Heating Air Conditioning: Other Audi A8 D3 facelift

Equipment

1. The fault memory is designed as a non-volatile memory and is thus independent of the power supply.
2. Data transfer between , Climatronic Control Module J255 (Rear A/C Control Head (Climatronic) E265 as optional equipment) and Diagnostic Operation System VAS 5051 A occurs via "Rapid data transfer" mode. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
3. For this vehicle, it is not possible to perform On Board Diagnostic (OBD) using fault read out device V.A.G 1551 or mobile scan tool V.A.G 1552.
4. Tester displays differ and are dependent on the version and type of the tester (e.g. Diagnostic Operation System VAS 5051 A , Vehicle Diagnosis Service System VAS 5052 etc.), on the software stored in the tester, on the version of the software stored in the front Climatronic Control Module J255 (and Rear A/C Control Head (Climatronic) E265) and can therefore differ from the display shown in this article.

Function

The , Climatronic Control Module J255 and (Rear A/C Control Head (Climatronic) E265 as optional equipment) are equipped with DTC memory.

After evaluating the information, the , Climatronic Control Module J255 (and Rear A/C Control Head (Climatronic) E265 as optional equipment), distinguishes between different malfunctions --> DTC table, and saves those malfunctions until DTC memory is erased after DTC memory is checked. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Available functions

* 1. The control module version is always displayed on the Diagnostic Operation System VAS 5051 A during On Board Diagnostic (OBD).

* 2. Output Diagnostic Test Mode (DTM) is possible only up to a vehicle speed of less than 5 km/h. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

* 3. At this time, only the , Climatronic Control Module J255 can be coded. The Rear A/C control head (Climatronic) E265 is not coded; different settings are entered via the "Adaptation" function.

Safety precautions

Pay attention to the following if testers and measuring instruments have to be used in the course of a test drive

Basic Setting

Note. This article only outlines the function "Basic Setting". Perform "Basic Setting" in Guided Fault Finding Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. On vehicles with Rear A/C control head E265 as optional equipment, basic setting must be performed for Rear A/C control head E265 after basic setting for , Climatronic control module J255 has been performed. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

1. With ignition switched off, connect diagnostic operation system VAS 5051 A with diagnostic cable VAS 5051/5A to 16-pin Data Link Connector (DLC) in vehicle --> «Vehicle Diagnostic, Testing and Information System VAS 5051 A , connecting and selecting functions»(ref-289225-S22299735562008062700000) .
2. Select AC/Heating electronics or " Rear A/C control head" using address word "08" or "28" --> «Vehicle Diagnostic, Testing and Information System VAS 5051 A , connecting and selecting functions»(ref-289225-S22299735562008062700000) .

Note. Coding of , Climatronic Control Module J255 was checked and, if necessary, corrected --> Read Measuring Value Block (the currently valid coding is displayed in measuring value block) --> Climatronic Control Module J255 , coding . DTC memory was checked --> Checking DTC memory , displayed malfunctions were eliminated and DTC memory was erased --> Erasing DTC memory, End Output . The A/C system is switched on (operating mode "Auto").

Indication on display of diagnostic operation system VAS 5051 A

1. Select function "04 - Basis Setting".

Scheme 13

Indication on display of diagnostic operation system VAS 5051 A

1. Display field - 1 - indicates request to input display group.
2. Display field - 2 - shows input keyboard.

1. Enter the desired display group number, e.g. "01" or "001" for "Display group number 001" via the input keyboard in the display field - 2 - , and confirm by pressing the Q button.

Scheme 14

Indication on display of diagnostic operation system VAS 5051 A

Control motors installed are then actuated in the specified sequence.

End positions of control motors (resistance values at stop) are stored in the , Climatronic Control Module J255 , or Rear A/C control head E265 (resistance value of potentiometers installed in control motors) and used for further regulation.

Once control motors have reached both end stops, they are moved again from one stop to the other. During this, the adjustment time is measured and stored in the Climatronic Control Module J255 (Rear A/C control head E265 in the event an emergency running is necessary.

Indication on display of diagnostic operation system VAS 5051 A

Wait until "0" is displayed for the indicated feedback values in display field - 1 -.

Note. If "0" is displayed in the display fields, basic setting is completed. By clicking the <-- button, you will return to the selection menu. If a malfunction is detected at a potentiometer of a control motor during Basic Setting, a substitution value is stored as the adaptation value (learned value for this potentiometer) and displayed in the corresponding measuring value block. The malfunction "upper limit exceeded or lower limit exceeded" is stored in DTC memory for this control motor. Pressing button - 2 - changes to a different display group. Press button - 3 - to change to a different function (e.g. from "Basic Setting" to "Read Measuring Value Block" and back again).

1. Check DTC memory --> «Checking DTC memory»(ref-289225-S22508441102008062700000) .

Note. Perform Basic Setting again if a malfunction was detected and repaired.

1. End On Board Diagnostic (OBD) at Climatronic Control Module J255 --> «End Output»(ref-289225-S39064161082008062700000) .
2. Select Rear A/C Control Head (Climatronic) E265 (optional equipment) via address word "28" --> «Vehicle Diagnostic, Testing and Information System VAS 5051 A , connecting and selecting functions»(ref-289225-S22299735562008062700000) .
3. Perform basic setting for the components which have been actuated by Rear A/C Control Head (Climatronic) E265 in the same way as for components which have been actuated by the front Climatronic Control Module J255.

End Output

Note. DTC memory of front Climatronic Control Module J255 (and of Rear A/C Control Head (Climatronic) E265) was checked and erased, basic setting was performed and coding of front Climatronic Control Module J255 was checked --> Climatronic Control Module J255 , coding . Adaptation of Climatronic Control Module J255 (and Rear A/C Control Head (Climatronic) E265) was checked --> Climatronic Control Module J255 and Rear A/C Control Head (Climatronic) E265 , adaptation .

Indication on display of diagnostic operation system VAS 5051 A

1. Select the "06 - End output" function.

1. Wait until this display (start menu) appears in display of diagnostic operation system VAS 5051 A.
2. Switch off ignition and unplug diagnostic connector.

Climatronic Control Module J255 , coding

Note. "Coding" function for , Climatronic control module J255 is not described in this article, perform coding using "Guided Fault Finding" function. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. Coding of , Climatronic Control Module J255 , is indicated in measured value block (display group "50"). At this time, the Rear A/C Control Head (Climatronic) E265 is not coded (vehicle-specific settings are performed here via the "Adaptation" function).

Reason

The coding of front Climatronic Control Module J255 consists of a 3-part coding that is combined into a total coding. The code is based on a two-digit number code, to which certain numerical values have to be added depending on vehicle equipment (e.g. "2" for parking/auxiliary heater, "64" for rear window shade, etc.). A program which significantly facilitates this procedure is stored in Guided Fault Finding.

Read Measuring Value Block

Note. This article lists the various measured value blocks for information purposes only. Perform the function "Read measuring value block" in Guided Fault Finding, here is also found a clarification of the corresponding measured values and notes on the function of various components. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. Component locations of activated components --> Components for control and regulation of air conditioner not located in passenger compartment and --> Components for control and regulation of air conditioner located in passenger compartment . Depending on the position of the actuator, the various flaps are closed and opened over the adjustment range of the actuator via the installed cam disk. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. If a value greater than "250" (open circuit or fault in Ground (GND) connection) or less than "5" (open circuit, fault in 5 V voltage supply or short circuit to GND connection) is displayed for one (or more) potentiometer(s) in one (or more) control motor(s), this indicates a malfunction in wire connection to control motor or in potentiometer of the or a control motor (same B+ supply or GND connection). If displayed value of actuator is outside permitted range, check allocation of levers and cam disks which connect actuator shaft to flap(s) --> Heating and A/C unit, disassembling and assembling . If no permissible value can be determined for a potentiometer in a control motor during the function "Basic Setting" , display group corresponding to this control module displays a substitute value and stores a DTC in DTC memory. By using this substitute value (approx. average value in permissible tolerance range), the front Climatronic Control Module J255 (or Rear A/C Control Head (Climatronic) E265) controls the flap position when in emergency running mode. Depending on version of Climatronic Control Module J255 and Rear A/C Control Head (Climatronic) E265 , "On" or "1" and "Off" or "0" may be displayed in measuring value block.

Read measuring value block (Climatronic Control Module J255)

1. With ignition switched off, connect diagnostic operation system VAS 5051 A with diagnostic cable VAS 5051/5A to 16-pin Data Link Connector (DLC) in vehicle --> «Vehicle Diagnostic, Testing and Information System VAS 5051 A , connecting and selecting functions»(ref-289225-S22299735562008062700000) .
2. Switch on ignition or start engine.
3. Set operating mode "Auto" on , Climatronic Control Module J255.
4. Select Address word "08" for A/C heater/electronics --> «Vehicle Diagnostic, Testing and Information System VAS 5051 A , connecting and selecting functions»(ref-289225-S22299735562008062700000) .

Indication on display of diagnostic operation system VAS 5051 A

1. Check DTC memory --> «Checking DTC memory»(ref-289225-S22508441102008062700000) .
2. Select function "08 - Read Measuring Value Block".

Scheme 15

Indication on display of diagnostic operation system VAS 5051 A

1. Display field - 1 - indicates request to input display group.
2. Display field - 2 - shows input keyboard.

1. Enter the desired display group (e.g. "01" or "001" display group number "001") via the input keyboard in display field - 2 - , and confirm by pressing the Q button.

