lever for the instrument panel vent -C- "right center" and the different connecting rods for the doors on the air distribution housing.

Slide the lever on the door for the instrument panel vent -C- all the way up in the direction of arrow.

Note. Since the air flow direction was set to "DEF" on the Climatronic control module -J255- before removing the heater core housing, the curved washer -D- is now positioned so that the pin -B- fits into the groove in the washer -E- when the heater core housing is installed.

Line up the door connecting rods so they do not get caught when the heater core housing is completely installed.

Carefully push the heater core housing -A- all the way into the A/C unit.

Check the position of the pin -B- inside the groove in the curved washer -E- using an illuminated mirror or endoscope.

Install the screws -E-.

Carefully connect the various connector rods -A- through -D- to the lever of each door.

Note. The connecting rods (from -A- through -D-) are clipped into the levers; unclip them carefully so that the lever does not get damaged. Depending on the production date, there are different versions of the levers and connections on the A/C unit. Refer to AIR CONDITIONER, LEVERS AND CONNECTING ELEMENTS .

Install the screws -C- and -F-.

Carefully attach the connecting rod -B- (so the lever does not get damaged) on the lever on the right temperature flap -A-.

Note. Depending on the production date, there are different versions of the levers and connections on the A/C unit. Refer to AIR CONDITIONER, LEVERS AND CONNECTING ELEMENTS .

Route the wiring -E- into the mounting point on the mounting plate as illustrated so that any moving components cannot come in contact.

Connect the connector -B-, -C- and -D- according to the markings on the motors.

Install the removed parts in the opposite order.

Switch on the ignition.

Perform a basic setting and the output Diagnostic Test Mode (DTM) on the A/C system using the Vehicle diagnostic tester in "Guided Fault Finding".

Note. On this vehicle, the control motors are equipped with electronics. During the first basic setting, a new control motor learns its position on the air conditioner and can then be controlled by the Climatronic Control Module -J255- (currently all control motors are identical). Refer to the Vehicle diagnostic tester in "Guided Fault Finding". During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM .

Check the Climatronic Control Module DTC memory and erase any displayed malfunction if necessary using the Vehicle diagnostic tester in "Guided Fault Finding".

Adjust and check the air flow direction on the different air ducts via Climatronic control module, if the quantity of air actually changes at each setting.

HYBRID BATTERY RECIRCULATION DOOR POSITIONING MOTORS 1 AND 2 -V479- / -V480

With high voltage systems (hybrid vehicles)

Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system. Refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS and refer to GENERAL INFORMATION .

If it is necessary for the following procedure to perform work in the vicinity of high voltage components, perform a visual inspection of the high voltage components and cables for damages. Refer to VISUAL INSPECTION OF HIGH-VOLTAGE COMPONENTS AND CABLES FOR DAMAGE and always follow the warnings when working on the high voltage system. Refer to GENERAL INFORMATION .

Note. For these vehicles, both adjustment motors (for the hybrid battery recirculation door positioning motor 1 -V479- and the hybrid battery recirculation door positioning motor 2 -V480-) on the battery cooling module are controlled by the battery regulation control module -J840- via the data line. Both adjustment motors are connected to the battery regulation control module via the data line (LIN-Bus). If an adjustment motor is incorrectly installed and the adjustment motors and the battery cooling module are switched, there will be a malfunction in a control motor or in the wiring which may result in various DTC memory entries with different malfunction types. Refer to the Vehicle diagnostic tester in "Guided Fault Finding" and the appropriate SYSTEM WIRING DIAGRAMS information. The adjustment motors on the battery cooling module are identical to the adjustment motors on the A/C system, in that the battery regulation control module cannot perform any assignment for the adjustment motors. Only adjustment motors which are already assigned with the correct assignments may be installed on the battery cooling module. Follow the correct installation position when installing and the correct version (part number) when replacing. Refer to the Vehicle diagnostic tester in "Guided Fault Finding". Note that in the vehicle diagnosis, various terms and definitions are used for the adjustment motors hybrid battery recirculation door positioning motor 1 and hybrid battery recirculation door positioning motor 2 : The hybrid battery recirculation door positioning motor 1 is marked as " valve 1 for the air guide for the hybrid battery", the hybrid battery recirculation door positioning motor 2 as "valve 2 for the air guide for the hybrid battery".

Note. Note the correct allocations. The hybrid battery recirculation door positioning motor 1 -V479- has the part number "8R0 820 504" at the start of production for example and the hybrid battery recirculation door positioning motor 2 -V480- has the part number "8R0 820 510".

Turn off the ignition.

Remove the luggage compartment floor. Refer to Removal and Installation .

Hybrid battery recirculation door positioning motor 1

Scheme 148

Disconnect the electrical connector -1-.

Remove the bolts -arrows- and then remove the hybrid battery recirculation door positioning motor 1.

Hybrid battery recirculation door positioning motor 2

Scheme 149

Remove the bolts -arrows-.

Remove the hybrid battery recirculation door positioning motor 2 and disconnect the connector -1-.

Installation is carried out in the reverse order while observing the following.

Install the remaining removed components.

Switch on the ignition.

After installing, check and, if necessary, erase the displayed faults in the DTC memory for the Climatronic control module -J255- and the battery regulation control module -J840-. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

If necessary, after installing the functionality test, perform an output diagnostic test for both of the adjustment motors on the battery cooling module using the battery regulation control module. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

INSTRUMENT PANEL VENTS AND REAR VENTS

Special tools and workshop equipment required

1. Hook 3438

Note. The following illustrations show the location of the components on an Audi A5 Coupe; an Audi A5 Sportback, Audi A4, Audi Q5 etc., the location of the components varies slightly. Removing and installing the components is the same as described for the Audi A5 Coup e. Instrument panel vents -B- and -C- removing and installing, refer to Removal and Installation . Remove the vent in the rear center console in the same way as removing the vents in the instrument panel. Refer to Removal and Installation .

Turn off the ignition.

Open the affected vent.

Insert the 3438 -A- into the vent as shown in the illustration.

Swivel the 3438 -A- approximately 90° toward the vent housing; insert the hook into the removal holes inside the vent housing.

Carefully remove instrument panel vent -B- or -C- from the instrument panel.

INTERIOR TEMPERATURE SENSOR FAN -V42

Note. The same Interior Temperature Sensor Fan -B- is currently installed in both versions of the Climatronic Control Module -J255- ("Basis" -E- and "Comfort" -F-) The blowers run at different rpm's (approximately 2, 500 to 3, 200 rpm on the "Basic" A/C system and approximately 2, 800 to 3, 500 rpm on the "Comfort" A/C system) due to the different installation locations of the A/C Control Head. Check using the Vehicle diagnostic tester in "Guided Fault Finding". Depending on the version of the Climatronic control module there may be a molded seal -C-. Install if necessary.

Remove the Climatronic control module. Refer to CLIMATRONIC CONTROL MODULE -J255- A/C CONTROL HEAD .

Remove bolts -A-.

Remove the interior temperature sensor fan -B- out of the Climatronic control module.

Installation is carried out in the reverse order while observing the following.

When installing interior temperature sensor fan, do not press on the fan wheel -D-, hold fan firmly at housing instead.

Switch on the ignition.

Check the Climatronic control module DTC memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

LEFT FRONT UPPER BODY VENT TEMPERATURE SENSOR -G385

Note. The Left Front Upper Body Outlet Temperature Sensor is installed only on vehicles with a "Comfort" version A/C system.

Turn off the ignition.

Remove the storage compartment on driver's side. Refer to Removal and Installation .

Disconnect the connector -A- from the temperature sensor.

Scheme 150

Turn the left front upper body vent temperature sensor -B- 90° and remove it from the mount inside the air guide channel -D-.

Installation is carried out in the reverse order while observing the following.

Check the seal -C- for damage and proper seating.

Switch on the ignition.

Check the Climatronic control module -J255- DTC memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

RIGHT FRONT UPPER BODY VENT TEMPERATURE SENSOR -G386

Note. The Right Front Upper Body Outlet Temperature Sensor is installed only on vehicles with a "Comfort" version A/C system.

Turn off the ignition.

Remove the glove compartment. Refer to Removal and Installation .

Disconnect the connector -A- from the temperature sensor.

Scheme 151

Turn the right front upper body vent temperature sensor -B- 90° and remove it from the mount inside the air channel guide -D-.

Installation is carried out in the reverse order while observing the following.

Check the seal -C- for damage and proper seating.

Switch on the ignition.

Check the Climatronic control module -J255- DTC memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

RIGHT FOOTWELL VENT TEMPERATURE SENSOR -G262

Note. The Right Footwell Vent Temperature Sensor is installed only on vehicles equipped with the "Comfort" A/C system.

Move the passenger seats as far back as possible.

Turn off the ignition.

Remove the glove compartment. Refer to Removal and Installation .

Remove the right footwell vent (passenger side) -C-. Refer to RIGHT FOOTWELL VENT .

Disconnect connector -A-.

Turn the sensor -D- 90° and remove it from the right footwell vent -C-.

Scheme 152

Installation is carried out in the reverse order while observing the following.

Check the seal -E- for damage and proper seating.

Install the removed parts in the opposite order.

Check the Climatronic control module -J255- DTC memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

Move the passenger seats as far back as possible.

Turn off the ignition.

Remove the glove compartment. Refer to Removal and Installation .

Remove the right (passenger) footwell vent. Refer to RIGHT FOOTWELL VENT .

Disconnect connector -A-.

Scheme 153

Loosen the evaporator vent temperature sensor -B- from the A/C bracket -C-.

Turn the evaporator vent temperature sensor -B- 180° and remove it from the A/C unit.

Note. The evaporator vent temperature sensor -B- is installed so that the temperature sensor -D- is facing the evaporator. To remove and install it when the air intake housing is installed, it must be turned it its mount 180° out of installation position after loosening or before tightening.

Installation is carried out in the reverse order while observing the following.

Loosen the evaporator vent temperature sensor -B- from the mount -C-.

Turn the evaporator vent temperature sensor -B- 180° and the mount it in the bracket.

Install the removed parts in the opposite order.

Switch on the ignition.

Check the Climatronic control module -J255- DTC memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

CENTER VENT TEMPERATURE SENSOR -G191

Note. The Center Outlet Temperature Sensor is installed only on vehicles equipped with the "Basis" A/C system.

Turn off the ignition.

Remove the radio or the CD changer (depending on the vehicle equipment level). Refer to Removal and Installation .

Reach through the installation shaft and disconnect the connector -A-.

Scheme 154

Turn the sensor -B- 90° and remove it from the air guide channel leading the "center" instrument panel vents.

Installation is carried out in the reverse order while observing the following.

Check the seal -C- for damage and proper seating.

Install the removed parts in the opposite order.

Switch on the ignition.

Check the Climatronic control module -J255- DTC memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

FOOTWELL VENT TEMPERATURE SENSOR -G192- / LEFT FOOTWELL VENT TEMPERATURE SENSOR -G261

The Footwell Outlet Temperature Sensor is installed only on vehicles equipped with the "Basis" A/C system.

The Left Footwell Vent Temperature Sensor is installed only on vehicles equipped with the "Comfort" A/C system.

Note. Different designation, of the currently identical sensor, depending on the A/C version. Refer to A/C UNIT AND AIR INTAKE HOUSING COMPONENTS (A/C components)

Move the driver seat as far back as possible.

Turn off the ignition.

Remove the storage compartment under the dash panel on the driver's side. Refer to Removal and Installation .

Disconnect connector -A-.

Scheme 155

Turn the sensor -B- 90° and remove it from the left (driver's side) footwell vent.

Installation is carried out in the reverse order while observing the following.

Check the seal -C- for damage and proper seating.

Reinstall the removed parts in the opposite order.

Check the Climatronic control module -J255- DTC memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

LEFT FOOTWELL VENTS

Move the driver seat as far back as possible.

Turn off the ignition.

Remove the storage compartment on driver's side. Refer to Removal and Installation .

Disconnect the terminal -C- from the Footwell Vent Temperature Sensor -G192- / Left Footwell Vent Temperature Sensor -G261-.

Scheme 156

Remove screws -A-.

Left footwell vent -B-, removing

Installing

Installation is carried out in the reverse order while observing the following.

Switch on the ignition.

Check the Climatronic control module -J255- DTC memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

OUTSIDE AIR TEMPERATURE SENSOR -G17

Note. The vehicle electrical system control module -J519- evaluates the measured values from the outside air temperature sensor and then transmits them to the Climatronic control module -J255- (and to the control module in the instrument cluster -J285-) via the Data bus. Refer to the Vehicle diagnostic tester in "Guided Fault Finding". The illustration shows the allocation of the outside air temperature sensor -A- on the Audi A5 Coupe, the Audi A5 Sportback, the Audi A4, Audi Q5 etc. The allocation can vary. If the vehicle has an outside air temperature sensor -A- and mount -B- installed on the air intake grille above the bumper, it is possible that a higher temperature may register due to the installation location of the sensor because the heater core and condenser are radiating heat, for example on MY 08 vehicles. Beginning with MY 09, the location of the outside air temperature sensor -A- has been moved. The outside air temperature sensor and the new bracket -C- have been move slightly forward, closer to the radiator grille and under the impact member -D-. The measured value can be too high on vehicles that have the outside air temperature sensor -A- and mount -B- installed on the air intake grille above the impact member. Install the outside air temperature sensor -A- and the revised bracket -C- slightly forward and under the bumper -D-. The wire connections may have to be lengthened. The bracket -C- is clipped into the impact member -D-. It may be necessary to drill a 7 mm hole into the impact member -D-.

Turn off the ignition.

Remove the upper cover on the lock carrier cover. Refer to Description and Operation .

Disconnect the connector -E- on the temperature sensor -A- and remove the temperature sensor from the bracket (-B- or -D-).

Note. It may be necessary to first remove the bumper in order to remove the outside air temperature sensor -A- from the bracket -C- under the impact member -D- if the sensor is not accessible from above.

After installing, check the Climatronic control module DTC memory (and the instrument cluster control module -J285- DTC memory) and erase any faults. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

PASSENGER COMPARTMENT FORCED AIR EXTRACTION

Note. The following is a test for the forced air extraction on an Audi A5 Coupe. On other vehicles such as the Audi A5 Sportback, Audi A4, Audi Q5 etc, the location of the components may differ, but removing and installing the components is identical. On the Audi A4 sedan, the passenger compartment is ventilated by an opening between the rear window -B- and the rear shelf -A- (in the body) into the luggage compartment. The air is guided through the ventilation openings -C- in the space between the body and the luggage compartment trim -D-. On the Audi A4 Avant/Allroad and the Audi Q5 the air is routed on the left and right sides through the vents in the side trim -A- and in the back of the luggage compartment. From there the air flows to the ventilation frame -B-. On the roof is closed on the Audi A5 Cabrio, for example, over the openings near the rear shelf -A- (behind the head restraints -B-), the air is guided through the safety belt guides -C- and through the roof trim -D-. The passenger compartment on the Audi A5 Cabrio is ventilated the same way as on the other vehicles when the roof is closed. There are ventilation slots -C- in the luggage compartment trim panel -B-, which guide the air to the ventilation frame for forced air extraction -A-. One vent frame -A- is installed in the body vent opening -C- on the left and the right for the forced air extraction. Forced air extraction vent frames -A- are removed and installing from the outside (with the bumper cover removed). There are different versions of the vent frame for the forced air extraction -A- on vehicles with and without noise insulation -D-. Installing the noise insulation -D- depends on the version of the vehicle. It may be necessary to remove the auxiliary battery -A1- in order to access the left noise insulation on vehicles with a high voltage system (hybrid vehicles) -D-. Refer to Removal and Installation .

Checking the ventilation openings in the luggage compartment trim panel

Check the ventilation passage in the luggage compartment trim panel on both the left and right side -C- and in the rear luggage compartment trim pane (left and right) -A- to make sure they are not blocked.

Note. To ensure proper passenger compartment ventilation, the left and right ventilation frames -C- in the luggage compartment trim panel must not be blocked. Obstructed ventilation frames in the luggage compartment trim panels -C- or obstructed vents in the ventilation frames -A- can cause the windows to fog up. The illustration shows the luggage compartment on an Audi A5 Coupe. On the Audi A5 Sportback, the Audi A4, the Audi Q5 etc, the location of the components may differ.

Check forced air extraction vent frames from inside

Remove luggage compartment trim panel (left and right). Refer to Removal and Installation .

Make sure the left and right ventilation frames -A- are not obstructed.

Note. Sealing lips -B- in vent frames -A- must move freely and close by themselves, stuck sealing lips -B- can cause windows to fog. On vehicles equipped with noise insulation -D-, make sure the air vent under the noise insulation -arrow- leading to the ventilation frame -A- is not obstructed by objects. Closed or plugged air ducts to the vent frames -A- can cause windows to fog. To ensure sealing lips -B- close correctly, vent frame -A- must be installed on the correct side.