List of available display group numbers

1. Display group "001" to "019" --> «List of available display group numbers "001" to "019"»(ref-289225-S18998809782008062700000)
2. Display group "020" to "039" --> «List of available display group numbers "020" to "039"»(ref-289225-S19692614902008062700000)
3. Display group "040" to "050" --> «List of available display group numbers "040" to "050"»(ref-289225-S03314701422008062700000)

Scheme 16

Indication on display of diagnostic operation system VAS 5051 A

1. Display field - 1 - shows the display group selected.
2. Display field - 2 - displays the values of the four display fields

1. Value for display field "1" is displayed in the first row.
2. Values for respective display zones appear on second, third and fourth lines.
3. If no display appears in this row, a display field is not assigned.

1. Pressing button - 3 - changes to a different display group.
2. Press button - 4 - to change to a different function (e.g. from "Read Measuring Value Block" to "Basic Setting" and back again).

1. Enter desired display group number.

List of available display group numbers "001" to "019"

Note. If a compressor switch-off condition exists for the compressor (--> display group 002) the A/C Compressor Regulator Valve N280 cannot be activated, nor during output Diagnostic Test Mode (DTM) (--> Output Diagnostic Test Mode (DTM) ). If no pressure signal is detected by High Pressure Sensor G65 , A/C Compressor Regulator Valve N280 must not be activated. Climatronic Control Module J255 calculates pressure in refrigerant circuit via duty cycle (display field 3). If refrigerant circuit has been correctly filled, pressure will be 2.6 bar at a temperature of -3°C. To avoid malfunction entries at low temperatures, Climatronic Control Module J255 recognizes a malfunction in the refrigerant circuit first at pressure less than 1.8 bar (attained at -12°C). However, at this temperature the High Pressure Sensor G65 is no longer checked. Permissible specified values are found in the table which is located in the "Guided Fault Finding" function. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Note. Further notes for designated compressor shut-off conditions are found in the table which is located in the "Guided Fault Finding" function. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Explanatory notes for compressor shut-off conditions in display group "002"

Note. On right-hand drive vehicles, front footwell flap is open rather than rear footwell flap (different air routing in footwell vent air duct).

Note. On right-hand drive vehicles, rear footwell flap is open rather than front footwell flap (different air routing in footwell vent air duct).

List of available display group numbers "020" to "039"

Coding information from control modules for seat ventilation (optional equipment)

The following control modules are concerned: Drivers Seat Ventilation Control Module J672 , Front Passenger s Seat Ventilation Control Module J673 , Rear Seat (driver s side) Ventilation Control Module J674 and Rear Seat (front passenger s side) Ventilation Control Module J675.

Note. With , Climatronic Control Module J255 , display appears in display fields "1" and "2" of display group "021" , and in display groups "1" and "2" of display group "007" with Rear A/C Control Head (Climatronic) E265. The currently selected front seat ventilation and seat heating level is displayed in measured value blocks "026" , "027" and "028" of , Climatronic Control Module J255. The currently selected level for seat ventilation and seat heater for rear seats is displayed in measured value blocks "004" and "005" of Rear A/C Control Head (Climatronic) E265. Activation of seat ventilation fan is not shown directly, activation of respective fan or respective control module for seat ventilation can be checked as follows: - Start engine - switch off electrical consumers with great power input (e.g. rear windshield heater). - Select lowest possible speed for Fresh Air Blower V2 - Set seat ventilation control for appropriate seat to maximum level (in front or rear A/C control head) - Check respective seat, noise of fan operation can be heard in seat. - Set seat heating control for appropriate seat to maximum level (in front or rear A/C control head), activation of seat heater can be seen from measured value block.

1. At this time, heed the following when operating seat ventilation

1. No seat ventilation possible with seat temperature less than 15°C (deactivation due to insufficient seat temperature)
2. Depending on seat temperature and selected level of seat ventilation, seat heater can be switched on automatically by control module after approx. 5 min. in seat ventilation mode. If necessary, only seat cushion is heated in seat ventilation mode, seat bolster heating not switched on
3. With seat ventilation mode, seat can be heated up to the following seat temperature, depending on selected level of seat ventilation (measuring value of temperature sensor in seat cushion)

Note. Specified temperatures for seat heater are different on vehicles with or without seat ventilation (values indicated in the following table are approximate values, exact value depends on control module version) At present, tolerance range */- 4°C (*/- 6°C for stage "6" on vehicles with seat ventilation). Since control is effected via characteristic curve, specified temperature of next higher stage is always greater than in lower stage.

List of available display group numbers "040" to "050"

Note. If value calculated by , Climatronic Control Module J255 and displayed in display field "3" is greater than 2.4 ohms or less than 1.5 ohms, check for short circuit or contact resistance in wiring between Heated Windshield Control Module J505 to Heated Windshield Z2. If value calculated by , Climatronic Control Module J255 and displayed in display fields "1" and "2" is greater than 3.4 ohms or less than 1.4 ohms, , Climatronic Control Module J255 does not actuate Heated Windshield Control Module J505.

Explanatory notes on code "1" (optional equipment)

Note. When performing coding in function "Guided Fault Finding" the system requests the optional equipment installed to enable the Diagnostic operation system VAS 5051 A to calculate the code by means of a stored program Vehicle Diagnosis, Testing and Information System in "Guided Fault Finding" function If the , Climatronic Control Module J255 is coded directly via function "07 - Code Control Module" by entering numerical code, characteristic numbers for different versions and 3 codes must be added together. Example: Code "1" (for vehicle with auxiliary heater, rear A/C control head (Climatronic) and rear window shade (1 + 2 + 16 + 64),code "2" e.g. 4096, code "3" e.g. 0,total number of codes "1" , "2" and "3" e.g. "0" , total number of codes "1" , "2" and "3" = "4179" (entry in Diagnostic Operation System VAS 5051 A for coding via function "07")

Explanatory notes on code "2" (country version and vehicle model)

Note. When performing coding in function "Guided Fault Finding" the system requests the optional equipment installed to enable the Diagnostic operation system VAS 5051 A to calculate the code by means of a stored program Vehicle Diagnosis, Testing and Information System in "Guided Fault Finding" function If the , Climatronic Control Module J255 is coded directly via function "07 - Code Control Module" by entering numerical code, characteristic numbers for different versions and 3 codes must be added together. Example: Code "1" , e.g. "83" , code "2" (on vehicle for Germany with 8-cyl. gasoline engine) "4096" , code "3" , e.g. "0" , total number of codes "1" , "2" and "3" = 4179 (entry in Diagnostic Operation System VAS 5051 A when coding via function "07") Body design is no longer coded with Climatronic Control Module J255 from software version "X078" With Climatronic Control Module J255 from software version "X078" , engine type is coded (on vehicles with FSI engine, transmission ratio at belt pulleys and thus, torque for driving the compressor is different from other engines).

Explanatory notes on code "3" (rear seat heating/rear seat ventilation, seat covers and window glass)

Note. Rear seat ventilation is only available together with heated rear seats When performing coding in function "Guided Fault Finding" the system requests the optional equipment installed to enable the Diagnostic operation system VAS 5051 A to calculate the code by means of a stored program Vehicle Diagnosis, Testing and Information System in "Guided Fault Finding" function If the , Climatronic Control Module J255 is coded directly via function "07 - Code Control Module" by entering numerical code, characteristic numbers for different versions and 3 codes must be added together. Example: Code "1" e.g. "83" , code "2" e.g. "4096" , code "3" (vehicles without Rear A/C Control Head (Climatronic) E265) "0" total number of codes "1" , "2" and "3" = "4179" (entry in Diagnostic Operation System VAS 5051 A when coding via function "07") Display has 8 positions of which the first 2 are however not used and are therefore not shown in this table (display of first 2 positions always "00XXXXXX")

Display groups front for Climatronic Control Module J255 which are not currently not intended for service use

Note. Depending on version of Climatronic Control Module J255 , these measuring value blocks may not indicate any display or the display field is black.

Reading measured value block (Rear A/C Control Head (Climatronic) E265)

1. With ignition switched off, connect diagnostic operation system VAS 5051 A with diagnostic cable VAS 5051/5A to 16-pin Data Link Connector (DLC) in vehicle --> «Vehicle Diagnostic, Testing and Information System VAS 5051 A , connecting and selecting functions»(ref-289225-S22299735562008062700000) .
2. Switch on ignition or start engine.
3. Set operating mode "Auto" on , Climatronic Control Module J255.
4. Select address word "28" for rear A/C control head --> «Vehicle Diagnostic, Testing and Information System VAS 5051 A , connecting and selecting functions»(ref-289225-S22299735562008062700000) .

Indication on display of diagnostic operation system VAS 5051 A

1. Check DTC memory --> «Checking DTC memory»(ref-289225-S22508441102008062700000) .
2. Select function "08 - Read Measuring Value Block".

Indication on display of diagnostic operation system VAS 5051 A

1. Display field - 1 - indicates request to input display group.
2. Display field - 2 - shows input keyboard.

1. Enter desired display group (e.g. "001" or "01" for display group number "001") via input keyboard in display field - 2 -. List of available display group numbers --> «List of available display group numbers "001" to "007" ("008")»(ref-289225-S36015369732008062700000) and confirm by touching Q button.

Indication on display of diagnostic operation system VAS 5051 A

1. Display field - 1 - shows the display group selected.
2. Display field - 2 - displays the values of the four display fields

1. Value for display field "1" is displayed in the first row.
2. Values for respective display zones appear on second, third and fourth lines.
3. Line remains blank if a display zone is not used.

1. Pressing button - 3 - changes to a different display group.
2. Press button - 4 - to change to a different function (e.g. from "Read Measuring Value Block" to "Basic Setting" and back again).

1. Enter display group number (list of available display group numbers --> «List of available display group numbers "001" to "007" ("008")»(ref-289225-S36015369732008062700000) ).