FORCED AIR EXTRACTION VENT FRAMES, CHECKING FROM OUTSIDE, REMOVING AND INSTALLING

Remove the rear bumper cover. Refer to Removal and Installation .

Make sure the left and right ventilation frames -A- are not obstructed and that the sealing lips -B- function properly.

Scheme 157

Note. Stuck sealing lips -B- can cause windows to fog. The ventilation frames -A- can only be installed in one position to ensure the sealing lips -B- close correctly. In this illustration, ventilation frame -A- is depicted with rear bumper cover removed. When installing, vent frame -A- should be pressed into opening on the rear lid end piece until all retaining tabs engage securely.

PLENUM CHAMBER WATER DRAIN

With high voltage systems (hybrid vehicles)

Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system. Refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS and refer to GENERAL INFORMATION .

If it is necessary for the following procedure to perform work in the vicinity of high voltage components, perform a visual inspection of the high voltage components and cables for damages. Refer to VISUAL INSPECTION OF HIGH-VOLTAGE COMPONENTS AND CABLES FOR DAMAGE and always follow the warnings when working on the high voltage system. Refer to GENERAL INFORMATION .

Turn off the ignition.

Remove the rubber seal -A- and the plenum chamber cover -B- (there are different versions). Refer to Removal and Installation .

1. Inspect the high voltage components -D- (the electric drive power and control electronics -JX1-) and the high voltage cables -E- after removing the plenum chamber cover -B-. Refer to «VISUAL INSPECTION OF HIGH-VOLTAGE COMPONENTS AND CABLES FOR DAMAGE»(/audi/a5/i-2007-2011/remont/automatic-hvac-system/#air-conditioning-coupe-1-of-2__visual-inspection-of-high-voltage-components-and) and GENERAL INFORMATION .

1. Be careful not to damage any high voltage components -D- or the high voltage cables -E-. Refer to GENERAL INFORMATION .
2. Inspect the high voltage components -D- and high voltage cables -E- after completing the work procedure and before installing the plenum chamber cover -B-. Refer to GENERAL INFORMATION .

Note. Remove the cowl panel -C- if it is necessary to clean the water drains. Refer to Description and Operation .

For vehicles without a high voltage system

Turn off the ignition.

Remove the plenum chamber cover and/or the cowl panel (there are different versions). Refer to Removal and Installation .

All vehicles

Note. The following illustrations show the location of the components on an Audi A5 Coupe; an Audi A5 Sportback, Audi A4, Audi Q5 etc., the location of the components varies slightly. The description of the components is not different; removing, installing and checking is performed in the same way as on the Audi A5 Coupe. The draining of water from plenum chamber may be impaired by deposits (leaves, diverse tree needles etc.) accumulating in plenum chamber water drains -A-. The water level in the plenum chamber then rises if the vehicle is taken to an automatic car wash or in the event of heavy rain, water enters via intake housing into the A/C unit and is blown by the Fresh Air Blower -V2- onto the evaporator together with the air conveyed. If both water drain grommets -A- (right and left in plenum chamber) are blocked by leaves and pine needles, it may cause the drains to freeze up in winter and water can no longer drain out. After a short drive, heat emitted from engine and exhaust system melts the ice in the drains again and water may drain off again before vehicle arrives at the workshop. The water drain grommets -A- are snapped into the plenum chamber openings from above. In addition to the two water drain grommets -A- there is an opening on the right side of the body -C- in which water can drain out behind the wheel housing in case both water drain grommets -A- should become obstructed. Likewise, make sure these openings are not obstructed by dirt.

Checking and cleaning

Remove the plenum chamber cover, if necessary (there are different versions). Refer to Removal and Installation .

Note. Use a commercially available and illuminated endoscope for example, to check the water drains that are difficult to reach. It is best to use one that has a flexible waterproof head. Use a commercially available flexible gripping tool to clean for example, coarse dirt from difficult to reach water drains. Then wash out the any remaining contaminates.

Clean the left and right water drains -A-.

Clean the plenum channel from debris (leaves, pine tree needles) and other objects.

Check the function of the -A- grommets (the valves -B- must not stick or be obstructed with dirt)

Remove the grommets -B- by pressing them from the top, out the water drain openings -A-.

Install the grommets -A- by pressing them from the top, into the water drain openings.

Check the function of the -A- grommets after installing them (the valves -B- must not stick and must close)

FRONT REFRIGERANT LINES TO BATTERY COOLING MODULE

With high voltage systems (hybrid vehicles)

Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system. Refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS and refer to GENERAL INFORMATION .

If it is necessary for the following procedure to perform work in the vicinity of high voltage components, perform a visual inspection of the high voltage components and cables for damages. Refer to VISUAL INSPECTION OF HIGH-VOLTAGE COMPONENTS AND CABLES FOR DAMAGE and always follow the warnings when working on the high voltage system. Refer to GENERAL INFORMATION

Special tools and workshop equipment required

1. Pry Lever 80 - 200

Turn off the ignition.

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Remove the left aerodynamic trim panel. Refer to Description and Operation .

Scheme 158

Free up the electric wire -1- using pry Lever 80 - 200 -arrows-.

Move the heat shield -2- slightly to the right.

Free up the wiring harness -2-.

Scheme 159

Remove the nut -1- and bolts -3, 5- and disconnect the refrigerant lines -4, 6-.

Remove the nuts -arrows- and bolts -1, 2- and disconnect the refrigerant lines.

Scheme 160

Note. Close all open lines and connections on the refrigerant line with suitable caps (avoid dirt and moisture from entering the system).

Remove the nuts -arrows- and the front refrigerant pipes.

Scheme 161

Installation is carried out in the reverse order while observing the following.

Note. Follow the instructions for installing the O-rings. Refer to REFRIGERANT CIRCUIT O-RINGS . Following attachment, check routing of refrigerant pipes. They must be inserted in holders provided and not make contact with other components.

Replace the O-ring seals -4- depending on the version.

Scheme 162

Clean the refrigerant line connections -3, 5- and inspect them for damage.

Make sure the O-ring fits correctly inside the grooves -4- on the respective mounts.

Inspect the alignment pin -2- (not present on all connections) for damage and make sure that it is seated correctly.

Tighten the bolts -1-.

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Install the remaining removed components.

Electrical connections and routing, refer to the appropriate SYSTEM WIRING DIAGRAMS information.

Switch on the ignition.

Check the event memory of the Climatronic control module -J255-, and erase any displayed malfunctions using the Vehicle diagnostic tester in "Guided Fault Finding".

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Note. Note the information regarding operating the A/C system after filling. Refer to A/C Service Station in Description and Operation .

REAR REFRIGERANT LINES TO BATTERY COOLING MODULE

With high voltage systems (hybrid vehicles)

Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system. Refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS and refer to GENERAL INFORMATION .

If it is necessary for the following procedure to perform work in the vicinity of high voltage components, perform a visual inspection of the high voltage components and cables for damages. Refer to VISUAL INSPECTION OF HIGH-VOLTAGE COMPONENTS AND CABLES FOR DAMAGE and always follow the warnings when working on the high voltage system. Refer to GENERAL INFORMATION

Turn off the ignition.

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Remove the left aerodynamic trim panel. Refer to Description and Operation .

Remove the EVAP canister. Refer to [For engine(s) CAUA, CAEB, CALA] Removal and Installation .

Open the retainer -arrow A-, pull it to the right -arrow B- and free up the wire -1- on the bracket.

Scheme 163

Remove the nuts -arrows- and move the heat shield -1- slightly downward.

Scheme 164

Remove the nut -arrow- from the bracket for the refrigerant pipes.

Scheme 165

Remove the nuts -arrows- and bolts -1, 2- and disconnect the refrigerant lines.

Remove the bolts -1, 3- and disconnect and remove the refrigerant lines -2, 4-.

Scheme 166

Note. Close all open lines and connections on the refrigerant line with suitable caps (avoid dirt and moisture from entering the system).

Installation is carried out in the reverse order while observing the following.

Note. Follow the instructions for installing the O-rings. Refer to REFRIGERANT CIRCUIT O-RINGS . Following attachment, check routing of refrigerant pipes. They must be inserted in holders provided and not make contact with other components.

Replace the O-ring seals -4- depending on the version.

Clean the refrigerant line connections -3, 5- and inspect them for damage.

Make sure the O-ring fits correctly inside the grooves -4- on the respective mounts.

Inspect the alignment pin -2- (not present on all connections) for damage and make sure that it is seated correctly.

Tighten the bolts -1-.

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Install the remaining removed components.

Electrical connections and routing, refer to the appropriate SYSTEM WIRING DIAGRAMS information.

Switch on the ignition.

Check the event memory of the Climatronic control module -J255-, and erase any displayed malfunctions using the Vehicle diagnostic tester in "Guided Fault Finding".

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Note. Note the information regarding operating the A/C system after filling. Refer to A/C Service Station in Description and Operation .

PASS-THROUGH REFRIGERANT LINES IN LUGGAGE COMPARTMENT

With high voltage systems (hybrid vehicles)

Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system. Refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS and refer to GENERAL INFORMATION .

If it is necessary for the following procedure to perform work in the vicinity of high voltage components, perform a visual inspection of the high voltage components and cables for damages. Refer to VISUAL INSPECTION OF HIGH-VOLTAGE COMPONENTS AND CABLES FOR DAMAGE and always follow the warnings when working on the high voltage system. Refer to GENERAL INFORMATION

The following procedure requires working on the high voltage system. De-energize the high voltage system. Refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS , GENERAL INFORMATION and Read and follow the high voltage electrical system general warnings. Refer to GENERAL INFORMATION .

De-energize the high voltage system. Refer to GENERAL INFORMATION .

Disable the high voltage system

Note. Disable the high voltage system: Connect the vehicle diagnosis tester Select the Guided Fault Finding mode Using the GO TO button, select the following menu commands Functions/Component selection Body Electrical Equipment OBD-capable system 8C - Hybrid battery management -J840 8C - Hybrid battery management, functions 51 - Disable the high voltage system (Rep.Gr. 93)

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Remove the traction battery. Refer to REMOVAL AND INSTALLATION .

Remove the bolts -2 and 4- and the refrigerant pipes -1 and 3-.

Scheme 167

Remove the bolts -1, 3- and disconnect and remove the refrigerant lines -2, 4-.

Note. Close all open lines and connections on the refrigerant line with suitable caps (avoid dirt and moisture from entering the system).

Remove the nuts -arrows- and remove the pass-through for the refrigerant lines -1-.

Scheme 168

Installation is carried out in the reverse order while observing the following.

Note. If the seal for the pass-through is damaged, seal the seal in this spot with for example, silicone adhesive D 176 001 A3. The adhesive surface must be clean and free of grease when applying the silicone adhesive.

Install the rear refrigerant lines on the floor panel for the battery cooling module. Refer to REAR REFRIGERANT LINES TO BATTERY COOLING MODULE .

Install the refrigerant lines for the battery cooling module in the luggage compartment. Refer to REFRIGERANT LINES FOR BATTERY COOLING MODULE IN LUGGAGE COMPARTMENT .

Install the remaining removed components.

Electrical connections and routing, refer to the appropriate SYSTEM WIRING DIAGRAMS information.

Energize the voltage to the high voltage system. Refer to GENERAL INFORMATION

Restart the high voltage system

Note. Restart the high voltage system: Connect the vehicle diagnosis tester Select the Guided Fault Finding mode Using the GO TO button, select the following menu commands Functions/Component selection Body Electrical Equipment OBD-capable system 8C - Hybrid battery management -J840 8C - Hybrid battery management, functions 51 - High voltage restart (Rep.Gr. 93)

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Switch on the ignition.

Check and, if necessary, erase the displayed faults in the DTC memory for the Climatronic control module -J255- display and control head and the A/C compressor control module -J842-. Refer to Vehicle Diagnosis Tester in the Guided Fault Finding Function.

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Note. Note the information regarding operating the A/C system after filling. Refer to A/C Service Station in Description and Operation .

EXPANSION VALVE WITH HYBRID BATTERY REFRIGERANT SHUT-OFF VALVE 2 -N517

With high voltage systems (hybrid vehicles)

Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system. Refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS and refer to GENERAL INFORMATION .

If it is necessary for the following procedure to perform work in the vicinity of high voltage components, perform a visual inspection of the high voltage components and cables for damages. Refer to VISUAL INSPECTION OF HIGH-VOLTAGE COMPONENTS AND CABLES FOR DAMAGE and always follow the warnings when working on the high voltage system. Refer to GENERAL INFORMATION

Turn off the ignition.

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Remove the luggage compartment floor. Refer to Removal and Installation .

Remove the bolts -2, 3- and remove the refrigerant lines -1, 4-.

Scheme 169

Disconnect and remove the electrical connector -2- from the mount.

Scheme 170

Remove screws -1-.

Remove the hybrid battery refrigerant shut-off valve 2 -N517- -3- from the refrigerant lines for the evaporator.

Note. Close all open lines and connections on the refrigerant line with suitable caps (avoid dirt and moisture from entering the system).

Scheme 171

Installation is done is reverse order, observe the following

Clean the connection pipe -C- and -E- leading to the evaporator and the expansion valve connections, and check for damage.

Note. Expansion valve is available in different versions (same housing but a different control characteristic), therefore ensure the exact allocation. Follow the instructions for installing the O-rings. Refer to REFRIGERANT CIRCUIT O-RINGS .

Replace the O-rings -B- and -F-.

Coat the O-ring seals with refrigerant oil prior to installation. Refer to REFRIGERANT CIRCUIT O-RINGS .

Make sure the retaining plate -D- fits correctly on the connection pipes -C- and -E- leading to the evaporator.

Tighten the screws -G-.

1. Tightening specification: 10 Nm.

Install the refrigerant lines for the battery cooling module in the luggage compartment. Refer to REFRIGERANT LINES FOR BATTERY COOLING MODULE IN LUGGAGE COMPARTMENT .

Install the remaining removed components.

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Switch on the ignition.

Check the event memory of the Climatronic control module -J255-, and erase any displayed malfunctions using the Vehicle diagnostic tester in "Guided Fault Finding".

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Note. Note the information regarding operating the A/C system after filling. Refer to A/C Service Station in Description and Operation .

REFRIGERANT LINES FOR BATTERY COOLING MODULE IN LUGGAGE COMPARTMENT

With high voltage systems (hybrid vehicles)

Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system. Refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS and refer to GENERAL INFORMATION .

If it is necessary for the following procedure to perform work in the vicinity of high voltage components, perform a visual inspection of the high voltage components and cables for damages. Refer to VISUAL INSPECTION OF HIGH-VOLTAGE COMPONENTS AND CABLES FOR DAMAGE and always follow the warnings when working on the high voltage system. Refer to GENERAL INFORMATION

The following procedure requires working on the high voltage system. De-energize the high voltage system. Refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS , GENERAL INFORMATION and Read and follow the high voltage electrical system general warnings. Refer to GENERAL INFORMATION .

Disable the high voltage system

Note. Disable the high voltage system: Connect the vehicle diagnosis tester Select the Guided Fault Finding mode Using the GO TO button, select the following menu commands Functions/Component selection Body Electrical Equipment OBD-capable system 8C - Hybrid battery management -J840 8C - Hybrid battery management, functions 51 - Disable the high voltage system (Rep.Gr. 93)

Turn off the ignition.

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Remove the high voltage battery. Refer to REMOVAL AND INSTALLATION .

Remove the bolts -2, 3- and remove the refrigerant lines -1, 4-.

Remove the bolts -2 and 4- and disconnect and remove the refrigerant pipes -1 and 3-.

Note. Close all open lines and connections on the refrigerant line with suitable caps (avoid dirt and moisture from entering the system).

Installation is carried out in the reverse order while observing the following.

Note. Follow the instructions for installing the O-rings. Refer to REFRIGERANT CIRCUIT O-RINGS . Following attachment, check routing of refrigerant pipes. They must be inserted in holders provided and not make contact with other components.

Replace the O-ring seals -4- depending on the version.

Clean the refrigerant line connections -3, 5- and inspect them for damage.

Make sure the O-ring fits correctly inside the grooves -4- on the respective mounts.

Inspect the alignment pin -2- (not present on all connections) for damage and make sure that it is seated correctly.

Tighten the bolts -1-.

Install the remaining removed components.

Electrical connections and routing, refer to the appropriate SYSTEM WIRING DIAGRAMS information.

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Energize the voltage to the high voltage system. Refer to HIGH VOLTAGE SYSTEM, ENERGIZING

Restart the high voltage system

Note. Restart the high voltage system: Connect the vehicle diagnosis tester Select the Guided Fault Finding mode Using the GO TO button, select the following menu commands Functions/Component selection Body Electrical Equipment OBD-capable system 8C - Hybrid battery management -J840 8C - Hybrid battery management, functions 51 - High voltage restart (Rep.Gr. 93)

Switch on the ignition.

Check and, if necessary, erase the displayed faults in the DTC memory for the Climatronic control module -J255- display and control head and the A/C compressor control module -J842-. Refer to Vehicle Diagnosis Tester in the Guided Fault Finding Function.

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Note. Note the information regarding operating the A/C system after filling. Refer to A/C Service Station in Description and Operation .

HYBRID BATTERY REFRIGERANT SHUT-OFF VALVE 1 -N516

With high voltage systems (hybrid vehicles)

Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system. Refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS and refer to GENERAL INFORMATION .

If it is necessary for the following procedure to perform work in the vicinity of high voltage components, perform a visual inspection of the high voltage components and cables for damages. Refer to VISUAL INSPECTION OF HIGH-VOLTAGE COMPONENTS AND CABLES FOR DAMAGE and always follow the warnings when working on the high voltage system. Refer to GENERAL INFORMATION

Turn off the ignition.

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Free up the clip -2- for the wiring harness on the refrigerant pipe.

Remove the bolt -3- and separate the refrigerant pipe -4-.

Note. Ignore -items 1, 5, 6-.

Disconnect and remove the electrical connector -3- from the mount.

Scheme 172

Remove the union nuts -1 and 2-. Counterhold on the connection while doing this and remove hybrid battery refrigerant shut-off valve 1.

Installation is carried out in the reverse order while observing the following.

Note. Follow the instructions for installing the O-rings. Refer to REFRIGERANT CIRCUIT O-RINGS . Following attachment, check routing of refrigerant pipes. They must be inserted in holders provided and not make contact with other components.

Replace the O-ring seals depending on the version.

Install the union nuts -1 and 2- all the way by hand and then tighten them.

1. Union nut tightening specification -1 and 2- : 16.5 Nm

Note. Make certain when tightening the union nuts that the refrigerant lines are not taut.

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Switch on the ignition.

Check and, if necessary, erase the displayed faults in the DTC memory for the Climatronic control module -J255- and the A/C compressor control module -J842-. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Note. Note the information regarding operating the A/C system after filling. Refer to A/C Service Station in Description and Operation .

BATTERY COOLING MODULE

With high voltage systems (hybrid vehicles)

Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system. Refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS and refer to GENERAL INFORMATION .

If it is necessary for the following procedure to perform work in the vicinity of high voltage components, perform a visual inspection of the high voltage components and cables for damages. Refer to VISUAL INSPECTION OF HIGH-VOLTAGE COMPONENTS AND CABLES FOR DAMAGE and always follow the warnings when working on the high voltage system. Refer to GENERAL INFORMATION

Turn off the ignition.

Draini the refrigerant circuit. Refer to A/C Service Station in Description and Operation

Remove the air guide air inlet for the traction battery. Refer to TRACTION BATTERY INLET AIR GUIDE .

Remove the bolts -2, 3- and remove the refrigerant lines -1, 4-.

Note. Close all open lines and connections on the refrigerant line with suitable caps (avoid dirt and moisture from entering the system).

Disconnect and free up the connectors -1, 2-.

Scheme 173

Remove the nuts -arrows- and remove the battery cooling module.

Installation is carried out in the reverse order while observing the following.

Note. Follow the instructions for installing the O-rings. Refer to REFRIGERANT CIRCUIT O-RINGS . Following attachment, check routing of refrigerant pipes. They must be inserted in holders provided and not make contact with other components.

Replace the O-ring seals -4- depending on the version.

Clean the refrigerant line connections -3, 5- and inspect them for damage.

Make sure the O-ring fits correctly inside the grooves -4- on the respective mounts.

Inspect the alignment pin -2- (not present on all connections) for damage and make sure that it is seated correctly.

Tighten the bolts -1-.

Install the refrigerant lines for the battery cooling module in the luggage compartment. Refer to REFRIGERANT LINES FOR BATTERY COOLING MODULE IN LUGGAGE COMPARTMENT .

Install the remaining removed components.

Electrical connections and routing, refer to the appropriate SYSTEM WIRING DIAGRAMS information.

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Switch on the ignition.

Check the event memory of the Climatronic control module -J255-, and erase any displayed malfunctions using the Vehicle diagnostic tester in "Guided Fault Finding".

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Note. Note the information regarding operating the A/C system after filling. Refer to A/C Service Station in Description and Operation .

REFRIGERANT LINES DISCONNECTING FROM QUICK-RELEASE COUPLINGS AND CONNECTING

Special tools and workshop equipment required

1. Release tool for the refrigerant lines T40149
2. Removal tool T40232 (if the connections cannot be unlocked with T40149)

Turn off the ignition.

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Note. Depending on the allocation of the service connection and on the refrigerant line, and on the version of the vehicle, it may be necessary to remove the additional reinforcement on the left suspension strut dome so that the service coupling of the service station can be connected (for example, on the Audi Q5). Refer to Removal and Installation and Description and Operation . There are different quick-release coupling versions -A- and -D-. The refrigerant lines -C- can unlocked and removed using the release tool T40149/1 in the same manner with both versions. The check pins on the -B- quick-release couplings -A- installed at Start Of Production are visible after installing the refrigerant line -C-, when the locked refrigerant line -C- is pulled in the direction of arrow. Beginning with MY 2010, as a running change, the quick-release coupling -D- installed and the refrigerant line -C- are being installed in the same manner as the quick-release coupling -A-. If the refrigerant line -C- is pulled in the direction of arrow after assembling, the ring -E- will come out of the quick-release coupling -D- and will show that the retaining ring -F- is completely latched to the refrigerant line -C-. Then the ring -E- can be removed from the refrigerant line -C-. If it is not possible to unlock the quick-couplings -A- and -B- using T40149 without damaging them, then unlock them -A- and -B- using disassembling tool T40232 -C- three times on the circumference and loosen the ring -D- on the quick-couplings -A- and -B- and the refrigerant pipes -E- and -F-. Remove the refrigerant pipes -E- and -F- from the quick-couplings -A- and -B-.

Clean the refrigerant lines -A- and -C- in the area of the quick acting coupling connectors.

Scheme 174

Clean the refrigerant lines -A- and -C- in the area of the quick acting coupling connectors with a silicone-free lubricant.

Note. The refrigerant lines adhere to the O-ring with the A/C is used; loosen the O-ring before mounting the release tool for air conditioner couplings, for example by pulling and pushing the refrigerant lines; never twist the refrigerant lines. The Audi RS 4 and the Audi RS 5 have a block connector instead of quick-release connector. Removing and installing the block connector is same as removing and installing the block connector on the condenser. Refer to All except RS5 REFRIGERANT PIPES FROM CONDENSER or RS5 REFRIGERANT PIPES FROM CONDENSER .

Press the refrigerant lines -A- and -C- by hand all way into the connecting piece -B- of the refrigerant line with the inner heat exchanger.

Connect the Release Tool for Air Conditioner Couplings T40149/1 to the refrigerant line -A- all the way (you should hear and feel the mounting ring open), when doing this, the retaining with will expand.

Remove the refrigerant line -A- using the release tool for air conditioner coupling from the connector piece -B- of the refrigerant line with inner heat exchanger.

Connect the Release Tool for Air Conditioner Couplings T40149/2 to the refrigerant line -C- all the way (you should hear and feel the mounting ring open), when doing this, the retaining with will expand.

Remove the refrigerant line -C- using the release tool for air conditioner coupling from the connector piece -B- of the refrigerant line with inner heat exchanger.

Note. If the refrigerant lines cannot be pulled out or pushed in, then never twist them in the connector piece -C-. In this case, open (or cut) the quick-couplings -A- or -B- with the disassembly tool T40232 and remove the ring -D-. When cutting the coupling, make sure not to damage the connector piece -A- of the refrigerant line with inner heat exchanger.

Close all open lines and connections on the refrigerant line with suitable caps (avoid dirt and moisture from entering the system).

Loosen the connection on the quick-coupling connections using the disassembly tool T40232.

Mount the disassembly tool -C- on the quick-couplings -A- or -B- and separate the coupling 3 times.

Note. Be careful not to damage the connection on the inner heat exchanger -G- and the refrigerant pipes -E- and -F- when separating the quick-coupling -A- and -B-. Insert the cutter on the disassembly tool -C- into the quick-coupling until it audibly breaks the cut location.

Carefully bend open the cut quick-coupling -A- or -B- (being careful not to damage the refrigerant pipe) and remove the ring -D-.

Spray the refrigerant pipes near the opened quick-coupling with a silicone-free lubricant.

Note. The refrigerant pipes stick to the O-ring when the A/C is working. Pulling and pushing the refrigerant pipe after spraying the lubricant can loosen the pipe from the O-ring making it easier to remove. Never rotate refrigerant pipes.

Remove the refrigerant pipe -E- and -F- from the connection.

Seal off the open pipes and connections on the refrigerant pipe with caps to keep dirt and humidity from getting in.

Installation is done is reverse order, observe the following

Scheme 175

Pry the couplings -B- and -C- using a screwdriver -A- out of the refrigerant line -D- with inner heat exchanger -arrow-.

Thoroughly clean all parts of the refrigerant line connections (for example, using Cleaning Solution D 009 401 04).

Scheme 176

Check the connector -A- for the refrigerant line with inner heat exchanger for damage.

Replace the O-rings -B and G-, the support rings -C and F- and the couplings -D and E-.

Note. Follow the instructions for installing the O-rings. Refer to REFRIGERANT CIRCUIT O-RINGS .

Coat the O-ring seals with refrigerant oil prior to installation. Refer to REFRIGERANT CIRCUIT O-RINGS .

Press on the couplings -D- and -E- until this audibly latch into the refrigerant line with inner heat exchanger connector piece -A-.

Thoroughly clean the refrigerant lines -A- and -B- around the connection area and check for damage.

Scheme 177

Install the refrigerant lines -A- and -B- all the way so that they are free of tension.

Check for correct installation of the refrigerant lines.

Scheme 178

1. Try to disconnect the refrigerant lines -A- and -B- ; the stop must be felt.
2. The pins -B- on the retaining ring must be visible on the quick-release coupling, version -A- (installed at Start Of Production) when the locked refrigerant line -C- is pulled in direction of arrow.
3. On the quick-release coupling -D- (running change from MY 2010), the ring -E- must come out of the quick-release coupling -D-, when, after assembling, the locked refrigerant line -C- is pulled in direction of arrow. Then the ring -E- can be removed from the refrigerant line -C-.

Note. Install refrigerant pipes such that they are not strained. Check installation position of refrigerant lines to the quick acting couplings (they should not come in contact with other components).

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Switch on the ignition.

Install the remaining removed components.

Switch on the ignition.

Check the Climatronic control module -J255- DTC memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Note. Note the information regarding operating the A/C system after filling. Refer to A/C Service Station in Description and Operation .

REFRIGERANT PIPE WITH INNER HEAT EXCHANGER - ENGINE CODE(S): CHJA

Special tools and workshop equipment required

1. Release tool for air conditioner couplings T40149 or removal tool T40232
2. Engine Bung Set VAS 6122

Turn off the ignition.

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Note. Depending on the allocation of the service connection an on the refrigerant line, and on the version of the vehicle, it may be necessary to remove the additional reinforcement on the left suspension strut dome so that the service coupling of the service station can be connected (for example, on the Audi Q5). Refer to Removal and Installation and Description and Operation .

Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system. Refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS and refer to GENERAL INFORMATION .

If it is necessary for the following procedure to perform work in the vicinity of high voltage components, perform a visual inspection of the high voltage components and cables for damages. Refer to VISUAL INSPECTION OF HIGH-VOLTAGE COMPONENTS AND CABLES FOR DAMAGE and always follow the warnings when working on the high voltage system. Refer to GENERAL INFORMATION

The following procedure requires working on the high voltage system. De-energize the high voltage system. Refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS , GENERAL INFORMATION and Read and follow the high voltage electrical system general warnings. Refer to GENERAL INFORMATION .

Disable the high voltage system

Note. Disable the high voltage system: Connect the vehicle diagnosis tester Select the Guided Fault Finding mode Using the GO TO button, select the following menu commands Functions/Component selection Body Electrical Equipment OBD-capable system 8C - Hybrid battery management -J840 8C - Hybrid battery management, functions 51 - Disable the high voltage system (Rep.Gr. 93)

Remove the rubber seal -A- and the plenum chamber cover -B- (there are different versions). Refer to Removal and Installation .

1. Inspect the high voltage components -D- (the electric drive power and control electronics -JX1-) and the high voltage cables -E- after removing the plenum chamber cover -B-. Refer to «VISUAL INSPECTION OF HIGH-VOLTAGE COMPONENTS AND CABLES FOR DAMAGE»(/audi/a5/i-2007-2011/remont/automatic-hvac-system/#air-conditioning-coupe-1-of-2__visual-inspection-of-high-voltage-components-and) and GENERAL INFORMATION .

De-energize the high voltage system. Refer to GENERAL INFORMATION .

Disconnect the ground cable from the battery -A-. Refer to [For engine(s) CAUA, CAEB, CALA] Removal and Installation .

Loosen the power distribution panel -1- and move it toward the windshield with the wires. Refer to REMOVAL AND INSTALLATION .

Remove the high voltage cables for the electric drive power and control electronics -JX1-. Refer to REMOVAL AND INSTALLATION .

Cover the electric drive power and control electronics -JX1- and wires to prevent them getting damaged and to protect them from dirt. Refer to DESCRIPTION AND OPERATION .

Note. Use clean 20 mm bungs -B-, taken from engine bung set VAS 6122, to seal off the connection on the electric drive power and control electronics -JX1- -A-.

1. Be careful not to damage any high voltage components -D- or the high voltage cables -E-. Refer to GENERAL INFORMATION .

Note. Remove the cowl panel -C- if it is necessary to remove and install the refrigerant pipe. Refer to Description and Operation . From MY 10 and on certain versions and depending on the engine, refrigerant lines with an inner heater core -A- are installed which have an additional weight (balance) -B- to reduce noise. When installing refrigerant pipes with an inner heater core -A- and the plenum chamber, make sure the weight -B- and the refrigerant pipes -A- are not too close or touching the other components.

Remove the refrigerant line from the quick-release coupling connections. Refer to REFRIGERANT LINES DISCONNECTING FROM QUICK-RELEASE COUPLINGS AND CONNECTING .

Note. Close all open lines and connections on the refrigerant line with suitable caps (avoid dirt and moisture from entering the system).

Loosen the plenum chamber front wall -A- from the vehicle. Refer to Description and Operation .

Note. Both coolant hoses are routed to the heater core through the plenum chamber front wall -A-. Loosen the grommet on both coolant hoses and move the plenum chamber front wall to the side (when doing this, the refrigerant circuit must not be opened). When loosening the plenum chamber front wall, be careful not to damage the brake booster vacuum line.

Disengage the catches -arrows A- and remove the upper part of the line pass-through -2- upward -arrow B-.

Scheme 179

Note. Disregard -item 1-.

Loosing the wiring harness from the lower part of the line pass-through -2- and remove the lower part.

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

Scheme 180

Remove screws -A-.

Disconnect the refrigerant line -B- with the inner heat exchanger from the expansion valve.

Note. Seal the open connections on the refrigerant line and on the expansion valve with suitable caps (to prevent dirt and moisture from entering the system).

Installation is done is reverse order, observe the following

Note. Electrical connections and routing, refer to the appropriate SYSTEM WIRING DIAGRAMS information.

Thoroughly clean all the connections in the expansion valve -B- and in the refrigerant line -D- with the inner heat exchanger.

Scheme 181

Check the connections in the expansion valve -B- and on the refrigerant line -D- for damage.

Replace the quick acting coupling connectors on the refrigerant line with inner heat exchanger. Refer to REFRIGERANT LINES DISCONNECTING FROM QUICK-RELEASE COUPLINGS AND CONNECTING

Replace the O-rings -A- and -C-.

Note. Follow the instructions for installing the O-rings. Refer to REFRIGERANT CIRCUIT O-RINGS .

Coat the O-ring seals with refrigerant oil prior to installation. Refer to REFRIGERANT CIRCUIT O-RINGS .

Make sure the O-rings fit properly inside the grooves on the refrigerant line connections -D-.

Tighten the bolts -E- for the refrigerant line -D- with inner heat exchanger.

1. Tightening specification -E- : 10 Nm.

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

Install the plenum chamber front wall. Refer to Description and Operation .

Note. Install refrigerant line such that it is not strained. Check installation position of refrigerant line to expansion valve (it should not come in contact with other components).

Install the refrigerant line to the quick acting couplings. Refer to REFRIGERANT LINES DISCONNECTING FROM QUICK-RELEASE COUPLINGS AND CONNECTING .

Install the remaining removed components.