List of available display group numbers "001" to "007" ("008")

Display in display groups "006" to "008" for vehicles manufactured until November 2002 (gradual conversion)

Note. The display in display groups "006" and "007" differs depending on whether Rear A/C Control Head (Climatronic) E265 was installed prior to or as of November 2002. Furthermore, display group "008" was no longer used in version as of November 2002. Since November 2002, Rear A/C Control Head (Climatronic) E265 have been installed for which display group "008" is no longer used.

Adaptation procedure in the various adaptation channels

Note. This article only outlines the function "Adaptation". Perform adaptation via "Guided Fault Finding" function, notes on functions that are changed can also be found here. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. Certain adaptation channels are not provided on A/C control heads installed at start of production; these functions can therefore not be changed.

1. Check DTC memory of Climatronic Control Module J255 (and of Rear A/C Control Head (Climatronic) E265) --> «Checking DTC memory»(ref-289225-S22508441102008062700000) and erase DTCs displayed if necessary.
2. Check coding of Climatronic Control Module J255 for vehicle-specific optional equipment and correct if necessary --> «Climatronic Control Module J255 , coding»(ref-289225-S04494600862008062700000) and Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
3. With ignition switched off, connect Diagnostic Operation System VAS 5051 A with diagnostic cable VAS 5051/5A to 16-pin Data Link Connector (DLC) in vehicle and select address word "08" or "28" A/C/Heating Electronics, or "rear A/C control head" --> «Vehicle Diagnostic, Testing and Information System VAS 5051 A , connecting and selecting functions»(ref-289225-S22299735562008062700000) .

Indication on display of diagnostic operation system VAS 5051 A

1. Select function "10 - Adaptation" for appropriate Climatronic Control Module J255 or Rear A/C Control Head (Climatronic) E265.

Indication on display of diagnostic operation system VAS 5051 A

1. Display field - 1 - indicates request to input channel number.
2. Display field - 2 - shows input keyboard.

1. Enter desired channel number in display field - 2 - via keyboard --> «Rear A/C Control Head (Climatronic) E265 , adaptation»(ref-289225-S05909280602008062700000) and (overview of designated adaptation channels) and confirm by pressing Q button.

Scheme 17

Note. If "Function unknown or cannot be carried out at the moment" is displayed in display field - 1 - , the following may be the cause: Control unit adaption neither as specified nor complete Fault in convenience data bus

Indication on display of diagnostic operation system VAS 5051 A

1. Display field - 1 - indicates "Channel X read and test".
2. In area - 2 - , the currently adjusted value for this function is displayed.
3. Area - 3 - displays scroll bar with an identification number for currently valid setting.

1. The adjustment can be changed within the determined limits via the scroll bar.

Note. If an identification number is entered via scroll bar that is outside the determined limits, identification number is shown but will not be implemented. If an identification number which is too large or too small is entered via scroll bar, the display changes back automatically. Area - 2 - displays newly set value for this adaptation channel.

Entry can also be made by way of keypad.

1. Touch button - 4 - (input via keyboard)

Indication on display of diagnostic operation system VAS 5051 A

1. Display field - 1 - indicates display "Enter adaptation value: 0....XXXXX".
2. Display field - 2 - shows input keyboard.

1. Use input keyboard in display field to enter desired value for this adaptation channel and --> «Rear A/C Control Head (Climatronic) E265 , adaptation»(ref-289225-S05909280602008062700000) (overview of designated adaptation channels for Climatronic Control Module J255 or Rear A/C Control Head (Climatronic) E265) for re-adaptation of Climatronic Control Module J255 (or Rear A/C Control Head (Climatronic) E265).

Note. If an identification number is entered via keyboard that is outside the determined limits, identification number is shown but will not be implemented. If an identification number which is too large or too small is entered via keyboard, the display changes back automatically. Area - 2 - displays entered identification number.

1. Press "Q- button" to confirm input.

Scheme 18

Indication on display of diagnostic operation system VAS 5051 A

1. Area - 2 - displays new value for this adaptation channel.
2. Area - 3 - displays entered characteristic number above scroll bar.

1. Save input by touching button - 5 -.

Indication on display of diagnostic operation system VAS 5051 A

1. Display field - 1 - indicates "Channel X read and test".
2. Area - 2 - displays new value for this adaptation channel.
3. Area - 3 - displays original and new identification number for this adaptation channel.

1. Accept and save input by touching button - 4 -.

1. Display field - 1 - indicates "Channel X save, value 0 - XXXX saved".

Note. If an identification number that is outside the determined limits was entered, identification number is shown but will not be implemented. If an identification number which is too large or too small was entered, the display changes back automatically. By clicking the <-- button, you will return to the selection menu.

1. End On Board Diagnostic (OBD) --> «End Output»(ref-289225-S39064161082008062700000) and switch ignition off.
2. Check function of the new, entered adaptation.

A/C System, electrical checks

Note. The function "electrical testing" is not described in this article. Perform electrical testing via "Guided Fault Finding" function, here can also be found notes on the functions which should be tested. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. Temperature-dependent resistance values of the various temperature sensors are stored in one table, this can be called up via the "Guided Fault Finding" function. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Heated seats, checking

Note. If there is a condition at which heater of driver or passenger seat cannot be switched on (short circuit in connection to seat heating element, open circuit in voltage supply to front Climatronic Control Module J255), this is stored as a malfunction in Climatronic Control Module J255. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. Checking actuation of heated seat operation is described in guided fault-finding for air conditioner. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. If there is a condition at which heater of rear seats cannot be switched on (short circuit in connection to seat heating element, open circuit in voltage supply to Rear A/C Control Head (Climatronic) E265), this is stored as a malfunction in Rear A/C Control Head (Climatronic) E265. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. If voltage measured at Energy Management Control Module J644 at terminal "30" falls below a value stored in Energy Management Control Module J644 , performance level of seat heater is reduced (currently to approx. 50%) or switched off completely and load on generator is relieved (duty cycle of activation of 100% reduced to 90 to 0 % by electronics of Climatronic Control Module J255/Rear A/C Control Head (Climatronic) E265). Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. Measured value block of Climatronic Control Module J255 indicates that front seat heating is switched on, or why no activation is occurring despite a request (display group "027" , "028" , "033" , "034" and "035") Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. Measuring value block of Rear A/C Control Head (Climatronic) E265 indicates that heater for rear seats is switched on, or why no activation is occurring despite a request (display group "004" , "005" , "007" and "008"). Climatronic Control Module J255 indicates that rear seat heater has been switched off e.g. due to excessive load on vehicle electrical system (display group "049") Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Rear footwell auxiliary heater (where applicable), checking

Note. Left Rear Footwell Heater Z42 and Right Rear Footwell Heater Z43 are actuated by Climatronic Control Module J255 via data wire, actuation is displayed in measured value block (display group "041" and "042"). Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. Heater element is installed only on vehicles with Rear A/C Control Head (Climatronic) E265. Checking actuation of heater elements Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Heated Windshield Z2 , checking

Note. Heated Windshield Control Module J505 is actuated via data wire by Climatronic Control Module J255 , actuation is indicated in measured value block (display group "045" to "047"). Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. Checking actuation of heated windshield Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. Description of heated windshield Z2 function --> Heated windshield

A/C Refrigerant Circuit

The assemblies and piping system of the air conditioner are filled with the following refrigerant

1.1.1.2 Tetrafluorethane (CF 3 -CH 2 F or CH 2 F-CF 3 )

Currently, this refrigerant is known under the following trade names R134a, H-FKW 134a, SUVA 134a and KLEA 134a (other trade names may be used in other countries).

A/C refrigerant circuit, safety measures

The following safety measures should be observed for these refrigerants (additional guidelines apply in individual countries).

If is necessary to open the refrigerant circuit during service work, discharge the refrigerant circuit first --> A/C refrigerant circuit, evacuating . In doing so, the utmost care is to be taken to avoid contact with liquid refrigerant or refrigerant vapors. Should refrigerant nevertheless escape, avoid inhaling the resultant refrigerant/air mixture.

Extraction systems are therefore to be switched on and use made of both rubber gloves and protective goggles.

Reason

Intensive exposure to refrigerant on unprotected parts of the body will result in frostbite.

Should refrigerant come into contact with other parts of the body despite compliance with all the pertinent safety measures, these are similarly to be rinsed thoroughly in cold water without delay for at least 15 minutes.

Although refrigerant does not represent a fire hazard, smoking, welding, soldering and brazing are not permitted in areas exposed to refrigerant.

Reason

The high temperature of a naked flame or hot objects causes decomposition of refrigerant gas. Inhalation of the resultant toxic decomposition products leads to dry coughing and nausea.

A/C refrigerant circuit, evacuating

Refrigerant is never to be allowed to escape into the atmosphere, but rather it is to be extracted from the refrigerant circuit using an extractor or service station. The drained refrigerant will be locally recycled or is send to an environment-recycling place to the manufacturer (different or additional laws may apply in individual companies). Vehicles are therefore to be taken to a specialist air conditioner workshop, which will have the necessary equipment.

Reason

If refrigerant R134a is released into the environment, it enhances the green house effect.

Note. Refrigerant R134a has far less of a greenhouse effect than R12. R134a does not effect the ozone layer in the earths atmosphere (R134a is an H-FC with no chlorine atoms). Depletion of the ozone layer in the upper atmosphere is however only brought about by the splitting of carbonchlorine bonds (as is the case, for example, with refrigerant R12).

After discharging the air conditioner, disconnect harness connector from A/C Compressor Regulator Valve N280 or from High Pressure Sensor G65.

Reason

A/C Compressor Regulator Valve N280 is then no longer activated and compressor runs at idle. Compressor is designed such that lubrication of compressor components is guaranteed by way of an internal oil circuit at idle (provided there is sufficient refrigerant oil in the compressor).

A/C refrigerant circuit, repairs

Work on refrigerant system should only be performed in a ventilated rooms (workshops). Ensure that with in 5 meters circumference are no working-pits, basement staircases or shafts. Extraction systems are to be switched on.