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Inspect the high voltage components -D- and high voltage cables -E- after completing the work procedure and before installing the plenum chamber cover -B-. Refer to GENERAL INFORMATION .

Electrical connections and routing, refer to the appropriate SYSTEM WIRING DIAGRAMS information.

Energize the voltage to the high voltage system. Refer to HIGH VOLTAGE SYSTEM, ENERGIZING .

Restart the high voltage system

Note. Restart the high voltage system: Connect the vehicle diagnosis tester Select the Guided Fault Finding mode Using the GO TO button, select the following menu commands Functions/Component selection Body Electrical Equipment OBD-capable system 8C - Hybrid battery management -J840 8C - Hybrid battery management, functions 51 - High voltage restart (Rep.Gr. 93)

Switch on the ignition.

Check the Climatronic control module -J255- DTC memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Note. Note the information regarding operating the A/C system after filling. Refer to A/C Service Station in Description and Operation .

REFRIGERANT PIPE WITH INNER HEAT EXCHANGER - ENGINE CODE(S): CFSA

Special tools and workshop equipment required

1. Engine bung set VAS 6122
2. Release tool for air conditioner couplings T40149 or removal tool T40232

Scheme 182

Turn off the ignition.

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

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

Remove the refrigerant pipe -2- from the quick-release connection -1-. Refer to REFRIGERANT LINES DISCONNECTING FROM QUICK-RELEASE COUPLINGS AND CONNECTING .

Remove the bolt -3- and disconnect the refrigerant line -4-.

Seal open lines and connections with clean bungs from engine bung set VAS 6122.

Remove the plenum chamber cover and/or the cowl panel (there are different versions). Refer to Body Front .

Disconnect the ground cable from the battery -A-. Refer to [For engine(s) CAUA, CAEB, CALA] Removal and Installation .

Scheme 183

Disengage the catches -arrows A- and remove the upper part of the line pass-through -2- upward -arrow B-.

Loosen the wiring harness -1- from the lower part of the wire pass-through and then remove the lower part.

Loosen the plenum chamber front all -A- from the vehicle. Refer to Description and Operation .

Remove screws -1-.

Scheme 184

Disconnect the refrigerant line -2- with the inner heat exchanger from the expansion valve.

Seal open lines and connections with clean bungs from engine bung set VAS 6122.

Installation is done is reverse order, observe the following

Note. Electrical connections and routing, refer to the appropriate SYSTEM WIRING DIAGRAMS information.

Thoroughly clean all the connections in the expansion valve -B- and in the refrigerant line -D- with the inner heat exchanger.

Check the connections in the expansion valve -B- and on the refrigerant line -D- for damage.

Replace the quick-coupling connection on the refrigerant line with inner heat exchanger. Refer to REFRIGERANT LINES DISCONNECTING FROM QUICK-RELEASE COUPLINGS AND CONNECTING .

Replace the O-rings -A- and -C-.

Note. Follow the instructions for installing the O-rings. Refer to REFRIGERANT CIRCUIT O-RINGS .

Coat the O-ring seals with refrigerant oil prior to installation. Refer to REFRIGERANT CIRCUIT O-RINGS .

Make sure the O-rings fit properly inside the grooves on the refrigerant line connections -D-.

Tighten the bolts -E- for the refrigerant line -D- with inner heat exchanger.

1. Tightening specification -E- : 10 Nm.

Note. On certain versions, the refrigerant pipe with an inner heater core -A- also have a weight (balance) -B- to reduce noise. When installing the refrigerant pipes with an inner heater core and the plenum chamber bulkhead, make sure the weight and the refrigerant pipe are not too close to the other components or touching them.

Clean the connections on the refrigerant pipe and check for damage.

Scheme 185

Inspect the alignment pin -4- for damage and check that it is seated correctly.

Inspect the guide ring -2- on the refrigerant line connection for damage.

Note. Coat the O-ring with refrigerant oil before installing. Refer to REFRIGERANT CIRCUIT O-RINGS . Make sure the O-ring fits correctly inside the groove in the refrigerant pipe.

Insert the O-ring seal -3- in the groove -arrow- on the refrigerant line connection -1-.

The cover -1- must sit correctly on the refrigerant pipe -2- as illustrated.

Scheme 186

Make sure the rubber bushing -4- is seated in the mount.

Install the refrigerant pipe -6- on the inner heat exchanger and tighten the bolt -5-.

1. Tightening specification: 9 Nm.

Attach the refrigerant pipe -3- to the quick-coupling connection. Refer to REFRIGERANT LINES DISCONNECTING FROM QUICK-RELEASE COUPLINGS AND CONNECTING .

Note. Install refrigerant line such that it is not strained. Check installation position of refrigerant line to expansion valve (it should not come in contact with other components).

Install the remaining removed components.

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Switch on the ignition.

Check the DTC memory and erase any displayed entries. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

REFRIGERANT PIPE WITH INNER HEAT EXCHANGER - ENGINE CODE(S): CAEB & CALA

Special tools and workshop equipment required

1. Release tool for air conditioner couplings T40149 or removal tool T40232
2. Engine bung set VAS 6122

Turn off the ignition.

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Note. Depending on the allocation of the service connection an on the refrigerant line, and on the version of the vehicle, it may be necessary to remove the additional reinforcement on the left suspension strut dome so that the service coupling of the service station can be connected (for example, on the Audi Q5). Refer to Removal and Installation and Description and Operation .

Remove the plenum chamber cover and/or the cowl panel (there are different versions). Refer to Removal and Installation .

Disconnect the ground cable from the battery -A-. Refer to Battery, Starter, Generator, Cruise Control .

Note. From MY 10 and on certain versions and depending on the engine, refrigerant lines with an inner heat exchanger -A- are installed which have an additional weight (balance) -Removal and Installation- to reduce noise. When installing refrigerant pipes with an inner heat exchanger -A- and the plenum chamber, make sure the weight -B- and the refrigerant pipes -A- are not too close or touching the other components.

Remove the refrigerant line from the quick-release coupling connections. Refer to REFRIGERANT LINES DISCONNECTING FROM QUICK-RELEASE COUPLINGS AND CONNECTING

Note. Close all open lines and connections on the refrigerant line with suitable caps (avoid dirt and moisture from entering the system).

Loosen the plenum chamber front all -A- from the vehicle. Refer to Description and Operation .

Note. Both coolant hoses are routed to the heater core through the plenum chamber front wall -A-. On these vehicles, loosen the grommet on both coolant hoses and move the plenum chamber front wall to the side (when doing this, the refrigerant circuit must not be opened). When loosening the plenum chamber front wall, be careful not to damage the brake booster vacuum line.

Disengage the catches -arrows A- and remove the upper part of the line pass-through -2- upward -arrow B-.

Note. Disregard -item 1-.

Loosing the wiring harness from the lower part of the line pass-through -2- and remove the lower part.

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

Remove screws -A-.

Disconnect the refrigerant line -B- with the inner heat exchanger from the expansion valve.

Note. Seal the open connections on the refrigerant line and on the expansion valve with suitable caps (to prevent dirt and moisture from entering the system).

Installation is done is reverse order, observe the following

Note. Electrical connections and routing, refer to the appropriate SYSTEM WIRING DIAGRAMS information.

Thoroughly clean all the connections in the expansion valve -B- and in the refrigerant line -D- with the inner heat exchanger.

Check the connections in the expansion valve -B- and on the refrigerant line -D- for damage.

Replace the quick acting coupling connectors on the refrigerant line with inner heat exchanger. Refer to REFRIGERANT LINES DISCONNECTING FROM QUICK-RELEASE COUPLINGS AND CONNECTING .

Replace the O-rings -A- and -C-.

Note. Follow the instructions for installing the O-rings. Refer to REFRIGERANT CIRCUIT O-RINGS .

Coat the O-ring seals with refrigerant oil prior to installation. Refer to REFRIGERANT CIRCUIT O-RINGS .

Make sure the O-rings fit properly inside the grooves on the refrigerant line connections -D-.

Tighten the bolts -E- for the refrigerant line -D- with inner heat exchanger.

1. Tightening specification -E- : 10 Nm.

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

Note. Install refrigerant line such that it is not strained. Check installation position of refrigerant line to expansion valve (it should not come in contact with other components).

Install the refrigerant line to the quick acting couplings. Refer to REFRIGERANT LINES DISCONNECTING FROM QUICK-RELEASE COUPLINGS AND CONNECTING .

Install the remaining removed components.

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Switch on the ignition.

Check the Climatronic control module -J255- DTC memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Note. Note the information regarding operating the A/C system after filling. Refer to A/C Service Station in Description and Operation .

EXPANSION VALVE

Note. After switching off the A/C compressor in this vehicle, it may take a relatively long time for the pressure on the high pressure side to decrease. This is because the expansion valve is cold and the pressure on the low pressure side increases quickly after shutting the compressor off, then the expansion valve closes and the refrigerant flows slowly to the low pressure side. If the A/C compressor is switched on, the pressure on the low pressure side goes down, the expansion valve open and the refrigerant can flow of the low pressure side. From the start of production through the change-over from MY 12, evaporators approximately 40 mm (1.6 in.) wide (block depth) -A- are being installed (air conditioner part number "8K_ 820 005"). From MY 12, as a running change and depending on the version of the vehicle, an approximately 50 mm (2 in.) wide evaporator (block depth) -A- is being installed (air conditioner part number "8T_ 820 005"). Pay attention to the correct allocation of the evaporator expansion valve (there are different versions). There is a label -A- on the outside of the A/C unit with a part -B- that tells which version is installed. The part number -B- on the decal -A- can be read when the CD changer is removed (depending on the vehicle equipment level). Refer to Removal and Installation .

Turn off the ignition.

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Note. Depending on the allocation of the service connection an on the refrigerant line, and on the version of the vehicle, it may be necessary to remove the additional reinforcement on the left suspension strut dome so that the service coupling of the service station can be connected (for example, on the Audi Q5). Refer to Removal and Installation and Description and Operation

With high voltage systems (hybrid vehicles)

Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system. Refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS and refer to GENERAL INFORMATION .

If it is necessary for the following procedure to perform work in the vicinity of high voltage components, perform a visual inspection of the high voltage components and cables for damages. Refer to VISUAL INSPECTION OF HIGH-VOLTAGE COMPONENTS AND CABLES FOR DAMAGE and always follow the warnings when working on the high voltage system. Refer to GENERAL INFORMATION

The following procedure requires working on the high voltage system. De-energize the high voltage system. Refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS , GENERAL INFORMATION and Read and follow the high voltage electrical system general warnings. Refer to GENERAL INFORMATION .

De-energize the high voltage system. Refer to GENERAL INFORMATION .

Disconnect the ground cable from the battery -A-. Refer to Removal and Installation .

Remove the refrigerant line with inner heat exchanger. Refer to REFRIGERANT CIRCUIT COMPONENTS .

Note. It may be necessary to remove the cowl panel -C- in order to remove and install the expansion valve. Refer to Description and Operation .

For vehicles without a high voltage system

Disconnect the ground cable from the battery -A- Battery, Starter, Generator, Cruise Control .

Remove the plenum chamber cover and/or the cowl panel (there are different versions). Refer to Description and Operation .

All vehicles

Loosen the refrigerant line with inner heat exchanger from the expansion valve and lay it to the side (do not remove). Refer to REFRIGERANT CIRCUIT COMPONENTS .

Note. The plenum chamber front wall cannot be loosened or removed from the vehicle (there is not enough space available). When loosening the plenum chamber front wall, be careful not to damage the brake booster vacuum line.

All vehicles

Remove screws -A-.

Scheme 187

Disconnect the expansion valve -B- from the refrigerant lines leading to the evaporator.

Note. Seal all open lines and connections on evaporator with suitable caps (avoid dirt and moisture from entering the system).

Installation is done is reverse order, observe the following

Clean the connection pipes -C- and -E- leading to the evaporator and the expansion valve connections, and check for damage.

Note. Expansion valve is available in different versions (same housing but a different control characteristic), therefore ensure the exact allocation. Follow the instructions for installing the O-rings. Refer to REFRIGERANT CIRCUIT O-RINGS .

Replace the O-rings -B- and -F-.

Coat the O-ring seals with refrigerant oil prior to installation. Refer to REFRIGERANT CIRCUIT O-RINGS .

Make sure the retaining plate -D- fits correctly on the connection pipes -C- and -E- leading to the evaporator.

Tighten the screws -G-.

1. Tightening specification: 10 Nm.

Install the refrigerant line with inner heat exchanger. Refer to REFRIGERANT CIRCUIT COMPONENTS .

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

With high voltage systems (hybrid vehicles)

Inspect the high voltage components -D- and high voltage cables -E- after completing the work procedure and before installing the plenum chamber cover -B-. Refer to GENERAL INFORMATION .

Electrical connections and routing, refer to the appropriate SYSTEM WIRING DIAGRAMS information.

Energize the voltage to the high voltage system. Refer to GENERAL INFORMATION

All vehicles

Install the remaining removed components.

Switch on the ignition.

Check the Climatronic control module -J255- DTC memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Note. Note the information regarding operating the A/C system after filling. Refer to A/C Service Station in Description and Operation .

REFRIGERANT PIPES FROM CONDENSER - ENGINE CODE(S): CAEB & CALA

Special tools and workshop equipment required

1. Engine Bung Set VAS 6122

Note. There are different versions of the condenser. Check the version and allocation before installing. Refer to CONDENSER, CHECKING VERSION . To remove the condenser from the front end or to remove the radiator, it may be necessary to drain the refrigerant circuit and to remove the refrigerant pipe from the condenser, depending on the version of the radiator and of the condenser. Refer to CONDENSER .

Turn off the ignition.

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Note. Depending on the allocation of the service connection an on the refrigerant line, and on the version of the vehicle, it may be necessary to remove the additional reinforcement on the left suspension strut dome so that the service coupling of the service station can be connected (for example, on the Audi Q5). Refer to Removal and Installation and Description and Operation .

Remove the bolts (or clips) -1, 2, 3 and 5-. Refer to Removal and Installation .

Scheme 188

Remove the cover -4- from the lock carrier and hang it on the radiator grille. Removal and Installation .

Remove the bolt -B-.

Scheme 189

Remove the refrigerant line -A- from the condenser.

Unlock the retainers -arrows A- and remove the left air intake grille -1- from the bumper cover -arrow B-. Refer to Removal and Installation .

Scheme 190

Remove the bolt -B-.

Scheme 191

Remove the refrigerant line -A- from the condenser.

Note. Seal open pipes and connections at condenser with suitable caps (to prevent ingress of dirt and moisture). The Audi Q5 has a refrigerant line made up of two pieces; do not open the connections between both pieces to remove the condenser. If one piece of the refrigerant line on the Audi Q5 has to be replaced, then the same tightening specification for the bolt on the condenser connection applies to the bolt on the connection.

Installation is done is reverse order, observe the following

Clean the refrigerant line connections on the condenser and on the refrigerant lines and check for damage.

Scheme 192

Replace the O-rings -C-.

Note. Follow the instructions for installing the O-rings. Refer to REFRIGERANT CIRCUIT O-RINGS . Following attachment, check routing of refrigerant lines on condenser. They must be inserted in holders provided and not make contact with other components. The refrigerant line -C- (from the condenser to the quick-release coupling on the refrigerant line with the inner heat exchanger) is secured by a clip -B- to the fender brace -A- from MY 2008. The fender brace -A- has a hole -D- (diameter 6.5 mm). If the fender brace -A- does not have hole -D- (or a refrigerant line -C- without a clip -B-), then secure the refrigerant line -C- to the fender brace -A- with a cable tie. Wrap the refrigerant line -C- on the contact surface with a piece of foam (to protect against damage).

Coat the O-ring seals with refrigerant oil prior to installation. Refer to REFRIGERANT CIRCUIT O-RINGS .

Make sure the O-ring fits correctly inside the grooves -arrows- on each mount.

Check the fitting pin -A- (not installed on all connections) and refrigerant line connections -B- -E- and -F- for damage and proper seating.

Tighten the screws -D-.

1. Tightening specification: 9 Nm.

Install the cover on the lock carrier. Refer to Removal and Installation .

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Install the remaining removed components.

Switch on the ignition.

Check the Climatronic control module -J255- DTC memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Note. Note the information regarding operating the A/C system after filling. Refer to A/C Service Station in Description and Operation .

REFRIGERANT PIPES FROM CONDENSER - ENGINE CODE(S): CFSA

Special tools and workshop equipment required

1. Engine Bung Set VAS 6122

Note. There are different versions of the condenser. Check the version and allocation before installing. Refer to CONDENSER, CHECKING VERSION . It may be necessary to evacuate the refrigerant circuit and remove the refrigerant pipes from the condenser in order to remove the condenser from the front end or to remove the radiator depending on the version of the radiator and the condenser. Refer to CONDENSER . On the Audi RS 5, the condenser is installed at a different version than as on other vehicles of this series and the length of the refrigerant pipes may also differ from other vehicles. For the correct allocation and refrigerant R134a capacities, refer to Specifications .

Turn off the ignition.

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Remove the air guide for the left auxiliary radiator .

Remove the bolt -B-.

Remove the refrigerant line -A- from the condenser.

Remove the bolt -1-.

Scheme 193

Remove the refrigerant pipe -2- from the condenser.

Seal open lines and connections with clean bungs from VAS 6122.

Installation is done is reverse order, observe the following

Replace the O-ring seals depending on the version.

Check the alignment pin -A- (if equipped) for damage and make sure it fits correctly.

Check the guide ring -B- on the refrigerant line connection for damage.

Insert the O-ring -C- into the groove -arrow- in the refrigerant pipe connection -E and F-.

Note. Coat the O-ring with refrigerant oil before installing. Refer to REFRIGERANT CIRCUIT O-RINGS . Make sure the O-ring fits correctly inside the groove in the refrigerant pipe.

Tighten the screws -D-.

1. Tightening specification: 9 Nm.

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

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Install the remaining removed components.

Switch on the ignition.

Check the DTC memory and erase any displayed entries using the Vehicle diagnostic tester in "Guided Fault Finding".

CONDENSER - ENGINE CODE(S): CALA & CAEB

Note. The radiator and condenser may have small indentations on the fins even when installed correctly. It is not damage. Do not replace the radiator or condenser because of those small indentations. Slight deformations on the side securing straps on the condenser (for example, due to an accident), can result in an unparallel flow from the condenser and radiator; this can be resolved by pulling the straps back as long as the function/condenser sealing is not impaired. The straps on the condenser do not need to be replaced if there are small deformations. A slight bending of the condenser (up to 4 mm) is permissible as long as there is sufficient distance (minimum 4 mm) between the condenser and the radiator and the function/sealing of the condenser (of the refrigerant circuit) is not impaired. The condenser does not have to be replaced if there are slight deformations. Different versions of the condenser are available depending on the vehicle version, refer to CONDENSER, CHECKING VERSION . To remove the condenser from the front end or to remove the radiator, it may be necessary to drain the refrigerant circuit and to remove the refrigerant pipe from the condenser, depending on the version of the radiator and of the condenser. Refer to REFRIGERANT PIPES FROM CONDENSER .

Turn off the ignition.

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Note. Depending on the allocation of the service connection an on the refrigerant line, and on the version of the vehicle, it may be necessary to remove the additional reinforcement on the left suspension strut dome so that the service coupling of the service station can be connected (for example, on the Audi Q5). Refer to Removal and Installation and Description and Operation .

Remove the refrigerant lines from the condenser. Refer to REFRIGERANT PIPES FROM CONDENSER .

Remove the bolts (or clips) -1, 2, 3 and 5-. Refer to Removal and Installation .

Remove the cover -4- from the lock carrier and disengage the radiator grille. Refer to Removal and Installation .

Remove the bolts -arrows-.

Scheme 194

Remove the air guide -1- on the flange -2- for the air filter housing.

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

Scheme 195

Disconnect the electrical connector -B- leading to the sensors for the front park assist and the electrical connector for the Outside Air Temperature Sensor -G17- -Pos. A-.

Note. Different installation locations of the outside air temperature sensor -G17- (the illustration shows the location in MY 2008 vehicles). Refer to OUTSIDE AIR TEMPERATURE SENSOR -G17 .

Remove the front end piece on the bumper cover (depending on the vehicle version, for example currently not necessary on the Audi Q5). Refer to Removal and Installation

Unlock the retaining straps -arrows A- (each two straps, one on top and one below on the air guide) and move the left and right air guide -1- toward the center of the vehicle -arrow B-.

Scheme 196

Vehicles with a power steering oil cooler

Scheme 197

Unlock the retaining clamps -arrow A- and move the power steering cooling coil -1- forward -arrow B-.

Remove the power steering oil cooler cooling coil from the condenser and lay it on the engine.

Note. In the illustration the installation position is shown with the bumper cover removed.

All Vehicles

Scheme 198

Unlock the retaining clamps -1- in -arrow direction A- and remove the condenser -2- upward and out of the brackets on the radiator -arrows B-.

Note. In the illustration, with the bumper cover removed.

Installation is done is reverse order, observe the following

Note. The removed condenser contains refrigerant oil that must be returned to the refrigerant circuit (with the new condenser). Removal and Installation . There are different versions of the condenser. Check the version and allocation before installing. Refer to CONDENSER, CHECKING VERSION . The refrigerant circuit capacity depends on which version of the condenser is installed. Refer to Specifications .

Install the refrigerant lines to the condenser. Refer to REFRIGERANT PIPES FROM CONDENSER .

Vehicles with a power steering oil cooler

Install the power steering oil cooler. Refer to Removal and Installation .

All Vehicles

Install the cover on the lock carrier. Refer to Removal and Installation .

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Install the remaining removed components.

Switch on the ignition.

Check the Climatronic control module -J255- display and control head DTC memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Note. Note the information regarding operating the A/C system after filling. Refer to A/C Service Station in Description and Operation .

CONDENSER - ENGINE CODE(S): CFSA

Audi RS 5

Note. The radiator and condenser may have small indentations on the fins even when installed correctly. It is not damage. Do not replace the radiator or condenser because of those small indentations. Slight deformations on the side securing straps on the condenser (for example, due to an accident), can result in an unparallel flow from the condenser and radiator; this can be resolved by pulling the straps back as long as the function/condenser sealing is not impaired. The straps on the condenser do not need to be replaced if there are small deformations. A slight bending of the condenser (up to 4 mm) is permissible as long as there is sufficient distance (minimum 4 mm) between the condenser and the radiator and the function/sealing of the condenser (of the refrigerant circuit) is not impaired. The condenser does not have to be replaced if there are slight deformations. Different versions of the condenser are available depending on the vehicle version, refer to CONDENSER, CHECKING VERSION . The Audi RS 5 have a condenser version that is not installed on other vehicles in this model line. For the correct allocation and refrigerant capacity, refer to CONDENSER, CHECKING VERSION and Specifications . It may be necessary to evacuate the refrigerant circuit and remove the refrigerant pipes from the condenser in order to remove the condenser from the front end or to remove the radiator depending on the version of the radiator and the condenser. Refer to REFRIGERANT PIPES FROM CONDENSER .

Turn off the ignition.

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Remove the refrigerant lines from the condenser. Refer to REFRIGERANT PIPES FROM CONDENSER .

Remove the bolts -arrows-.

Remove the left and right air guide -1- from the intermediate flange -2- on the air filter housing.

Unlock the retaining straps -arrows A- (each two straps, one on top and one below on the air guide) and move the left and right air guide -1- toward the center of the vehicle -arrow B-.

Unlock the retaining clamps -1- in -arrow direction A- and remove the condenser -2- upward and out of the brackets on the radiator -arrows B-.

Installation is done is reverse order, observe the following

Note. The removed condenser contains refrigerant oil that must be returned to the refrigerant circuit (with the new condenser). Refer to Specifications .

Install the refrigerant lines to the condenser. Refer to REFRIGERANT PIPES FROM CONDENSER .

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Install the remaining removed components.

Switch on the ignition.

Check the DTC memory and erase any displayed entries using the Vehicle diagnostic tester in "Guided Fault Finding".

FLUID RESERVOIR

Note. There are different versions of the reservoir and condenser. For correct allocation refer to CONDENSER, CHECKING VERSION . The reservoir may be attached to or integrated in the condenser, depending on the version of the condenser. If the condenser has an integrated reservoir, replace the dryer cartridge. Refer to All Except Hybrid and RS5 CONDENSER or RS5 CONDENSER .

Removed fluid reservoir contains refrigerant oil which must be restored to the refrigerant circuit (with new fluid reservoir). Adding oil depends on the type of complaint. Refer to Removal and Installation .

1. If, for example, the reservoir (or condenser) was damaged during an accident (no refrigerant has leaked out, no moisture or dirt has gotten into the refrigerant circuit); drain the refrigerant oil from the removed reservoir (and the damaged condenser). Fill the refrigerant circuit (for example condenser) with the quantity of the drained refrigerant plus 10 cm 3 with fresh refrigerant ; this way the refrigerant circuit can be easily repaired. Refer to «Specifications»(/audi/a5/i-2007-2011/remont/automatic-hvac-system/#general-technical-data-refrigerant-r134a-servicing-coupe-2-of-2) .
2. If a certain amount of refrigerant oil has leaked due to an accident or contaminants or moisture has entered the refrigerant circuit, circuit must be flushed. Refer to A/C Service Station in «Description and Operation»(/audi/a5/i-2007-2011/remont/general-servicing-all-makes/#general-technical-data-refrigerant-r134a-servicing-coupe-1-of-2) .

Turn off the ignition.

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Note. Depending on the allocation of the service connection an on the refrigerant line, and on the version of the vehicle, it may be necessary to remove the additional reinforcement on the left suspension strut dome so that the service coupling of the service station can be connected (for example, on the Audi Q5). Refer to Removal and Installation and Description and Operation

Remove the bolts (or clips) -1, 2, 3 and 5-. Refer to Removal and Installation .

Remove the cover -4- from the lock carrier and disengage the radiator grille. Refer to Removal and Installation .

Remove the bolts -arrows-.

Remove the air guide -1- on the flange -2- for the air filter housing.

Remove the front noise insulation. Refer to Removal and Installation

Note. It may be necessary to remove the bumper cover first before removing the front noise insulation, for example, on the Audi A4 allroad. Refer to Removal and Installation .

Vehicles with charge air cooler or engine oil cooler, installed under the condenser

Remove the condenser. Refer to All Except Hybrid and RS5 CONDENSER or RS5 CONDENSER .

All Vehicles

Remove screws -A-.

Scheme 199

Remove the bolt -C- and the bracket -D- upward.

Remove the reservoir -F- upward from the condenser -E- -arrow-.

Note. Be sure not to loose the rubber grommet -B- when removing the reservoir. Seal open connections on reservoir and condenser with suitable caps (to prevent dirt and moisture from entering).

Installation is done is reverse order, observe the following

Note. Follow the instructions for installing the O-rings. Refer to REFRIGERANT CIRCUIT O-RINGS . Keep the reservoir closed as long as possible. Only remove the cape immediately prior to installation (reservoir contains a desiccant bag which soon becomes saturated with moisture and thus unusable when reservoir is open).

Clean the condenser surface -C-.

Scheme 200

Check the connections on the condenser and on the reservoir for damage.

Replace the seals -D- and the O-rings -E-.

Coat the O-ring seals with refrigerant oil prior to installation. Refer to REFRIGERANT CIRCUIT O-RINGS .

Make sure the O-ring fits correctly inside the grooves -arrows- on each mount.

Mount the reservoir -B- on the condenser and tighten the screws.

1. Tightening specification: 10 Nm

Pull the protective sleeve -A- over the connection.

Vehicles with charge air cooler, installed under the condenser

Install the condenser. Refer to All Except Hybrid and RS5 CONDENSER or RS5 CONDENSER .

All Vehicles

Install the front noise insulation. Refer to Removal and Installation .

Note. It may be necessary to remove the bumper cover first before removing the front noise insulation, for example, on the Audi A4 allroad. Refer to Removal and Installation

Install the air guide on the air filter housing flange. Refer to [For engine(s) CALA] Description and Operation or to [For engine(s) CAEB] Description and Operation or to [For engine(s) CAUA] Description and Operation .

Install the cover on the lock carrier. Refer to Removal and Installation .

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Install the remaining removed components.

Switch on the ignition.

Check the Climatronic control module -J255- display and control head DTC memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Note. Note the information regarding operating the A/C system after filling. Refer to A/C Service Station in Description and Operation .

DRYER CARTRIDGE

Note. There are different condenser versions and the dryer cartridge installed inside them. Pay attention to the correct allocation, refer to CONDENSER, CHECKING VERSION . The reservoir may be attached to or integrated in the condenser, depending on the version of the condenser. Replace an attached reservoir. Refer to FLUID RESERVOIR .

Turn off the ignition.

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Note. Depending on the allocation of the service connection an on the refrigerant line, and on the version of the vehicle, it may be necessary to remove the additional reinforcement on the left suspension strut dome so that the service coupling of the service station can be connected (for example, on the Audi Q5). Refer to Removal and Installation and Description and Operation .

Remove the bolts (or clips) -1, 2, 3 and 5-. Refer to Removal and Installation .

Remove the cover -4- from the lock carrier and disengage the radiator grille. Refer to Removal and Installation .

Remove the bolts -arrows-.

Remove the air guide -1- on the flange -2- for the air filter housing.

Remove the front noise insulation. Refer to Removal and Installation .

Note. It may be necessary to remove the bumper cover first before removing the front noise insulation, for example, on the Audi A4 allroad. Refer to Removal and Installation .

Remove the front end piece on the bumper cover (depending on the vehicle version, for example currently not necessary on the Audi Q5). Refer to Removal and Installation .

With charge air cooler or engine oil cooler, installed under the condenser

Remove the condenser. Refer to All Except Hybrid and RS5 CONDENSER or RS5 CONDENSER .

Vehicles, where it is not necessary to remove the condenser in order to remove the dryer cartridge -D

Scheme 201

Check the refrigerant circuit pressure using, for example, a pressure gauge from the A/C Service Station. Refer to Diagnosis and Testing .

All

Remove the plastic screw -A- (with filter -C-) (tightening specification: 2 Nm).

Remove the dryer cartridge -D- downward and out of the condenser.

Note. Seal the open connection on the condenser with the plastic screw -A- to prevent dirt and moisture from getting in.

Installation is done is reverse order, observe the following

1. Check the reservoir on the condenser above the opening -E- for dirt.
2. Make sure the reservoir thread -E- on the condenser is not dirty or damaged.
3. Replace the plastic screw -A- (with filter -C-), the dryer cartridge -D- and the O-ring -B-.
4. Coat the O-ring -C- lightly with refrigerant oil before installing. Refer to «REFRIGERANT CIRCUIT O-RINGS»(/audi/a5/i-2007-2011/remont/automatic-hvac-system/#air-conditioning-coupe-1-of-2__refrigerant-circuit-o-rings) .
5. Make sure the O-ring -B- fits correctly inside the groove on the plastic screw -A-.
6. Keep the dryer cartridge -D- sealed in its air-tight package as long as possible. Open the package just before installing the dryer cartridge into the condenser. The dryer cartridge absorbs moisture in a very short time and become unusable.

Remove the dryer cartridge -D- from its original package.

Insert the dryer cartridge -D- into the condenser reservoir.

Install the plastic screw -A- (with filter -C-) (tightening specification: 2 Nm).

Install the condenser, the front bumper cover end plate, etc. (depending on the vehicle version). Refer to Removal and Installation .

Install the front noise insulation. Refer to Removal and Installation .

Note. It may be necessary to remove the bumper cover first before removing the front noise insulation, for example, on the Audi A4 allroad. Refer to Removal and Installation .

Discharge and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Install remaining components.

Switch on the ignition.

Check the Climatronic control module -J255- display and control head DTC memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Note. Note the information regarding operating the A/C system after filling. Refer to A/C Service Station in Description and Operation .

Note. There are different condenser versions and the dryer cartridge installed inside them. Pay attention to the correct allocation, refer to CONDENSER, CHECKING VERSION . The reservoir may be attached to or integrated in the condenser, depending on the version of the condenser. Replace an attached reservoir. Refer to FLUID RESERVOIR .

Turn off the ignition.

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Remove the bolts (or clips) -1, 2, 3 and 5-. Refer to Removal and Installation .

Remove the cover -4- from the lock carrier and disengage the radiator grille. Refer to Removal and Installation .

Remove the bolts -arrows-.

Remove the front engine oil cooler .

Remove the left and right air guide -1- from the intermediate flange -2- on the air filter housing.

Check the refrigerant circuit pressure using, for example, a pressure gauge from the A/C Service Station. Refer to Diagnosis and Testing .

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

Remove the dryer cartridge -D- downward and out of the condenser.

Seal the open reservoir with the plastic screw -A- to prevent dirt and moisture from getting in.

Installation is done is reverse order, observe the following

1. Using the opening, inspect the reservoir on the condenser for dirt and damage on the threaded- and sealing surfaces.
2. Replace the plastic screw -A- (with filter -C-), the dryer cartridge -D- and the O-ring -B-.
3. Coat the O-ring -C- lightly with refrigerant oil before installing. Refer to «REFRIGERANT CIRCUIT O-RINGS»(/audi/a5/i-2007-2011/remont/automatic-hvac-system/#air-conditioning-coupe-1-of-2__refrigerant-circuit-o-rings) .
4. Make sure the O-ring -B- fits correctly inside the groove on the plastic screw -A-.
5. Keep the dryer cartridge -D- sealed in its air-tight package as long as possible. Open the package just before installing the dryer cartridge into the condenser. The dryer cartridge absorbs moisture in a very short time and become unusable.