Reason

The refrigerant emerging is not only colorless and odorless, but also heavier than air and thus displaces oxygen. Should refrigerant gas nevertheless escape, this can result in an imperceptible danger of asphyxiation in poorly ventilated areas and inspection pits.

Note. The escaping refrigerant/air mixture should not be inhaled, but should be sucked out via an existing exhaust ventilation system.

Do not attempt repair on filled air conditioning systems by soldering, brazing or welding. This applies also for welding and soldering work on the vehicle, in the event that parts of the A/C system may heat up.

Reason

Exposure to heat creates considerable pressure in the system, which could cause it to burst.

Corrective action

Discharge refrigerant circuit --> A/C refrigerant circuit, evacuating .

Note. Damaged or leaking parts of the air conditioner are never to be repaired by welding or soldering them; they are always to be replaced.

When servicing air conditioner, all open components and pipe connections are to be immediately re-sealed.

Reason

Moisture will ingress into air conditioner components if they are left open for a lengthy period. If this is the case, air conditioners cannot be re-filled without having to replace parts of the system.

Painting work on vehicles with air conditioner

When performing paintwork repairs, object temperatures of 80°C are not to be exceeded in drying booths or their pre-heating areas.

Reason

Exposure to heat creates considerable pressure in the system, which could cause it to burst.

Further information

1. Appropriate current flow diagrams can be found in Current Flow Diagrams, Electrical Fault-finding and Fitting Locations binder.
2. A data plate in engine compartment indicates the refrigerant used and capacity.
3. Additional notes for repair work on vehicles with A/C system and for handling refrigerant can be found in --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000) .

A/C Refrigerant Circuit, general notes

Note. Disconnect batteries before beginning electric welding. --> 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Refrigerant circuit of A/C system must not be discharged and opened (--> A/C refrigerant circuit, evacuating ) unless this is necessary because of safety precautions (--> A/C refrigerant circuit, repairs ) or unless components of the refrigerant circuit of the A/C system have to be to replaced.

The air conditioner refrigerant circuit is not to be opened when performing all other standard vehicle repair operations.

Servicing operations that can be performed on the heating and air conditioning system without opening the refrigerant circuit are described in this article --> Components for control and regulation of air conditioner not located in passenger compartment .

Note. The connections for the senders/switches described in this article are fitted with a valve which closes automatically when the switches are unscrewed. These switches can thus be replaced in any Audi and VW workshop even though the refrigerant circuit is fully charged.

Servicing operations on A/C system for which it is necessary to discharge the refrigerant circuit and thus cannot be performed in every Audi and VW workshop are described --> A/C Refrigerant Circuit, servicing (vehicle must be delivered to an A/C system service point workshop to discharge the refrigerant circuit).

A/C Refrigerant Circuit, servicing

Note. Repair work on refrigerant circuit --> A/C Refrigerant Circuit, servicing . All work or components marked with 1) can be repaired, replaced or performed in any workshop (work that does not pertain to refrigerant circuit). All refrigerant circuit components not marked with 1) as well as all coolant hoses and -lines can only be serviced or replaced in an A/C system service point workshop (refrigerant circuit must be discharged).

Exploded view of components

HD = High-pressure end

ND = Low-pressure end

Scheme 19

1 - A/C Compressor Regulator Valve N280

1. Checking activation and function --> «A/C Compressor Regulator Valve N280 cut-in signal, checking»(ref-289225-S39143243932008062700000)

2 - Compressor

1. Removing compressor from bracket and re-installing in vehicles with 8-cyl. MPI engine --> «Removing compressor from bracket and installing in vehicles with 8-cyl. MPI engine»(ref-289225-S14195474132008062700000)
2. Removing compressor from bracket and re-installing in vehicles with 12-cyl. engine --> «Compressor, removing from bracket and re-installing - vehicles with 12-cyl. engine»(ref-289225-S11543673622008062700000)
3. Compressor, removing and installing in vehicles with 8-cyl. FSI engine --> «A/C compressor, removing and installing - vehicles with 8-cyl. FSI engine»(ref-289225-S28803055272008062700000)
4. Compressor, removing and installing in vehicles with 10-cyl. engine --> «Compressor, removing and installing - vehicles with 10-cyl. engine (Audi S8)»(ref-289225-S40754187942008062700000)

1. On installing refrigerant lines and corresponding holder, make sure there is adequate distance between belt, holder and pulley
2. Type of compressor differs depending on engine (8, 10 or 12-cyl. gasoline engine)

Depending on compressor type ("6 SEU 14" , "7 SEU 16" or "7 SEU 17") different refrigerant oil fill capacities are designated for the refrigerant circuit and --> 87 - AIR CONDITIONING

3 - Compressor belt pulley/drive unit

1. Replacing compressor pulley 1) --> «A/C Compressor Pulley»(ref-289225-S14146475182008062700000)
2. Ribbed belt, removing and installing 1) --> «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-289203-S16488527182008062700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-289204-S09096153412008062700000) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-289206-S19139229562008062700000) for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB
3. Replacing compressor drive unit (vehicles with 8-cyl. FSI or 10-cyl. engine) --> «Compressor drive unit, checking, replacing»(ref-289225-S40868384782008062700000)

Note. Rubber element is fitted between pulley and drive shaft of compressor to protect belt if compressor is blocked or not operating smoothly. An overload safeguard is installed between drive unit and drive shaft of compressor to protect engine chain drive in the event compressor is seized or does not move freely. If compressor is runs with resistance, overload safeguard interrupts power transmission to compressor. Rubber elements are installed between belt pulley/drive unit and compressor drive shaft, vibrations which may occur during compressor operation may be dissipated via these rubber elements (damper function at torque fluctuations). Depending on compressor type, different belt pulleys are installed on compressor. --> A/C Compressor Pulley

4 - Oil drain plug

5 - High pressure relief valve

6 - Connection with valve

7 - High Pressure Sensor G65

1. Removing and installing --> «High Pressure Sensor G65 , removing and installing»(ref-289225-S12705460112008062700000)
2. Checking signal --> «Pressure signal of High Pressure Sensor G65 , checking»(ref-289225-S00982019582008062700000)

8 - Condenser

9 - Cap

1. With seal
2. Always to be screwed on

10 - Service connection

1. High pressure side
2. Used for measuring, discharging and recharging by A/C system service point workshops

11 - Bolts in refrigerant line

12 - Restrictors

13 - Evaporator

14 - Service connection

1. Low pressure side
2. Used for measuring and discharging by A/C system service point workshops

15 - Cap

1. With seal
2. Always to be screwed on

16 - Accumulator

High Pressure Sensor G65 , removing and installing

1. Remove radiator grille. --> «63 - BUMPERS»(ref-289221-S15322224352008062700000)

Scheme 20

1. Disconnect connector - A -.
2. Remove High Pressure Sensor G65 - B - , tightening torque: 5 Nm.
3. Replace O-ring-seal - C - (10.8 mm, 1.8 mm) --> «Refrigerant circuit O-rings»(ref-289225-S00601433862008062700000) .

Note. Cooling performance cannot be checked with High Pressure Sensor G65 removed, Climatronic Control Module J255 does not switch on the compressor. Refrigerant circuit remains closed (connection with valve). Checking function of High Pressure Sensor G65 and signal sent --> Pressure signal of High Pressure Sensor G65 , checking . Lubricate O-ring seal lightly with refrigerant oil before installing --> Refrigerant circuit O-rings .

Pressure signal of High Pressure Sensor G65 , checking

1. Remove radiator grille. --> «63 - BUMPERS»(ref-289221-S15322224352008062700000)

1. Disconnect connector - A -.

Scheme 21

Contact 1ground

Terminal 2 signal output (square wave signal to Climatronic Control Module J255)

Contact 3Positive (terminal 75)

Note. With harness connector - B - disconnected, the compressor will not switch on. High pressure sensor - A - is an electronic control module; it creates a square wave signal, the duty cycle ratio changes with pressure in the refrigerant circuit.

Scheme 22

A - Refrigerant system pressure, high pressure side in bar (absolute pressure)

B - Signal ratio of square wave signal

C - Characteristic curve

Note. Climatronic Control Module J255 switches on compressor (by actuating A/C Compressor Regulator Valve N280) as soon as no compressor shut-off condition is present: If duty cycle is greater than 12 % (corresponding to approx. 1.8 bar absolute) and less than 87.5% (corresponding to approx. 32 bar absolute) The compressor is not switched on if the duty cycle is smaller than 12 % or greater than 87.5% (A/C Compressor Regulator Valve N280 is not activated). Duty cycle and pressure calculated by Climatronic Control Module J255 is displayed in measured value block (display group "001") Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. In terms of absolute pressure, 0 bar corresponds to an absolute vacuum. Normal ambient pressure equals approx. 1 bar absolute pressure. On the scales of most pressure gauges, 0 bar corresponds to an absolute pressure of one bar (can be seen from -1 mark below 0). The Climatronic Control Module J255 transmits request to switch on coolant fans to Engine Control Module (ECM) via Comfort data bus, ECM switches coolant fans on via coolant fan control module. As soon as compressor is switched on, irrespective of pressure in refrigerant circuit Climatronic Control Module J255 transmits request for increased coolant speed via Comfort data bus to Engine Control Module (ECM) with compressor activated, depending on pressure calculated in refrigerant circuit. The fan speed determined by Climatronic Control Module J255 is displayed in the measured value block (display group "022") Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. The signal generated from High Pressure Sensor G65 is also used to control the engine. Climatronic Control Module J255 sends information to Engine Control Module (ECM) via the Comfort data bus (necessary torque to drive compressor depends on pressure in refrigerant circuit). Depending on engine control unit version, signal is displayed as duty cycle in measured value block. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Scheme 23

This pattern appears on oscilloscope screen (e.g. on diagnostic operation system VAS 5051 A) when the following conditions are met.

1. Ignition switched on (B+ at terminal "3" and Ground (GND) terminal "1" on High Pressure Sensor G65 present)
2. Oscilloscope settings:5 V/div. DC (5V per unit DC) 5 ms/div. (5 milliseconds per unit)
3. Measuring lead (signal wire) connected to terminal "2" on High Pressure Sensor G65.
4. Measuring lead (shielding) connected to terminal "1" (Ground -GND- on High Pressure Sensor G65).

Note. To connect High Pressure Sensor G65 , e.g. measuring leads from connector test kit V.A.G 1594 C may be used. The display shows a signal that is transferred when the pressure in the refrigerant circuit is approximately 7 bar, it corresponds to an approximate duty cycle of 25% (with compressor not engaged, an ambient temperature of 30°C and properly filled refrigerant circuit). The impulse width - A - depends on the pressure in the refrigerant circuit (if pressure increases, area - A - gets wider). The signal distance - B - is always 20 milliseconds (corresponds to frequency of 50 Hertz). The duty cycle is determined by the ratio of impulse width - A - and signal distance - B -.

Refrigerant circuit O-rings

1. Only to be used once; always replace.
2. Moisten with refrigerant oil before fitting.
3. Pay attention to correct positioning on pipe/in groove.
4. Ensure cleanliness when working.

Note. Install only O-rings that are resistant to refrigerant R134a and corresponding refrigerant oil. These O-rings are color-coded to avoid mistakes (currently "red" , "light purple" and "dark purple"). The O-ring dimensions - a - and - b - are different depending on installation location In addition to the color-coded O-ring seals, use is also made at the factory of black O-ring seals for certain connections.

Removing compressor from bracket and installing in vehicles with 8-cyl. MPI engine

Note. The compressor can be removed and installed at the bracket without opening the refrigerant lines. Do not discharge the refrigerant circuit, do not remove refrigerant hoses and lines from compressor. After detaching, use wire for example to attach compressor to longitudinal member. Never leave hanging from refrigerant lines. Before removing, mark direction of operation of ribbed belt with chalk or felt-tipped pen. Running a used belt in the opposite direction could destroy it. Depending on engine and country version, different compressors are installed (8, 10 or 12-cyl. gasoline engine). Removing compressor from bracket and re-installing in vehicles with 12-cyl. engine --> Compressor, removing from bracket and re-installing - vehicles with 12-cyl. engine

Compressor, removing from bracket and reinstalling

Note. Do not unfasten refrigerant lines and corresponding clamps. This illustration shows compressor for 8-cyl. MPI engine. For the other engine versions, allocation differs only slightly from this (e.g. different refrigerant lines). --> 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK Depending on version of vehicle, it may be necessary to push aside or disconnect individual hose lines that are routed in the vicinity of the compressor.

1. Remove noise insulation --> «63 - BUMPERS»(ref-289221-S15322224352008062700000) .
2. Bring lock carrier into service position --> «50 - BODY - FRONT»(ref-289221-S10914933722008062700000)
3. Mark connector to A/C Compressor Regulator Valve N280 because of danger of interchanging with connector to electric engine mount.

Note. If connectors to A/C Compressor Regulator Valve N280 and to electric engine mount are interchanged, no DTC is entered in DTC memory, however the evaporator may ice-up since the compressor is actuated continuously.

1. Disconnect electrical connection to A/C Compressor Regulator Valve N280 at harness connector.

Scheme 24

1. Remove bolts - A - (25 Nm).

Note. Install one washer each - B - at bolts - A -. Before fastening compressor, check both bushings - C - in bracket or compressor for correct seating. After fastening compressor, check installation position of refrigerant lines - D - and - E - , lines must be engaged in brackets provided (if installed, depending on engine). After attaching compressor, also check refrigerant lines and corresponding holders for adequate clearance with respect to other components, ensuring sufficient distance between belt, holder and pulley.

A/C Compressor Regulator Valve N280 cut-in signal, checking

1. Switch off ignition.

Scheme 25

1. Unplug connector at air-conditioner compressor.
2. Reproduce the connection between connector - A - and connector - B - at regulator valve using an adapter cable from connector test kit V.A.G 1594 C.

Note. Activation of A/C Compressor Regulator Valve N280 and current flowing via A/C Compressor Regulator Valve N280 measured by Climatronic Control Module J255 is displayed in measured value block of Climatronic Control Module J255 (display group "001") Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. Use can also be made of an improvised adapter cable for this test. To do this, e.g. use one connector each - A - and - B - (part number 1J0 973 702 and 1J0 973 802 and relevant terminal contacts), two standard sockets for banana connectors - C - and two wires with 0.5 mm 2 diameter. Part numbers are for reference only. Always check with your Parts Department for the latest part number information

1. Connect DSO measuring leads 1 2 VAS 5051/8 to adapter leads.
2. Measuring cable (signal wire) to terminal - 2 -.
3. Measuring cable (shielded, ground) to terminal - 1 -.
4. On Diagnostic operation system VAS 5051 A , set measurement mode: DSO (Digital Storage Oscilloscope)

1. Setting 5V/Div = 0.5 ms/Div (5 volts DC and 0.5 milliseconds per unit)
2. Start engine.
3. Set pre-select temperature to "Lo" on Climatronic Control Module J255
4. Switch on and off activation of A/C Compressor Regulator Valve N280 at Climatronic Control Module J255 by operating buttons "Auto" and "Off/On".

Shown on screen of oscilloscope, depending on setting of Climatronic Control Module J255

1. No square wave signal (regulator valve is not activated) for operating mode "OFF".

Scheme 26

1. A square wave signal with an impulse width - A - between 75% and 100% (regulator valve is activated) for operating mode "Auto" and temperature setting "Lo".

Note. (Scheme 31) shows a signal with a duty cycle of approx. 80%. Impulse width - A - is dependent on desired cooling performance, vehicle voltage etc. (over the width of region - A -, voltage is regulated via A/C Compressor Regulator Valve N280 by Climatronic Control Module J255). The signal distance - B - is always 2 milliseconds (corresponds to frequency of 500 Hertz). The duty cycle is determined by the ratio of impulse width - A - and signal distance - B -.

1. The impulse width of the square wave signal changes (duty cycle between 100% and greater than 30%, regulator valve is activated so that required compressor output is obtained to reach the specified temperatures) depending on setting at Climatronic Control Module J255 and measured surrounding conditions.

Note. For operating mode setting "Auto" and temperature setting "Lo" , A/C Compressor Regulator Valve N280 is activated so that the maximum permissible current of approx. 0.65 A flows via A/C Compressor Regulator Valve N280 (maximum compressor output). In control mode, actuation time is governed by required cooling output and vehicle electrical system voltage, for example. It is however always of sufficient duration to achieve a mean current of 0.3 A.

Belt pulley, replacing (Version "1")

Note. Different versions of the pulley are installed, depending on compressor construction type and engine version Pulley, removing from compressor and re-installing --> A/C compressor pulley, removing from compressor and re-installing (Version "1") Belt pulley version "1" is installed e.g. on compressor of "7 SEU 16" type.

Scheme 27

1 - Screw

1. Replace
2. Tightening torque 20 Nm
3. Loosening and tightening --> «A/C compressor pulley, removing from compressor and re-installing (Version "1")»(ref-289225-S19563035442008062700000)

2 - Drive plate

1. Different versions
2. Removing and installing --> «A/C compressor pulley, removing from compressor and re-installing (Version "1")»(ref-289225-S19563035442008062700000)
3. Disengages with torque to high (e.g. compressor produces friction)

3 - Circlip

1. Replace
2. Install on proper side (level side to compressor)
3. Removing and installing --> «A/C compressor pulley, removing from compressor and re-installing (Version "1")»(ref-289225-S19563035442008062700000)

4 - Belt pulley

1. Rubber element of pulley disengages when torque is too-high (e.g. compressor produces friction) and pulley runs freely without driving the compressor.
2. Different versions
3. Removing and installing --> «A/C compressor pulley, removing from compressor and re-installing (Version "1")»(ref-289225-S19563035442008062700000)

Note. Under certain conditions (e.g. rough engine idle), rubber element of pulley can disengage without a malfunction existing at compressor or in refrigerant circuit.

5 - Compressor

1. Different versions are installed, depending on engine version and country version of vehicle.
2. Clean compressor flange before sliding on pulley.

A/C compressor pulley, removing from compressor and re-installing (Version "1")

Note. If overload safeguard of pulley triggers, check compressor for ease of motion before replacing the pulley, replace it completely if compressor moves with resistance. The function of overload protection for pulley is described in e.g. Self Study Program. To remove belt pulley, it depends on engine version if it is necessary to remove compressor from engine --> Removing compressor from bracket and installing in vehicles with 8-cyl. MPI engine . The compressor can be removed and installed at the bracket without opening the refrigerant lines. 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. Depending on engine and optional equipment, different compressors are installed (8-, or 12-cyl. gasoline engine).

1. Remove noise insulation --> «63 - BUMPERS»(ref-289221-S15322224352008062700000) .
2. Bring lock carrier into service position --> «50 - BODY - FRONT»(ref-289221-S10914933722008062700000)
3. Release tension on ribbed belt and remove it. --> «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-289203-S16488527182008062700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-289204-S09096153412008062700000) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-289206-S19139229562008062700000) for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB

Scheme 28

1. Remove bolt - A - (tightening torque 20 Nm).

Note. To loosen and tighten bolt - A - , counterhold it at drive plate - B - using a commercially available pin wrench - C - (pin diameter 5.0 mm). Bolt - A - is to be replaced (because of locking compound). Clean thread in compressor shaft before inserting new bolt. If belt pulley cannot be removed with compressor installed, remove compressor from engine --> from --> Removing compressor from bracket and installing in vehicles with 8-cyl. MPI engine

Scheme 29

1. Carefully and uniformly pry off drive plate - A - using 2 screwdrivers - B -.

Note. Make sure that the collar for pulley - C - is not damaged when prying off drive plate - A -. There are different versions of pulley - C - and drive plate - A - , therefore note the exact assignment.