Remove the dryer cartridge -D- from its original package.

Insert the dryer cartridge -D- into the condenser reservoir.

Install the plastic screw -A- (with filter -C-) (tightening specification: 2 Nm).

Discharge and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Install the remaining removed components.

Switch on the ignition.

Check the DTC memory and erase any displayed entries using the Vehicle diagnostic tester in "Guided Fault Finding".

EVAPORATOR, A/C UNIT INSTALLED

Special tools and workshop equipment required

1. Pliers T40147
2. Strong carpet knife with a point; the blade must be secure and the handle must be strong.

Note. The removed evaporator contains refrigerant oil that must be returned to the refrigerant circuit (with the new evaporator). Refer to Removal and Installation . Revised A/C units and evaporators are being installed from MY 12 (use depends on the vehicle version) (A/C unit part number "8T_ 820 005"). It is not possible to replace the evaporator on this A/C unit when the A/C unit is installed. See if the evaporator is available as an installation kit either without the evaporator housing or only together with the housing. If the evaporator is available only together with the housing, then it is necessary to remove the A/C unit and replace the evaporator with the evaporator housing. Refer to EVAPORATOR HOUSING . Evaporators with a block depth -A- of approximately 40 mm (1.6 in) (air conditioner part number "8K_ 820 005") are being installed from start of production through the change-over from MY 12. These evaporators can be replaced with the air conditioner still installed. From MY 12, Evaporators with a block depth -A- of approximately 50 mm (2 in.) are being installed (air conditioner part number "8T_ 820 005") as a running change depending on the vehicle version. These evaporators can be replaced only with the air conditioner removed together with the evaporator housing. There is a label -A- on the outside of the A/C unit with a part -B- that tells which version is installed. The part number -B- on the decal -A- can be read when the CD changer is removed (depending on the vehicle equipment level). Refer to Removal and Installation . Pay attention to the correct allocation of the evaporator expansion valve (there are different versions).

Note. The refrigerant pipe -D- on the Audi Q5 hybrid is wrapped with insulation (butyl or tar tape) to reduce noise. The insulating tape shields the A/C compressor noise, which seems to be louder when the engine is idling. If the evaporator is going to be replaced on an Audi Q5 Hybrid, then wrap the refrigerant pipe -C- on the replacement evaporator with insulating tape. Approximately 30 cm (12 in.) of 5 cm (2 in.) wide insulating tape (commercially available butyl or tar tape) -B- with a 3 mm strength will be needed. This insulating tape -B- is used when handling refrigerant as commercially available butyl or tar tape. It is available in refrigerant materials stores and comes in rolls approximately 10 m (33 ft.) long.

Move the driver and passenger seats as far back as possible.

Turn off the ignition.

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Note. Depending on the allocation of the service connection an on the refrigerant line, and on the version of the vehicle, it may be necessary to remove the additional reinforcement on the left suspension strut dome so that the service coupling of the service station can be connected (for example, on the Audi Q5). Refer to Removal and Installation and Description and Operation .

With high voltage systems (hybrid vehicles)

Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system, refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS and refer to GENERAL INFORMATION .

If it is necessary for the following procedure to perform work in the vicinity of high voltage components, perform a visual inspection of the high voltage components and cables for damages, refer to VISUAL INSPECTION OF HIGH-VOLTAGE COMPONENTS AND CABLES FOR DAMAGE and always follow the warnings when working on the high voltage system. Refer to GENERAL INFORMATION .

The following procedure requires working on the high voltage system. De-energize the high voltage system. Refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS , GENERAL INFORMATION and read and follow the high voltage electrical system general warnings. Refer to GENERAL INFORMATION .

De-energize the high voltage system. Refer to GENERAL INFORMATION .

Disable the high voltage system

Note. Disable the high voltage system: Connect the vehicle diagnosis tester Select the Guided Fault Finding mode Using the GO TO button, select the following menu commands Functions/Component selection Body Electrical Equipment OBD-capable system 8C - Hybrid battery management -J840 8C - Hybrid battery management, functions 51 - Disable the high voltage system (Rep.Gr. 93)

Disconnect the ground cable from the battery -A-. Refer to Removal and Installation .

Remove the rubber seal -A- and the plenum chamber cover -B- (there are different versions). Refer to Removal and Installation .

Inspect the high voltage components -D- (the electric drive power and control electronics -JX1-) and the high voltage cables -E- after removing the plenum chamber cover -B-. Refer to VISUAL INSPECTION OF HIGH-VOLTAGE COMPONENTS AND CABLES FOR DAMAGE and REMOVAL AND INSTALLATION .

Loosen the power distribution panel -1- and move it toward the windshield with the wires. Refer to REMOVAL AND INSTALLATION .

Remove the high voltage cables for the electric drive power and control electronics -JX1-. Refer to REMOVAL AND INSTALLATION .

Cover the electric drive power and control electronics -JX1- and wires to prevent them getting damaged and to protect them from dirt. Refer to REMOVAL AND INSTALLATION .

Note. Use clean 20 mm bungs -B-, taken from engine bung set VAS 6122, to seal off the connection on the electric drive power and control electronics -JX1- -A-.

1. Be careful not to damage any high voltage components -D- or the high voltage cables -E-. Refer to GENERAL INFORMATION .

Note. It may be necessary to remove the cowl panel -C- in order to remove and install the expansion valve. Refer to Description and Operation .

For vehicles without a high voltage system

Turn off the ignition.

Remove the plenum chamber cover and/or the cowl panel (there are different versions). Refer to Removal and Installation .

Disconnect the ground cable from the battery -A-. Refer to Removal and Installation .

Note. Disconnect the battery -A- ground connection so that it cannot short circuit when the jumper cable post -C- is removed.

Remove the jumper cable post cover -C-.

All vehicles

If equipped and necessary, remove the suspension strut dome -B- (for example Audi A5 Coupe, not necessary for example on the Audi Q5). Refer to Removal and Installation .

Note. The plenum chamber front wall cannot be loosened or removed from the vehicle (there is not enough space available). Both coolant hoses are routed to the heater core through the plenum chamber front wall -A-. On these vehicles, loosen the grommet on both coolant hoses and move the plenum chamber front wall to the side (when doing this, the refrigerant circuit must not be opened). When loosening the plenum chamber front wall, be careful not to damage the brake booster vacuum line.

Remove the expansion valve. Refer to EXPANSION VALVE .

Note. Seal open pipe connections.

Remove the expansion valve mounting plate -A- from the refrigerant lines -B- and -C-.

Scheme 202

Remove the storage compartment on driver's side. Refer to Removal and Installation

Remove the left footwell (driver side). Refer to LEFT FOOTWELL VENTS .

Remove the steering column. Refer to Removal and Installation .

Remove the pedal assembly and accelerator pedal module. Refer to Removal and Installation and Removal and Installation .

Remove the screw -A-.

Scheme 203

Loosen the locking mechanism -C- and remove the cover for the refrigerant lines leading to the evaporator -B-.

Disconnect both refrigerant lines leading to the evaporator -A- and -B- at the location identified with -E- using T40147.

Scheme 204

Note. This illustration show the refrigerant pipes -C- and -D- to the evaporator not wrapped with butyl or tar tape. The refrigerant pipe -D- on the Audi Q5 hybrid is wrapped with insulation (butyl or tar tape) to reduce noise. The butyl or tar tape shields the A/C compressor noise, which seems to be louder when the engine is idling.

Loosen the disconnected refrigerant lines -C- and -D- from the grommet -F- and remove both refrigerant lines.

Bend the part of the refrigerant line -A- (which is already on the evaporator) to the right (to the evaporator) so that it does not interfere when removing the evaporator.

Remove the glove compartment. Refer to Removal and Installation .

Remove the air intake housing. Refer to A/C UNIT AIR INTAKE HOUSING .

Cut the housing wall -A- (on the right side of the A/C unit) using a sharp knife (for example, a strong carpet knife with a point; the blade must be secure and the handle must be strong.) along the marked cutting line from the A/C unit.

Scheme 205

Remove the evaporator -B- in the direction of the arrow -arrow- from the A/C unit.

Prior to installing the evaporator, refer to Removal and Installation .

Installation is carried out in the reverse order while observing the following.

Check the A/C unit via the evaporator installation shaft for dirt; clean the A/C unit if necessary.

Scheme 206

Note. When doing this, pay attention to both condensation water drains -A- and their openings -B-.

Check both connections -B- and -C- on the replacement evaporator -A- for dirt and damage.

Scheme 207

Install both covers -D- and -F- on the correct side on the evaporator.

Note. Both covers are included in the replacement evaporator kit. Depending on the cover version -D- cut the part -E- from this cover (on the side with the connections installed).

Push the evaporator -A- into the A/C shaft; when doing this, be careful not to loosen the covers -D- and -F- from the evaporator.

Install the bracket -A- with the bolt -B- on the evaporator connector.

Scheme 208

Check the refrigerant lines -C- and -D- for damage and dirt.

Note. Even slight damage (a scratch) or a little bit of dirt (a hair) can cause leakage at a connection. The refrigerant lines -C- and -D-, the O-rings -E- and -F-, the bracket -A- and the bolt -B- and -H- are all included in the replacement evaporator kit.

Install the refrigerant lines -C- and -D- into the grommet -G-.

Note. If replacing the evaporator on an Audi Q5 Hybrid, then wrap the refrigerant pipe -C- on the replacement evaporator with insulating tape as illustrated before installing. Approximately 30 cm (12 in.) of 5 cm (2 in.) wide insulating tape (butyl or tar tape) -B- with a 3 mm strength will be needed. Wrap both ends of the refrigerant pipe -C- when it is removed, as illustrated. Do not wrap approximately 15 mm (0.6 in.) in area -A-. This is where a grommet will be installed facing the expansion valve. Likewise, do not wrap the connection area to the evaporator.

Coat the O-rings -E- and -F- with refrigerant oil before installing. Refer to REFRIGERANT CIRCUIT O-RINGS .

Mount the O-rings -E- and -F- on the refrigerant lines -C- and -D-.

Install the refrigerant lines -C- and -D- in the connection on the evaporator.

Install the bolt -H-.

Install both bolts -B- and -H- equally far enough so that both refrigerant lines -C- and -D- can be turned without pretension.

Note. When installing the bolts -B- and -H- be careful not to twist the bracket -A- together with the refrigerant lines. If the refrigerant pipe wrapping -B- touches the separating walls of the evaporator housing -C- on an Audi Q5 hybrid, rework the walls, if necessary.

Connect the expansion valve mounting plate -A- to the refrigerant lines -B- and -C-.

To align both refrigerant lines, first install the expansion valve, refer to EXPANSION VALVE and the refrigerant line with the inner heat exchanger, refer to REFRIGERANT CIRCUIT COMPONENTS .

Note. The expansion valve and the refrigerant line with the inner heat exchanger are installed first to align both refrigerant lines leading to the evaporator, and after tightening both bolts on the evaporator connect, they are removed again.

Tighten the bolts -B- and -H- on the evaporator connector (tightening specification 5 Nm).

Note. This illustration show the refrigerant pipes -C- and -D- to the evaporator not wrapped with butyl or tar tape. On the Audi Q5 hybrid, wrap the refrigerant pipe to the evaporator with a piece of butyl or tar tape in area -A- as illustrated after tightening the screws to reduce noise. Then wrap the entire area -D- on the evaporate with another piece of butyl or tar tape.

Remove the refrigerant line with the inner heat exchanger and the expansion valve again.

Install the expansion valve. Refer to EXPANSION VALVE .

Install the refrigerant line with inner heat exchanger. Refer to REFRIGERANT CIRCUIT COMPONENTS .

Install the cover for the evaporator refrigerant lines -B- and the bolt -A-.

Make sure the cover -B- fits correctly and that it is free of tension.

Note. Even the smallest lead at the groove/spring connection between the cover -B- and the air conditioner -A- will cause whistling noises. Coat the connecting surfaces lightly with silicone grease (part number G 000 405 A2).

Clean and dry the groove in the A/C unit -E- before installing the separating wall -C-.

Fill the groove on the A/C unit -E- before installing the separating wall -C- for example with silicone adhesive D 176 001 A3.

Install the separating wall -C-.

Note. The separating wall -C- is included in the replacement evaporator kit. There are different versions of the separating wall -C- (with and without the spayed on sealing lip). If the connecting location between the A/C unit -E- and the separating wall -C- is not sealing in area -D- condensation water from the A/C could leak into the footwell when, for example, driving around a curve.

Remove any excess adhesive (the adhesive may only in the area -D-); and remove any excess adhesive out of the groove -G-.

Install the air intake housing. Refer to A/C UNIT AIR INTAKE HOUSING .

With high voltage systems (hybrid vehicles)

Inspect the high voltage components -D- and high voltage cables -E- after completing the work procedure and before installing the plenum chamber cover -B-. Refer to GENERAL INFORMATION .

Electrical connections and routing, refer to the appropriate SYSTEM WIRING DIAGRAMS information.

Install the remaining removed parts in the opposite order.

Energize the voltage to the high voltage system. Refer to GENERAL INFORMATION .

Restart the high voltage system

Note. Restart the high voltage system: Connect the vehicle diagnosis tester Select the Guided Fault Finding mode Using the GO TO button, select the following menu commands Functions/Component selection Body Electrical Equipment OBD-capable system 8C - Hybrid battery management -J840 8C - Hybrid battery management, functions 51 - High voltage restart (Rep.Gr. 93)

For vehicles without a high voltage system

Reconnect the battery -A- ground connection; when doing this, pay attention to the notes regarding reconnecting the battery. Refer to Removal and Installation .

Install the remaining removed parts in the opposite order.

All vehicles

Evacuate the refrigerant circuit and fill it. Refer to A/C Service Station in Description and Operation .

Install the remaining removed components.

Switch on the ignition.

Perform a basic setting and the output Diagnostic Test Mode (DTM) on the A/C system using the Vehicle diagnostic tester in "Guided Fault Finding".

Note. On this vehicle, the control motors are equipped with electronics. During the first basic setting, a new control motor learns its position on the air conditioner and can then be controlled by the Climatronic Control Module -J255- (currently all control motors are identical). Refer to the Vehicle diagnostic tester in "Guided Fault Finding". During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM .

Check the Climatronic Control Module DTC memory and erase any displayed malfunction if necessary using the Vehicle diagnostic tester in "Guided Fault Finding".

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Note. Note the information regarding operating the A/C system after filling. Refer to A/C Service Station in Description and Operation .

EVAPORATOR HOUSING

Note. Evaporators with a 40 mm (1.6 in.) block depth -A- (air conditioner part number "8K_ 820 005") are being installed from start of production through the change-over from MY 12. These evaporators can be replaced with the air conditioner still installed. Refer to EVAPORATOR, A/C UNIT INSTALLED . From MY 12, Evaporators with a block depth -A- of approximately 50 mm (2 in.) are being installed (air conditioner part number "8T_ 820 005") as a running change depending on the vehicle version. These evaporators can be replaced only with the air conditioner removed together with the evaporator housing. Replace the evaporator and the evaporator housing if the evaporator is not available as a single part, or if for other reasons it must be replaced together with the evaporator housing (it is necessary to remove the air conditioner in order to replace the evaporator). There is a label -A- on the outside of the A/C unit with a part -B- that tells which version is installed. The part number -B- on the decal -A- can be read when the CD changer is removed (depending on the vehicle equipment level). Refer to Removal and Installation .

Remove the A/C unit. Refer to A/C UNIT .

Note. The following illustrations show a "Basis" air conditioner. The location of certain components on the "Comfort" air conditioner may differ (for example, the location and number of motors).

Remove the bolt -B-, unlock the tabs and remove the bracket -A-.

Remove the bolts -E-, unlock the tabs and remove the bracket -A-.

Remove the clamps -F- and the coolant pipes -G-.

Note. Be careful not to drop the seals -B- into the heater core or air conditioner when removing the coolant pipes -A-. Do not re-use the seals -B- and clamps -D-.

Remove the bolts -A- (above the left radiator housing -C- on the evaporator housing -B-).

Scheme 209

Note. Left radiator housing, removing and installing -C-, refer to LEFT HEATER CORE HOUSING WITH TEMPERATURE DOORS .

Remove the right radiator housing -H-. Refer to RIGHT HEATER CORE HOUSING, MOTOR MOUNTING PLATE REMOVED or RIGHT HEATER CORE HOUSING AND RIGHT MOTOR MOUNTING PLATE .

Scheme 210

Remove the heater core -I- and the honeycomb /auxiliary heater heating element -Z35-. Refer to HEATER CORE REMOVING AND INSTALLING and AUXILIARY AIR HEATER HEATING ELEMENT -Z35- / HONEY COMB .