Scheme 30

1. Remove circlip - A -.
2. Remove pulley - B -.

Note. Replace circlip - A -. When installing circlip - A - , note that it cannot be bent open more than is necessary for installation. Insert circlip - A - on proper side, the side with beveled insertion edge - C - faces away from compressor (install flat side facing compressor). Ensure proper seating of circlip in groove on compressor flange. Clean compressor flange before fitting the pulley on, pulley must be able to be fitted easily. (fitting must be possible without much force).

A/C compressor pulley, replacing (Version "2")

Note. Different versions of the pulley are installed, depending on compressor construction type and engine version Pulley, removing from compressor and re-installing --> A/C compressor pulley, removing from compressor and re-installing (Version "2") Belt pulley version "2" is installed e.g. on compressor types "6 SEU 14" and "7 SEU 17".

Scheme 31

1 - Circlip

1. Remove carefully using a small screwdriver or needle-nose pliers (especially note belt pulley when doing this)
2. Removing and installing --> «A/C compressor pulley, removing from compressor and re-installing (Version "2")»(ref-289225-S18939185632008062700000)
3. As of model year 2006, circlips with a rubber disc vulcanized on to them are installed as a running change, this rubber disc replaces the plastic disc which could be glued on up to then (not present on all compressors) --> «A/C compressor pulley, removing from compressor and re-installing (Version "2")»(ref-289225-S18939185632008062700000)

2 - Drive plate

1. Attached to compressor input shaft
2. Different versions
3. With overload safeguard, triggers when torque is too-high (e.g. compressor produces friction) and belt pulley runs freely without driving the compressor.
4. Removing and installing --> «A/C compressor pulley, removing from compressor and re-installing (Version "2")»(ref-289225-S18939185632008062700000)

1. Tightening torque 35 Nm
2. A plastic washer may be glued on, depending on time period of production --> «A/C compressor pulley, removing from compressor and re-installing (Version "2")»(ref-289225-S18939185632008062700000) .

3 - Circlip

1. Replace
2. Install on proper side (level side to compressor)
3. Removing and installing --> «A/C compressor pulley, removing from compressor and re-installing (Version "2")»(ref-289225-S18939185632008062700000)

4 - Spacer

1. Dimension: 17.5 x 10 x 3 mm

5 - Rubber element

1. 6x, install on proper side --> «A/C compressor pulley, removing from compressor and re-installing (Version "2")»(ref-289225-S18939185632008062700000)
2. Decouples belt pulley from compressor drive shaft, damps vibrations and noise.
3. For installation, lightly coat rubber elements, e.g. with tire mounting paste or a soap solution (as a lubricant)

6 - Belt pulley

1. Belt pulley is made of plastic and is sensitive to impact, therefore handle it with especial care
2. Different versions
3. Removing and installing --> «A/C compressor pulley, removing from compressor and re-installing (Version "2")»(ref-289225-S18939185632008062700000)

7 - Compressor

1. Different versions are installed, depending on engine version and country version of vehicle.
2. Clean compressor flange before sliding on pulley.

A/C compressor pulley, removing from compressor and re-installing (Version "2")

Note. Observe notes for removing belt pulley of version "1" , these also apply for version "2" --> A/C compressor pulley, removing from compressor and re-installing (Version "1") Perform preliminary work as for removing belt pulley of version "1" --> A/C compressor pulley, removing from compressor and re-installing (Version "1") Belt pulley is made of plastic and is sensitive to impact, therefore handle it with especial care If overload safeguard of drive plate - C - has triggered, drive plate can be pried off from belt pulley - D - after removing circlip - A - A plastic disc - B - may be glued on or a circlip with a rubber disc vulcanized on to it may be installed on drive plate of belt pulley - A - to optimize noise reduction . This plastic or rubber disc - B - can reduce a clapping (castanet-like) noise.

A/C compressor pulley, removing and installing (Version "2")

Detaching

Scheme 32

1. Remove plastic disc - B - from belt pulley - A - (if installed).

Scheme 33

1. Using e.g. a small screwdriver or needle-nose pliers, carefully remove circlip - A - (which might have rubber disc vulcanized on to it); take extreme care not to damage belt pulley when doing this.
2. Hold compressor drive shaft - B - firmly in place using a socket or socket wrench T10001/10 from shock absorber set (depending on version) and rotate drive plate - C - along with belt pulley - D - in direction of arrow - E - (tightening torque 35 Nm).

Scheme 34

1. Remove circlip - A -.
2. Remove pulley - B -.

Attaching

Note. Replace circlip - A -. Clean compressor flange before sliding on belt pulley. When installing circlip - A - , note that it cannot be bent open more than is necessary for installation.

1. Install belt pulley - B -.
2. Insert circlip - A - on proper side, the side with beveled insertion edge - C - faces away from compressor (install flat side facing compressor).
3. Insert rubber element - D - in belt pulley - B - according to (Scheme 40).
4. When installing drive plate, coat rubber element - D - lightly e.g. with tire mounting paste or soap solution (as sliding compound).

1. Insert drive plate - C - far enough into rubber elements - D - (Scheme 40) until it contacts compressor shaft - B -.
2. Screw drive plate - C - onto compressor shaft - B - by rotating in direction of arrow - F -.
3. Tighten drive plate - C - to 35 Nm by rotating using a conventional band wrench (with webbed band) in direction of arrow - E -, counter-hold compressor shaft - A - using a retainer - B - (e.g. using a socket or socket wrench T10001/10 from socket wrench set) on compressor shaft - A -.
4. Install circlip - A -.

1. Clean drive plate of belt pulley - A - and glue plastic disc - B - centered onto drive plate (only on compressors without rubber ring on circlip).

Components for control and regulation of air conditioner not located in passenger compartment

Note. If there is a malfunction in the system, first check DTC memory of Climatronic Control Module J255 (and of Rear A/C Control Head (Climatronic) E265). Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. If no fault is displayed, read measured value block of Climatronic Control Module J255 (paying particular attention to measured value blocks "001" , "002" , "034" , "035" and "050 " , and actuate any problematic components via "output Diagnostic Test Mode (DTM)" function. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. Service work on refrigerant circuit are described as of --> A/C Refrigerant Circuit, servicing . Perform the following work on completion of repair operations

1. Check DTC memory of Climatronic Control Module J255 (and of Rear A/C Control Head (Climatronic) E265) and erase DTCs displayed if necessary.
2. Check coding of A/C control head Climatronic Control Module J255
3. If necessary, check adaptation of Climatronic Control Module J255 and Rear A/C Control Head (Climatronic) E265 (not installed on all vehicles).
4. Perform air conditioner basic setting. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Scheme 35

1 - Sunroof (with solar cells)

1. Checking function of solar cells --> «Solar roof (where applicable), checking operation»(ref-289225-S36432292072008062700000)
2. Removing and installing --> «60 - SUNROOF»(ref-289221-S14816701152008062700000)
3. Depending on setting in MMI (Multi Media Interface), the sunroof closes as soon as Climatronic Control Module J255 switches over to air recirculation mode (automatic air recirculation via air quality sensor or manual air recirculation by operating the air recirculation button). This function is equipment-dependent, its introduction has not yet been finalized. Owners Manual

2 - Forced air extractor

1. Installed on left and right beneath rear bumper
2. Sealing lips of vent frame must move freely and close automatically
3. To ensure proper functioning of passenger compartment ventilation, air ducts must not be blocked by luggage compartment lining
4. Checking --> «Ventilation system frame, checking»(ref-289225-S10048948992008062700000)

3 - Evaporator drain hose

1. One evaporator drain each for drivers and front passengers side.
2. Checking, removing and installing --> «Evaporator drain hose, removing, checking and installing»(ref-289225-S28528887042008062700000)

4 - Recirculation Flap Motor V113

1. With Recirculation Flap Motor Position Sensor G143
2. Removing and installing --> «Recirculation Flap Motor V113 removing and installing»(ref-289225-S24887340242008062700000)

5 - Fresh Air Intake Duct Temperature Sensor G89

1. Removing and installing, checking resistance value --> «Fresh Air Intake Duct Temperature Sensor G89 removing and installing»(ref-289225-S40864103962008062700000)

6 - Air Flow Flap Motor V71

1. With Back Pressure Flap Motor Position Sensor G113
2. Removing and installing --> «Air Flow Flap Motor V71 with Back Pressure Flap Motor Position Sensor G113 , removing and installing»(ref-289225-S28604062512008062700000)

7 - Service connection

1. Low pressure side
2. Used for measuring, discharging and recharging by A/C system service point workshops
3. Cap with seal; always to be screwed on

8 - Outside Air Temperature Sensor G17

1. Removing: Remove bumper --> «50 - BODY - FRONT»(ref-289221-S10914933722008062700000)
2. Unplug connector at temperature sensor and unclip from mount in air duct
3. Measured value of Outside Air Temperature Sensor G17 is evaluated by Instrument Cluster Control Module J285 and transmitted via Comfort CAN-Bus system to Climatronic Control Module J255. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function

9 - Pump-valve unit

1. Consists of Left Heat Regulating Valve N175 and Right Heat Regulating Valve N176 and Coolant Pump V50
2. Checking function --> «A/C system heat output and pump valve unit, checking»(ref-289225-S16479413532008062700000)
3. Removing and installing --> «Pump/valve unit, removing and installing»(ref-289225-S19938788502008062700000)
4. Replace

10 - Air Quality Sensor G238

1. Function --> «Air Quality Sensor G238 , mode of operation»(ref-289225-S08899818802008062700000)
2. Checking --> «Air Quality Sensor G238 , checking»(ref-289225-S16040445322008062700000)
3. Removing and installing --> «Air Quality Sensor G238 removing and installing»(ref-289225-S23797990152008062700000)
4. Depending on setting in MMI (Multi Media Interface), the sunroof closes as soon as Climatronic Control Module J255 switches over to air-recirculation mode (automatic air recirculation via air quality sensor or manual air recirculation by operating the air recirculation button). This function is equipment-dependent, its introduction has not yet been finalized. Owners Manual

11 - Plenum chamber water drain

1. Checking, cleaning, removing and installing --> «Plenum chamber water drain, checking and cleaning»(ref-289225-S41806632272008062700000)

12 - Heated Windshield Z2

1. Actuation is effected via Heated Windshield Control Module J505 (installed in luggage compartment on right beneath battery A) --> «Heated windshield, operation»(ref-289225-S23809671062008062700000) and
2. Function --> «Heated windshield, operation»(ref-289225-S23809671062008062700000)
3. Removing and installing front windshield --> «64 - GLASS, WINDOWS»(ref-289221-S30390656582008062700000)

13 - Union in refrigerant pipe (with restrictor)

1. Threaded connection must only be opened with refrigerant circuit discharged; deliver vehicle to an A/C system service point workshop

14 - Service connection

1. High pressure side
2. Used for measuring, discharging and recharging by A/C system service point workshops
3. Cap with seal; always to be screwed on

15 - Accumulator

1. Must only be removed with refrigerant circuit discharged; deliver vehicle to an A/C system service point workshop
2. Removing and installing --> «Accumulator, removing and installing»(ref-289225-S17523221382008062700000)

16 - A/C Compressor Regulator Valve N280

1. Checking activation and function --> «A/C Compressor Regulator Valve N280 cut-in signal, checking»(ref-289225-S39143243932008062700000) .

17 - Compressor

1. Removing compressor from bracket and installing in vehicles with , 8-cyl. MPI engine --> «Removing compressor from bracket and installing in vehicles with 8-cyl. MPI engine»(ref-289225-S14195474132008062700000)
2. Removing compressor from bracket and re-installing in vehicles with 12-cyl. engine --> «Compressor, removing from bracket and re-installing - vehicles with 12-cyl. engine»(ref-289225-S11543673622008062700000)
3. Compressor, removing and installing in vehicles with 8-cyl. FSI engine --> «A/C compressor, removing and installing - vehicles with 8-cyl. FSI engine»(ref-289225-S28803055272008062700000)
4. Compressor, removing and installing in vehicles with 10-cyl. engine --> «Compressor, removing and installing - vehicles with 10-cyl. engine (Audi S8)»(ref-289225-S40754187942008062700000)

1. Refrigerant line, disconnecting from compressor and connecting --> «Refrigerant lines, disconnecting and connecting at compressor»(ref-289225-S01947645402008062700000)
2. Compressor, removing and installing (basics) --> «A/C compressor, removing and installing (basic guidelines)»(ref-289225-S08499229282008062700000)
3. Removing compressor with drive unit (shaft) from bracket and re-installing (vehicles with 8-cyl. FSI engine or 10-cylinder engine) --> «Compressor drive unit, checking, replacing»(ref-289225-S40868384782008062700000)
4. Replacing compressor drive unit (vehicles with 8-cyl. FSI or 10-cyl. engine) --> «Compressor drive unit, checking, replacing»(ref-289225-S40868384782008062700000)

1. Type of compressor differs depending on engine (8, 10 or 12-cyl. engine)
2. Ribbed belt, removing and installing: --> «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-289203-S16488527182008062700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-289204-S09096153412008062700000) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-289206-S19139229562008062700000) for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB
3. Belt pulley, replacing --> «A/C Compressor Pulley»(ref-289225-S14146475182008062700000)
4. Depending on compressor type ("6 SEU 14" , "7 SEU 16" or "7 SEU 17") different refrigerant oil fill capacities are designated for the refrigerant circuit and --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000)

18 - High Pressure Sensor G65

1. Function, removing and installing --> «High Pressure Sensor G65 , removing and installing»(ref-289225-S12705460112008062700000)
2. Measured value of sensor is displayed in function "Read measuring value block" display group "001" of Climatronic Control Module J255 and Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

19 - Condenser

1. Must only be removed with refrigerant circuit discharged; deliver vehicle to an A/C system service point workshop
2. Different versions (power steering fluid cooler is installed too depending on vehicle equipment) --> «48 - STEERING»(ref-289219-S07076849872008062700000)
3. Refrigerant lines, disconnecting and reconnecting --> «Detaching refrigerant lines from condenser/re-attaching»(ref-289225-S05971395372008062700000)
4. Condenser, removing and installing --> «Condenser, removing and installing»(ref-289225-S12724682252008062700000)

20 - Coolant Fan V7

1. Request to switch on coolant fan is transmitted to engine control module by Climatronic Control Module J255 via CAN bus system. Engine Control Module (ECM) then activates fans or Coolant Fan Control (FC)Control Module J293. --> «19 - ENGINE - COOLING SYSTEM»(ref-289203-S15357943982008062700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM «19 - ENGINE - COOLING SYSTEM»(ref-289204-S03664241582008062700000) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM «19 - COOLING SYSTEM»(ref-289206-S27114819052008062700000) for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB
2. The respective Engine Control Module (ECM) switches Coolant Fans (via Coolant Fan Control (FC) Control Module J293) continuously to desired output. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function
3. Different versions are installed depending on vehicle equipment.
4. Check activation by A/C control head Climatronic Control Module J255 (Read measuring value block, display group "022") Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.--> Electrical Wiring Diagrams, Troubleshooting and Component Locations

21 - Fresh Air Blower Control Module J126

1. Removing and installing --> «Fresh Air Blower Control Module J126 , removing and installing»(ref-289225-S30661909472008062700000)
2. Checking Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

22 - Fresh Air Blower V2

1. Removing and installing --> «Fresh Air Blower V2 , removing and installing»(ref-289225-S24370298332008062700000)
2. Checking Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

23 - Dust and pollen filter

1. Removing and installing --> «Dust and pollen filter, removing and installing»(ref-289225-S02097241612008062700000)
2. Observe replacement intervals
3. With active carbon filter element --> «Dust and pollen filter with activated charcoal filter element»(ref-289225-S06244391772008062700000)

24 - Label

1. Indicates type of refrigerant and intended capacity
2. In model year 2003, adhesive label was gradually discontinued, capacity for refrigerant R134a and notes on refrigerant can be found in --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000)

25 - Evaporator

1. Must only be removed with refrigerant circuit discharged, deliver vehicle to an A/C system service point workshop
2. Removing and installing --> «Evaporator, removing and installing»(ref-289225-S10206257522008062700000)
3. Clean air conditioning system evaporator with Ultrasonic HVAC Cleaning System VAS 6189 --> «A/C system evaporator, cleaning using Ultrasonic HVAC Cleaning System VAS 6189»(ref-289225-S38816546732008062700000)

26 - Opening for recirculated-air mode

Dust and pollen filter, removing and installing

Note. Change interval for dust and pollen filter: Filter element has an activated charcoal insert as integrated odor filter. Clean plenum chamber after replacing dust and pollen filter; pay particular attention to area beneath air conditioner. Clean surrounding area of dust and pollen filter before installing new filter.

1. Remove left and right plenum chamber covers.

Scheme 36

1. Release clamping pins - A - by turning 180° and remove cover - B - with dust and pollen filter - C -.
2. Remove dust and pollen filter - C - from housing.

Dust and pollen filter with activated charcoal filter element

1. The dust and pollen filter with additional activated charcoal filter element is installed in addition to Air Quality Sensor G238 (--> «Air Quality Sensor G238 , mode of operation»(ref-289225-S08899818802008062700000) ).
2. The activated charcoal filter element continues to function as a dust and pollen filter, however in addition the activated charcoal filter can also filter out gaseous pollutants e.g. ozone, benzene, nitrogen dioxide from the air flow.
3. The role of the activated charcoal is to store the impurities in the through-flowing air until the fresh air flap is closed and the air conditioning system is operating in air recirculation mode. The change over from fresh to recirculating mode occurs via Climatronic Control Module J255 , as soon as Air Quality Sensor G238 detects gaseous pollutants in the ambient air ("automatic air recirculation" mode must be selected).
4. The activated charcoal layer in the dust and pollen filter reacts differently to various pollutants in the air.

Certain pollutants bond permanently in the activated charcoal layer.

Others are converted into innoxious bonds as in a catalytic converter.

For the rest the activated charcoal works as a condenser (capacitor). With load increasing, pollutants are absorbed for as long until a certain saturation point is reached. If the amount of pollutants decreases, the activated charcoal layer continuously releases the absorbed particles.

1. Under the following operating conditions the dust and pollen filter must be replaced earlier than required, because a certain amount of pollutant particles is permanently bonded to the activated charcoal layer.

the vehicle is driven in areas with heavy air pollution.

If vehicle is predominantly driven with the "automatic recirculating" mode switched off.

1. If possible, vehicles with Air Quality Sensor G238 should always be operated in "automatic air recirculation" mode. If it is necessary or desired to switch the function off, the following should be observed

1. The active carbon layer in the dust and pollen filter is saturated after a certain time.
2. A saturated filter can no longer absorb pollutants and allows them to pass unhindered.