Note. It is not really necessary to remove the heater core -I- and the honeycomb / auxiliary heater heating element because these parts still fit loosely inside the left radiator housing. It is easy to remove them.

Remove the evaporator housing -A- from the left radiator housing -B- / air distribution housing -C-.

Scheme 211

Note. Currently the evaporator housing is not disassembled any further. For the evaporator housing construction, refer to EVAPORATOR HOUSING .

Installation is done is reverse order, observe the following

Check the evaporator housing -A-, left radiator housing -B- and air distribution housing -C- for dirt and damage and clean or replace if necessary.

Assemble the evaporator housing -A- and the left radiator housing -B- / air distribution housing -C-.

Note. Push the guides -D- (top and bottom) on the evaporator housing -A- into the grooves -E- in the left radiator housing -B-.

Install the bolts -A- (above the left radiator housing -C- on the evaporator housing -B-).

Install the heater core -I- and honeycomb / auxiliary heater heating element. Pay attention to the installed position. Refer to HEATER CORE REMOVING AND INSTALLING and AUXILIARY AIR HEATER HEATING ELEMENT -Z35- / HONEY COMB .

Install the right radiator housing -H-. Refer to RIGHT HEATER CORE HOUSING, MOTOR MOUNTING PLATE REMOVED or RIGHT HEATER CORE HOUSING AND RIGHT MOTOR MOUNTING PLATE .

Check both connections -C- on the heater core and the coolant pipes -A- for dirt and damage and clean or replace them if necessary.

Scheme 212

Coat both connections -C- on the heater core and coolant pipes -A- lightly with silicone grease.

Note. The silicone grease part number is G 000 405 A2.

Moisten the new seals -B- with coolant (or coat them lightly with silicone grease) and then push them onto the coolant pipes -A-.

Position the coolant pipes -A- on the evaporator housing and push them into the connections -C- in the heater core -arrow-.

Install the new coolant pipe clamps -F- on the connection -C- on the heater core as illustrated (push them all the way on -arrow-).

Note. Do not re-use removed seals -B- and clamps -D-. If a replacement heater core -C- is being installed instead of the heater core shown above (standard production version), then install the coolant pipes as described for this version of the heater core. Refer to HEATER CORE REMOVING AND INSTALLING .

Install the remaining components for the air conditioner.

Installing the heater and A/C unit, refer to A/C UNIT .

A/C UNIT

Special tools and workshop equipment required

1. Hose Clamps, Up to 40 mm diameter 3094
2. Hose Clamps Up to 25 mm diameter 3093
3. Commercial compressed-air gun with rubber end piece
4. Cooling system tester V.A.G 1274 (and corresponding adapter)

Note. On removal, note bolt lengths and assignment for installation later. All cable ties and other wiring harness fasteners released or cut open on removing air conditioner unit are to be re-attached in same position on installation.

Move the driver and passenger seats as far back as possible.

Turn off the ignition.

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Note. Depending on the allocation of the service connection an on the refrigerant line, and on the version of the vehicle, it may be necessary to remove the additional reinforcement on the left suspension strut dome so that the service coupling of the service station can be connected (for example, on the Audi Q5). Refer to Removal and Installation and Removal and Installation .

With high voltage systems (hybrid vehicles)

Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system, refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS and to GENERAL INFORMATION .

If it is necessary for the following procedure to perform work in the vicinity of high voltage components, perform a visual inspection of the high voltage components and cables for damages, refer to VISUAL INSPECTION OF HIGH-VOLTAGE COMPONENTS AND CABLES FOR DAMAGE and always follow the warnings when working on the high voltage system. Refer to GENERAL INFORMATION

The following procedure requires working on the high voltage system. De-energize the high voltage system. Refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS , GENERAL INFORMATION and read and follow the high voltage electrical system general warnings. Refer to GENERAL INFORMATION .

De-energize the high voltage system. Refer to HIGH VOLTAGE SYSTEM, DE-ENERGIZING .

Disable the high voltage system

Note. Disable the high voltage system: Connect the vehicle diagnosis tester Select the Guided Fault Finding mode Using the GO TO button, select the following menu commands Functions/Component selection Body Electrical Equipment OBD-capable system 8C - Hybrid battery management -J840 8C - Hybrid battery management, functions 51 - Disable the high voltage system (Rep.Gr. 93)

Remove the rubber seal -A- and the plenum chamber cover -B- (there are different versions). Refer to Removal and Installation .

Inspect the high voltage components -D- (the electric drive power and control electronics -JX1-) and the high voltage cables -E- after removing the plenum chamber cover -B-. Refer to VISUAL INSPECTION OF HIGH-VOLTAGE COMPONENTS AND CABLES FOR DAMAGE and GENERAL INFORMATION .

Disconnect the ground cable from the battery -A-. Refer to Removal and Installation .

Loosen the power distribution panel -1- and move it toward the windshield with the wires. Refer to REMOVAL AND INSTALLATION .

Remove the high voltage cables for the electric drive power and control electronics -JX1-. Refer to REMOVAL AND INSTALLATION .

Cover the electric drive power and control electronics -JX1- and wires to prevent them getting damaged and to protect them from dirt. Refer to REMOVAL AND INSTALLATION .

Note. Use clean 20 mm bungs -B-, taken from engine bung set VAS 6122, to seal off the connection on the electric drive power and control electronics -JX1- -A-.

1. Be careful not to damage any high voltage components -D- or the high voltage cables -E-. Refer to GENERAL INFORMATION .

Note. It may be necessary to remove the cowl panel -C- in order to remove and install the expansion valve. Refer to Description and Operation .

For vehicles without a high voltage system

Disconnect the ground cable from the battery -A-. Refer to Removal and Installation .

Remove the plenum chamber cover and/or the cowl panel (there are different versions). Refer to Removal and Installation .

Note. The battery -A- ground connection is disconnected so that it will not short circuit with the jumper cable post removed -C- and when disconnecting the positive cable to both relays for the Auxiliary Air Heater Heating Element -Z35- -J-.

Remove the jumper cable post cover -C-.

All vehicles

On vehicles equipped with auxiliary air heater heating element loosen the positive cable to both relays for the Auxiliary Air Heater Heating Element -J- from the jumper cable post -C-. Refer to Removal and Installation .

If equipped and necessary, remove the suspension strut dome -B- (for example Audi A5 Coupe, not necessary for example on the Audi Q5). Refer to Removal and Installation .

Note. The plenum chamber front wall cannot be loosen or removed from the vehicle (there is not enough space available). Both coolant hoses are routed to the heat exchanger through the plenum chamber front wall -A-. On these vehicles, loosen the grommet on both coolant hoses and move the plenum chamber front wall to the side (when doing this, the refrigerant circuit must not be opened). When loosening the plenum chamber front wall, be careful not to damage the brake booster vacuum line.

Remove the expansion valve. Refer to EXPANSION VALVE .

Note. The air conditioner can be removed and installed with the expansion valve still installed. Removing and installing with the expansion valve removed is described here due to the increased space. Seal open pipe connections. To seal off all open connections on expansion valve, sealing caps from a replacement expansion valve can be used (preventing dirt and moisture from entering the system).

Remove the expansion valve mounting plate -A- from the refrigerant lines -B- and -C- (so that it does not get lost while removing).

Coat the inner side of the grommet -D- with grease and remove the supporting ring -E-.

Loosen the grommet -D- from the plenum chamber rear wall toward the passenger compartment (it is removed and installed with the A/C unit).

Release pressure in cooling circuit by opening cap on coolant expansion tank.

Mark the arrangement of coolant hoses -A- (supply to cylinder head) and -B- (return to coolant pump).

Note. The heater core is designed for a specific coolant flow direction. Therefore, coolant hoses must be connected on the correct sides. Bleed the coolant circuit. Refer to [For engine(s) CAUA] Description and Operation or to [For engine(s) CAEB] Description and Operation or to [For engine(s) CALA] Description and Operation .

Clamp the coolant hoses -A- and -B- with hose clamps.

Cover the area beneath connections for coolant hoses -A- and -B- for example with absorbent paper.

Remove coolant hoses -A- and -B- from connections to A/C unit heater core.

Insert one section each of hose -A- and -B- on to both connections to heater core.

Place a container -B- under the other end of the hose -C-.

Using a compressed air gun -D-, carefully blow coolant out of heater core (into container -B-) via hose -A-.

Loosen the grommet -H- from the plenum chamber rear wall and remove it from the heat exchanger coolant pipes.

Remove the glove box, the center console and instrument panel. Refer to Removal and Installation .

Note. To prevent the instrument panel shell from damage, instrument panel should be placed on a clean work bench which is covered with clean cardboard.

Remove the air intake housing. Refer to A/C UNIT AIR INTAKE HOUSING .

Remove the air guides to the left and right instrument panel vents.

Note. The air guide channel leading the left instrument panel vent -A- is secured by an expanding clip or a screw -B- onto the instrument panel crossmember -C- ; the expanding clip or the screw can only be removed when the outer instrument panel shell is removed.

Remove the air guides to the instrument panel center vents -C- and to the defrost vent -D-.

Scheme 213

Remove the bolts -A- and -B-.

Remove the steering column. Refer to Removal and Installation

Disconnect the connector from the brake lamp switch -F-. Refer to Removal and Installation .

Loosen the instrument panel cross member -E- from the vehicle and from the A/C unit. Refer to Removal and Installation .

Note. Except for the left fuse box, do not loosen any other left relay- or control unit brackets from the instrument panel cross member.

Remove the air guide to the rear center console vent -C- (only on vehicles equipped with the "Comfort" A/C system).

Scheme 214

Loosen the air guide to the rear footwell vents -A- and -B- from the intermediate piece -D- and remove the intermediate piece -D-.

On vehicles equipped with a Auxiliary Air Heater Heating Element -Z35- loosen the ground connection -A- and disconnect the connector -B-. Refer to AUXILIARY AIR HEATER HEATING ELEMENT -Z35- / HONEY COMB .

Scheme 215

Disconnect both condensation water drain hoses from the A/C unit. Refer to CONDENSATION WATER DRAIN HOSE .

Disconnect the fuse panel "driver side" on the left side of the instrument panel cross member (central tube) -A- from the instrument panel cross member. Refer to Removal and Installation .

Scheme 216

Note. Since the instrument panel cross member is loosen only from the vehicle (not completely removed), the remaining relay-/fuse carriers and clutch stations must not be removed from the instrument panel cross member

Loosen all electric connections between the instrument panel cross member and the vehicle on the passenger side -B-.

Cover the carpet in the area of the center tunnel with a mat -C- (and both seats if not already done).

Note. The instrument panel cross member must not be completely removed in order to remove the A/C unit; it is enough to disconnect the A/C unit from the vehicle and then to swivel it to the rear and place it on the center tunnel.

Carefully remove the instrument panel cross member from the vehicle and carefully swivel it (and when doing this not to damage any components) to the passenger side -B- far enough to the rear -arrow- so that the A/C unit can be removed to the right -arrow-.

Remove the vehicle wiring harness in the area of the instrument panel cross member from the A/C unit.

Carefully remove the A/C unit from the vehicle (with doing this, do not damage any connections and components still not removed).

On vehicles equipped with a Auxiliary Air Heater Heating Element -Z35- mark the location of the mounting points -B- (with cable ties on the A/C unit) on the positive cable to both relays for the Auxiliary Air Heater Heating Element -A- (for example with a suitable pin on the cable).

Scheme 217

Disconnect the cable -A- from the A/C unit.

Remove the remaining vehicle wiring harness mounts (for example with cable ties) on the A/C unit.

Remove the A/C unit -A- in the direction of the passenger side.

Scheme 218

Note. The wiring harness "air conditioner" is removed together with the A/C unit.

Installation is carried out in the reverse order while noting the following

Note. Before installing, check all gaskets and grommets on the A/C unit for damage and replace if necessary.

Install the A/C unit -A- and the components also removed with the A/C unit (wiring harness "A/C unit", grommet on the evaporator refrigerant lines, etc.) in the vehicle

Coat the grommet -D- with grease and install it in the plenum chamber rear wall.

Install the support ring -E- in the grommet -D-.

Install the instrument panel cross member (central tube). Refer to Removal and Installation .

Install the expansion valve mounting plate -A- to the refrigerant lines -B- and -C-.

Install the grommet -H- in the plenum chamber rear wall.

Check the position of the coolant and refrigerant line in both grommets, and if necessary, align the A/C unit so that the lines are not tensioned in the grommets.

Install the screws -A-.

Slide the strap -F- all the way to the bracket -H-, then turn it downward (when doing this, the bracket -G- locks the A/C unit to the strap)

Install the bolts -B-.

Connect both condensation water drain hoses to the A/C unit. Refer to CONDENSATION WATER DRAIN HOSE .

Note. When installing the intermediate piece, -D-, the air guides to the rear footwells -A- and -B- and the air guide to the vent in the rear center console -C- make sure that they fit correctly and are securely connected. If they are not connected tightly, warm or cool air could leak out and influence how the A/C system works (this air will be drawn in by the Interior Temperature Sensor Fan -V42- and the values, measured by the Instrument Panel Interior Temperature Sensor -G56- will deviate from the actual temperature in the passenger compartment. The intermediate piece -D- latches on the air outlet openings on the air conditioner. There are slits inside the intermediate piece -D-. If the flap position is incorrect, especially on vehicles with the "Comfort" A/C system, whistling noise can come from these slits. The upper slits are covered with tape during production (running change from February 2009). Refer to REAR VENT AIR GUIDE SLOTS, SEALING .

Install the air intake housing. Refer to A/C UNIT AIR INTAKE HOUSING .

Install the expansion valve. Refer to EXPANSION VALVE .

Install the refrigerant line with inner heat exchanger. Refer to REFRIGERANT CIRCUIT COMPONENTS .

Make sure the grommet -H- fits correctly in the back of the plenum chamber.

Properly connect the coolant hoses to the heater core, pay attention to the marking.

A - Supply hose from cylinder head

B - Return to the coolant pump

Connect the coolant hose -A- to the heater core coolant pipe (pay attention to the marking) and secure it with the clamp -D-.

Attach the coolant hose for the heater core -B- onto the coolant pipe -F- just far enough as to not cover the bleed hole -G-.

Remove the hose clamp from the coolant hose -A-.

Fill the coolant expansion tank with coolant. Refer to [For engine(s) CAUA] General Information or to [For engine(s) CAEB] General Information or to [For engine(s) CALA] General Information .

Carefully force the coolant out of the coolant overflow reservoir into the heater core using, for example, the hand pump from the Cooling System Tester V.A.G 1274/.

As soon as the coolant comes out the ventilation hole -G-, install the coolant hose -B- on to the coolant pipe -F- at the marking.

Secure the coolant hose -B- with the clamp -E- on the marked location.

Remove the hose clamp from the coolant hose -D-.

Add more coolant to the coolant reservoir, if necessary. Refer to [For engine(s) CAUA] General Information or to [For engine(s) CAEB] General Information or to [For engine(s) CALA] General Information .

Note. This procedure completely bleeds the cooling system. If, for some other reason, there still should be some air in the cooling system, install all the components and bleed the system once again. Refer to [For engine(s) CAUA] General Information or to [For engine(s) CAEB] General Information or to [For engine(s) CALA] General Information .

Check the connections at the heater corer for leaks as follows

Carefully increase the pressure in the coolant circuit by using, for example, the hand pump of the cooling system tester V.A.G 1274/.

Check coolant circuit for leaks, pay particular attention to the connection between coolant hoses and heater core Engine Mechanical.

Note. This illustration shows the coolant pipes on a replacement heater core. The coolant pipes are attached to the heater core by clamps. Refer to HEATER CORE REMOVING AND INSTALLING . When bleeding coolant circuit, take special care to ensure complete bleeding of heater cores. If there are still air bubbles in the heater core, it may cause the customer to complain of insufficient heating performance in winter or different air temperature from vents at same setting in regulated mode. Refer to HEAT OUTPUT AND TEMPERATURE DOOR ACTIVATION, CHECKING . Depending on vehicle equipment and on engine, heat insulation has been applied to coolant hoses, these must not be damaged and must be re-applied after installing.

Secure the wiring harness once again on the provided places and install the different air guides in reverse order.

Install the instrument panel, the center console, and glove box, etc. Refer to Removal and Installation .

Note. When installing the instrument panel, make sure that the "defrost" intermediate piece its properly on A/C unit and the defrost vent does not pinch the intermediate piece. Refer to AIR ROUTING AND DISTRIBUTION IN PASSENGER COMPARTMENT .

With high voltage systems (hybrid vehicles)

Inspect the high voltage components -D- and high voltage cables -E- after completing the work procedure and before installing the plenum chamber cover -B-. Refer to GENERAL INFORMATION .

Electrical connections and routing, refer to the appropriate SYSTEM WIRING DIAGRAMS information.

Install the remaining removed parts in the opposite order.

Energize the voltage to the high voltage system. Refer to GENERAL INFORMATION .

Restart the high voltage system

Note. Restart the high voltage system: Connect the vehicle diagnosis tester Select the Guided Fault Finding mode Using the GO TO button, select the following menu commands Functions/Component selection Body Electrical Equipment OBD-capable system 8C - Hybrid battery management -J840 8C - Hybrid battery management, functions 51 - High voltage restart (Rep.Gr. 93)

For vehicles without a high voltage system

Reconnect the battery -A- ground connection; when doing this, pay attention to the notes regarding reconnecting the battery. Refer to Removal and Installation .

Install the remaining removed parts in the opposite order.

All vehicles

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Switch on the ignition.

Perform a basic setting and the output Diagnostic Test Mode (DTM) on the A/C system using the Vehicle diagnostic tester in "Guided Fault Finding".

Note. On this vehicle, the control motors are equipped with electronics. During the first basic setting, a new control motor learns its position on the air conditioner and can then be controlled by the Climatronic Control Module -J255- (currently all control motors are identical). Refer to the Vehicle diagnostic tester in "Guided Fault Finding". During the basic setting, the control motors are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the control motors will adapt incorrectly and the door control will be wrong. Refer to A/C CONTROL MOTOR BLOCK DIAGRAM .

Check the Climatronic Control Module DTC memory and erase any faults using the Vehicle diagnostic tester in "Guided Fault Finding".

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Note. Note the information regarding operating the A/C system after filling. Refer to A/C Service Station in Description and Operation .

A/C COMPRESSOR REFRIGERANT LINES

Note. An A/C compressor with an A/C clutch -N25- is installed as a running change on certain 4 cylinder vehicles from MY 12. Refer to BELT PULLEY WITH A/C CLUTCH -N25- OVERVIEW . The A/C clutch turns off the A/C compressor drive completely under certain conditions (for example "ECON"). The correct Climatronic control module -J255- must be installed and it must be coded correctly so that the Climatronic control module can control the A/C clutch. Refer to the Vehicle diagnostic tester in "Guided Fault Finding". The A/C compressor without an A/C clutch -N25- is always also driven when the engine is running. If the vehicle has an A/C compressor without an A/C clutch, then the vehicle may only be started when the refrigerant circuit has been properly assembled. For example; if the refrigerant lines are not connected to A/C compressor, when the engine is running the A/C compressor may heat up (via internal heat generation) so much that the A/C compressor will be damaged. Such internal heat generation results from the fact that - even with delivery near 0% - the compressor is confronted with a fixed resistance (sealed circuit). Close open lines and connections on A/C compressor using suitable caps (to prevent possible penetration of dirt and moisture).

Turn off the ignition.

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Note. Depending on the allocation of the service connection an on the refrigerant line, and on the version of the vehicle, it may be necessary to remove the additional reinforcement on the left suspension strut dome so that the service coupling of the service station can be connected (for example, on the Audi Q5). Refer to Removal and Installation and Removal and Installation .

With high voltage systems (hybrid vehicles)

Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system, refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS and to GENERAL INFORMATION .

If it is necessary for the following procedure to perform work in the vicinity of high voltage components, perform a visual inspection of the high voltage components and cables for damages, refer to VISUAL INSPECTION OF HIGH-VOLTAGE COMPONENTS AND CABLES FOR DAMAGE and always follow the warnings when working on the high voltage system. Refer to GENERAL INFORMATION .

Remove the bolts -1- and -4-.

Remove the refrigerant pipes.

For vehicles without a high voltage system

Note. On vehicles with a 4 cylinder engine, it is not always necessary to remove the A/C compressor from the bracket in order to remove the refrigerant lines. Depending on the style of the power steering vane pump, the refrigerant lines can be removed from the A/C compressor also when the A/C compressor is removed from the bracket. The power steering pump is installed only on vehicles with electro-mechanical power steering. Refer to Description and Operation . For vehicles with 4 cylinders, if the bolt on the connection for the refrigerant lines on the A/C compressor is not accessible, remove the A/C compressor from the bracket. Refer to A/C COMPRESSOR REMOVING FROM BRACKET . If the refrigerant line on the low pressure side is removed (from the refrigerant line with the inner heat exchanger to the compressor), then the components, which must be removed, depend on the routing of the refrigerant line.

Remove the screws -A-.

Scheme 219

Remove the refrigerant lines -B- and -C-.

All vehicles

Note. Seal open pipes and connections on the A/C compressor with caps (to prevent dirt and moisture from getting in).

Installation is the reverse of removal, noting the following

Replace O-rings seals -D- and -E-, version.

Check the guide ring -F- on the connections for both refrigerant lines -B- and -C- for damage.

Clean the refrigerant line and A/C compressor connections and check for damage.

Coat the O-ring seals with refrigerant oil prior to installation. Refer to REFRIGERANT CIRCUIT O-RINGS .

Insert the respective O-ring -D- and -E- in the groove -G- on the connections for both refrigerant lines -B- and -C-.

Note. Do not use the O-rings from the sealing caps that are installed on the connections in the replacement compressor when installing the lines. Make sure the O-rings fit correctly inside the groove -G- on each refrigerant line.

Insert both refrigerant lines -B- and -C- into each connection on the A/C compressor.

Tighten the bolts -A- to 9 Nm (bolts with a M6 thread) and to 25 Nm (bolts with a M8 thread).

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

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Install the remaining removed components.

Switch on the ignition.

Check the Climatronic control module -J255- DTC memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Note. Note the information regarding operating the A/C system after filling. Refer to A/C Service Station in Description and Operation .

Note. The A/C compressor is always also driven when the engine is running. The vehicle may only be started when the refrigerant circuit has been properly assembled. For example; if the refrigerant lines are not connected to A/C compressor, when the engine is running the A/C compressor may heat up (via internal heat generation) so much that the A/C compressor will be damaged. Such internal heat generation results from the fact that - even with delivery near 0% - the compressor is confronted with a fixed resistance (sealed circuit). Close open lines and connections on A/C compressor using suitable caps (to prevent possible penetration of dirt and moisture).

Note. The following procedure describes removing and connecting of the refrigerant lines on a vehicle equipped with a 6 cylinder TDI engine. For vehicles with 6 FSI engine, the A/C compressor may be dismantled and removed from the mount only when the refrigerant circuit is open. The gasoline engine may have a few differences, but the refrigerant lines are removed and installed in the same manner.

Turn off the ignition.

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Note. Depending on the allocation of the service connection an on the refrigerant line, and on the version of the vehicle, it may be necessary to remove the additional reinforcement on the left suspension strut dome so that the service coupling of the service station can be connected (for example, on the Audi Q5). Refer to Removal and Installation and Removal and Installation .

Remove the engine cover -arrows-.

Scheme 220

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

Scheme 221

Remove the air guide hose and the hose clamp -3-.

Disconnect the electrical connector -4-.

Remove the bolts -2- and the Throttle Valve Control Module -J338-.

Disconnect the connector -1- for the A/C Compressor Regulator Valve -N280-.

Scheme 222

Remove the bolts -2- and -3- and remove the refrigerant lines from the compressor.

Note. Close open lines and connections on A/C compressor using suitable caps (to prevent possible penetration of dirt and moisture). On vehicles with a gasoline engine and dynamic steering, depending on the installed position of the intake hose on the power steering pump and on the work procedure, use a commercially available long socket (if available, best with a ball head to loosen and tighten the bolt -2- on the refrigerant pipe. Move the intake hose carefully to the side while doing this. Refer to Removal and Installation . Loosen the A/C compressor from the bracket to remove the refrigerant pipes. Refer to A/C COMPRESSOR .

Installation is done is reverse order, observe the following

Replace the O-rings -D- and -C-.

Check the guide ring -F- on the connections for both refrigerant lines -B- and -C- for damage.

Clean the refrigerant line and A/C compressor connections and check for damage.

Note. Do not use the O-rings from the sealing caps that are installed on the connections in the replacement compressor when installing the lines. Follow the instructions for installing the O-rings. Refer to REFRIGERANT CIRCUIT O-RINGS .

Coat the O-ring seals with refrigerant oil prior to installation. Refer to REFRIGERANT CIRCUIT O-RINGS .

Insert the respective O-ring -D- and -E- into the groove -G- on the connections for both refrigerant lines -B- and -C-.

Insert both refrigerant line into each connection on the compressor.

Tighten bolts -2- and -3-.

1. Tightening specification: 9 Nm (screws with an M6 thread) and 25 Nm (screws with an M8 thread).

Note. Following attachment of refrigerant pipes to compressor (and installation of compressor) check routing of pipes. They must be inserted in holders provided and not make contact with other components.

Connect electrical connector -1- on A/C Compressor Regulator Valve -N280-.

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Install the remaining removed components.

Switch on the ignition.

Check the Climatronic control module -J255- DTC memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Note. Note the information regarding operating the A/C system after filling. Refer to A/C Service Station in Description and Operation .

Turn off the ignition.

Drain the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Note. Depending on the allocation of the service connection an on the refrigerant line, and on the version of the vehicle, it may be necessary to remove the additional reinforcement on the left suspension strut dome so that the service coupling of the service station can be connected (for example, on the Audi Q5). Refer to Removal and Installation and Removal and Installation . On the Audi RS 4 and Audi RS 5, it is not necessary to loosen the coolant reservoir to remove the A/C compressor, but rather, the left air filter must be removed. This is different from the other vehicles. Refer to [For engine(s) CAUA] Description and Operation .

Remove the coolant hose -3- from the coolant reservoir (not Audi RS 4 and Audi RS 5).

Remove the bolts -arrows- and then move the coolant reservoir to the side with the coolant hoses -1- and -2- still connected (not Audi RS 4 and Audi RS 5).

Remove the left air filter. Refer to [For engine(s) CAUA] Description and Operation (only on the Audi RS 4 and Audi RS 5).

Remove the front left wheelhouse liner. Refer to Removal and Installation .

Disconnect the vacuum hose -1- and lay the hydraulic oil hose to the side -arrow-.

Remove the nuts -2- and remove the vacuum reservoir.

Remove the screw -2- and disconnect the refrigerant line from the A/C compressor.

Remove the screw -1- and disconnect the refrigerant line from the A/C compressor.

Note. Close open lines and connections on A/C compressor using suitable caps (to prevent possible penetration of dirt and moisture).

Installation is done is reverse order, observe the following

Replace the O-rings -D- and -C-.

Note. Do not use the O-rings from the sealing caps that are installed on the connections in the replacement compressor when installing the lines. Follow the instructions for installing the O-rings. Refer to REFRIGERANT CIRCUIT O-RINGS .

Check the guide ring -F- on the connections for both refrigerant lines -B- and -C- for damage.

Clean the refrigerant line and A/C compressor connections and check for damage.

Coat the O-ring seals with refrigerant oil prior to installation. Refer to REFRIGERANT CIRCUIT O-RINGS .

Insert the respective O-ring -D- and -E- into the groove -G- on the connections for both refrigerant lines -B- and -C-.

Insert both refrigerant line into each connection on the compressor.

Tighten bolts -1- and -2-.

1. Tightening specification: 9 Nm (screws with an M6 thread) and 25 Nm (screws with an M8 thread).

Note. Following attachment of refrigerant pipes to compressor (and installation of compressor) check routing of pipes. They must be inserted in holders provided and not make contact with other components.

Install the front left wheelhouse liner. Refer to Removal and Installation

Evacuate and fill the refrigerant circuit. Refer to A/C Service Station in Description and Operation .

Install the remaining removed components.

Switch on the ignition.

Check the Climatronic control module -J255- display and control head DTC memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Note. Note the information regarding operating the A/C system after filling. Refer to A/C Service Station in Description and Operation .

RIGHT FOOTWELL VENT

Note. From 01.2008, A/C units which have an additional connection for the glove compartment cooling are being installed. Refer to GLOVE COMPARTMENT COOLING TO AIR INTAKE MANIFOLD CONNECTION . Make sure that the correct right heater core housing and air intake housing are installed.

Move the passenger seats as far back as possible.

Turn off the ignition.

Remove the glove compartment. Refer to Removal and Installation .

Disconnect the harness connector -A- from the temperature sensor (only on the "Comfort" A/C system).

Remove bolts -B-.

Remove the right footwell vent -C-.

Installation is carried out in the reverse order while observing the following.

Switch on the ignition.

Check the Climatronic Control Module -J255- DTC memory, and erase the malfunction displayed if necessary (only on the "Comfort" A/C system). Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

SUNLIGHT PHOTO SENSOR -G107

Note. There are different versions of the sunlight photo sensor, observe the correct allocation. If a Sunlight Photo Sensor is installed that is not intended for that vehicle (there is a different signal than the one intended in that Climatronic Control Module -J255-), the Climatronic Control Module cannot evaluate the signal from the sunlight photo sensor and the A/C system is not regulated correctly. The following illustrations show the location of the components on an Audi A5 Coupe; an Audi A5 Sportback, Audi A4, Audi Q5 etc., the location of the components varies slightly. Removing and installing the components is the same as described for the Audi A5 Coup e.

Turn off the ignition.

Carefully remove the sunlight photo sensor -A- from the defroster vent -B- (for the windshield) using a small screwdriver. Refer to Removal and Installation .

Scheme 223

Note. While doing this, be careful not to damage the surface of the sunlight photo sensor cover -A- and the defroster vent -B-.

Disconnect the connector -C-.

Installation is carried out in the reverse order while observing the following.

Switch on the ignition.

After installing, check the Climatronic control module DTC memory and erase any displayed faults using the Vehicle diagnostic tester in "Guided Fault Finding".

TEMPERATURE SENSOR BEFORE -G756- AND AFTER HYBRID BATTERY EVAPORATOR -G757

With high voltage systems (hybrid vehicles)

Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system, refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS and to GENERAL INFORMATION .

If it is necessary for the following procedure to perform work in the vicinity of high voltage components, perform a visual inspection of the high voltage components and cables for damages, refer to VISUAL INSPECTION OF HIGH-VOLTAGE COMPONENTS AND CABLES FOR DAMAGE and always follow the warnings when working on the high voltage system. Refer to GENERAL INFORMATION .

Turn off the ignition.

Remove the luggage compartment floor. Refer to Removal and Installation .

Bring the battery cooling module in the service position. Refer to BATTERY COOLING MODULE, SERVICE POSITION .

Temperature sensor before hybrid battery evaporator -G756

Scheme 224

Disconnect the electrical connector -1-.

Turn the temperature sensor counterclockwise -arrow- and remove.

Temperature sensor after hybrid battery evaporator -G757

Scheme 225

Disconnect the electrical connector -1-.

Loosen the temperature sensor after hybrid battery evaporator out of the retainer by pushing it back and forth -arrows- and then remove it.

Installation is carried out in the reverse order while observing the following.

Install the remaining removed components.

Check that the current seals are not damaged and in their correct positions.

Switch on the ignition.

After installing, check and, if necessary, erase the displayed faults in the DTC memory for the Climatronic control module -J255- and the battery regulation control module -J840-. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".

TRACTION BATTERY REAR OUTLET AIR GUIDE

With high voltage systems (hybrid vehicles)

Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system, refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS and to GENERAL INFORMATION .

If it is necessary for the following procedure to perform work in the vicinity of high voltage components, perform a visual inspection of the high voltage components and cables for damages, refer to VISUAL INSPECTION OF HIGH-VOLTAGE COMPONENTS AND CABLES FOR DAMAGE and always follow the warnings when working on the high voltage system. Refer to GENERAL INFORMATION .

Turn off the ignition.

Remove the luggage compartment floor. Refer to Removal and Installation .

Remove the left and right bolts -2-.

Scheme 226

Open the left and right retainers -arrow- and remove the rear outlet air guide toward the right.

Scheme 227

Installation is carried out in the reverse order while observing the following.

Note. Use several bolts -3- to attach the air guide to the battery cooling module -1- if one of the tabs -4- breaks off.

Push the air guide -2- onto the battery cooling module -1-. The tabs -4- on the left and right must click into place.

Reinstall the removed parts in the opposite order.

TRACTION BATTERY FRONT OUTLET AIR GUIDE

With high voltage systems (hybrid vehicles)

Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system, refer to HIGH VOLTAGE SYSTEM (HYBRID VEHICLES) REPAIRS and to GENERAL INFORMATION .

If it is necessary for the following procedure to perform work in the vicinity of high voltage components, perform a visual inspection of the high voltage components and cables for damages, refer to VISUAL INSPECTION OF HIGH-VOLTAGE COMPONENTS AND CABLES FOR DAMAGE and always follow the warnings when working on the high voltage system. Refer to GENERAL INFORMATION .

Turn off the ignition.

Remove the luggage compartment floor. Refer to Removal and Installation .