1. The most important task of the dust and pollen filter and air quality sensor is keep the load peaks out from the passenger compartment. To allow this to be effective, the following should be observed

1. If a vehicle is driven in an area with relative clean ambient air (with little gaseous pollutants in the air), the change over from fresh into recirculating mode occurs at different point in time as in an area with high basic load (e.g. industrial area).
2. Independently of the basic load, the change-over from fresh to recirculating mode always occurs, when the pollutant-load increases (e.g. when driving to through an exhaust cloud of a Diesel truck).

A/C system evaporator, cleaning using Ultrasonic HVAC Cleaning System VAS 6189

Note. Odors from the air conditioning system can be caused by various things, only a portion of these orders come from the evaporator and can be corrected by cleaning it with the Ultrasonic HVAC Cleaning System VAS 6189.

Possible causes of odor

1. Smell like burnt oil.

1. Mostly forms in the engine compartment due to leaks on the engine or transmission.

1. Sulphurous smell like exhaust.

1. Due to leaks in the exhaust system.
2. Due to exhaust that enters the vehicle, e.g. when driving in reverse (by driving through the cloud of exhaust).

1. Fishy smell like coolant.

1. From leak at cooling system of engine or of A/C system heater core.

Note. If fishy odor is detected also in fresh-air mode as well as in recirculated-air mode, check A/C system heater core for proper seal. Smell like a burned clutch. Evaporation from floor mats, decorative seat covers, etc. Rotten, mildewy, moldy or musty smell from plenum chamber.

1. Due to various contaminants, such as leaves, pine needles, etc. collecting.
2. From water which cannot flow out of the plenum chamber or air intake housing.

Note. Check water drains of plenum chamber and air conditioner. --> Plenum chamber water drain, checking and cleaning Smell from air conditioner.

Note. Odors originating in heating and A/C unit can mainly be detected in fresh air mode as well as in recirculated air mode. If a smell occurs only in fresh air or recirculation mode, the cause is probably not the A/C unit. When heater core is leaking, the odor of the escaping coolant can be detected even in fresh air mode as well as in recirculated air mode (heater core has continuous air flow).

1. Due to too much condensation water in A/C unit.

Note. Check both condensation water drains --> Evaporator drain hose, removing, checking and installing .

1. Due to an old or heavily contaminated dust and pollen filter.

Note. Check dust and pollen filter --> Dust and pollen filter, removing and installing

1. Due to deposits on evaporator fins.

Note. Clean evaporator with Ultrasonic HVAC Cleaning System VAS 6189.

Evaporator, cleaning

Tools required

1. Ultrasonic HVAC Cleaning System VAS 6189.
2. Cleaning Fluid VAS 6189/1

Preparation

1. Check whether odor is actually in A/C evaporator by switching from fresh air to recirculation.

Note. The odor can only be fixed by cleaning with the Ultrasonic HVAC Cleaning System VAS 6189 if it originates in the evaporator.

1. Check plenum chamber and water drain valves installed there and clean them if necessary --> «Plenum chamber water drain, checking and cleaning»(ref-289225-S41806632272008062700000) .
2. Check dust and pollen filter for odor and dirt --> «Dust and pollen filter, removing and installing»(ref-289225-S02097241612008062700000) .

Note. On this vehicle, dust and pollen filter is installed at fresh air intake before Fresh Air Blower V2 , therefore it must not be removed for cleaning.

1. Start engine.
2. Set operating mode "recirculated-air mode" at Climatronic Control Module J255 and switch off compressor "Econ".
3. Open instrument panel vent and on the operating and display unit, set the Climatronic Control Module J255 to the lowest possible temperature for the drivers and passengers side (e.g. temperature selection "Lo").
4. Close the windows and the sunroof.

1. On the operating and display unit, set the Climatronic Control Module J255 to the lowest fresh air blow level and select "Instrument panel vent" for air flow direction.

Cleaning

1. Shake bottle of Cleaning Fluid VAS 6189/1 and fill Ultrasonic HVAC Cleaning System VAS 6189 with it, following operating instructions that come with cleaning system.
2. Place Ultrasonic HVAC Cleaning System VAS 6189 in passengers side footwell.
3. Start up the Ultrasonic HVAC Cleaning System VAS 6189 (according to operating instructions) and route the outlet hose belonging to it so that the vapor escaping via the recirculated air opening of the heating and A/C unit (beneath instrument panel) is drawn in by the Fresh Air Blower V2.
4. Close vehicle doors.

Note. The cleaning process takes about 15 to 20 minutes. It is complete when vapor no longer comes out of outlet hose.

Finishing steps

1. Switch Ultrasonic HVAC Cleaning System VAS 6189 off.
2. Open vehicle doors and air out vehicle at least 10 minutes.
3. Remove Ultrasonic HVAC Cleaning System VAS 6189 from vehicle and clean it according to operating instructions.
4. Switch off ignition.

Scheme 37

Note. Air Quality Sensor G238 is a highly sensitive electronic component that can be damaged if it comes in direct contact with solvents, fuels or chemicals (e.g. impurities may enter through area - A -). For this reason, never fit sensors which have been kept in tool chests or the like. Following removal, do not set down sensor in areas where it could come into contact with solvents, fuels or certain chemical compounds (liquids or vapors). Air Quality Sensor G238 is available in different housings, but functionally they are the same.

Removing and installing

1. Remove plenum chamber cover on right.

Scheme 38

1. Disconnect harness connector - A - from sensor.
2. Rotate sensor 90° and pull sensor - B - upward out of mount.

Terminal assignment in connector - A

1 - B+ (terminal "15")

2 - Ground (terminal "31")

3 - Signal wire to Climatronic Control Module J255 , measured value is displayed in measured value block of Climatronic Control Module J255 (display group "022"). Square wave signal cannot be evaluated using workshop equipment.

Air Quality Sensor G238 , checking

Special tools, testers and other items required

1. Vehicle Diagnostic, Testing and Information System VAS 5051 A with diagnostic cable VAS 5051/5A
2. Test gas D 007 855 A2

Checking

1. With ignition switched off, connect diagnostic operation system VAS 5051 A with diagnostic cable VAS 5051/5A to 16-pin Data Link Connector (DLC) in vehicle --> «Vehicle Diagnostic, Testing and Information System VAS 5051 A , connecting and selecting functions»(ref-289225-S22299735562008062700000) . Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
2. Start engine.
3. Check DTC memory of Climatronic Control Module J255. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
4. Set operating mode "Auto" on Climatronic Control Module J255.

1. Switch on the "automatic air recirculation" function via the Climatronic Control Module J255 (function is displayed on screen of Multi Media Interface).
2. Wait 30 seconds (warm up time for Air Quality Sensor G238).
3. Select "Read measuring value block" (display group "022") via diagnostic operation system VAS 5051 A. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
4. Read indications shown in display fields "3" and "4".

Note. Display field "4" shows the operating condition of recirculating air flap and display field "3" shows signal condition of Air Quality Sensor G238. Explanatory notes on possible displays Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. Specified value in display field "4" (no request for "recirculating air mode" present, A/C system in fresh air mode)

Or

1. Specified value in display field "4" "partial recirculating air mode" , (fresh air and recirculating air flaps open)

Scheme 39

1. Place spray head - A - of test gas bottle over air inlet of air quality sensor - B -.
2. Press spray head - C - of test gas bottle for 1 second.

Note. There are various housings for the air quality sensor, but the mode of operation is always identical. The test gas canister is filled with pure oxygen with a specific nitrogen oxide component. Sensor also reacts when exposed to cigarette smoke or cigarette lighter gas (gas is heavier than air, sensor must therefore be removed and turned round).

1. Read indication in display field "4".

1. Specification: (request for "Automatic air recirculation" present, request is fulfilled, A/C switches to recirculating air mode)

1. Wait a short period time (approx. 1 minute, depending on amount of test gas sprayed in sensor).
2. Read indication in display field "4".

1. Specified value (no request for "Recirculating air mode" present, air conditioning in fresh air mode)

Or

1. Specification: (partial recirculated-air mode)

Note. In order to avoid frequent shifting of the recirculating air/fresh air flap, the requirement of sensor for "Automatic air recirculation" mode remains for at least 25 seconds (minimum duration period), even if the pollutant concentration is so far reduced that recirculating air mode is no longer necessary.

1. Operate switch for wiper/washer system until Windshield Washer Pump V5 has delivered fluid for approx. 2 seconds.
2. Read indication in display field "4".

1. Specification: (Requirement for "recirculating air mode" due to washer/wiper system, A/C switches for approx. 10 seconds to the air recirculating mode)

1. Wait briefly.
2. Read indication in display field "4".

1. Specification: (no request for "Recirculating air mode" present, air conditioning in fresh air mode)

Or

1. Specification: (partial recirculated-air mode)

Note. Depending on the composition of the windshield washer fluid, the sensor can determine impurities in the air and request for "Automatic air recirculation". If no change-over to recirculating air mode occurs when operating switch for windshield wiper/washer system, check function (information "wash windshield" is received by Steering Column Electronic Systems Control Module J527 via CAN-Bus Comfort), read measuring value block, display group 026. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

If the function of Air Quality Sensor G238 is OK for this test and there is a customer complaint continue as follows

1. Check dust and pollen filter for dirt.
2. Connect fault read-out device and select function "08 Read measuring value block".
3. Second person is required to read out values displayed whilst driving.
4. Pay attention to safety precautions.
5. Enter display group number "022".
6. Start by driving vehicle into an area with a relatively clean atmosphere (system in fresh-air mode).
7. Then drive vehicle into an area where the atmosphere is polluted (e.g. onto an uphill road with lorry traffic).
8. Read indications shown in display fields "3" and "4". Indication in display fields "3" and "4" must change e.g. when driving through a diesel exhaust cloud.
9. Also read and heed descriptions --> «Dust and pollen filter with activated charcoal filter element»(ref-289225-S06244391772008062700000) and --> «Air Quality Sensor G238 , mode of operation»(ref-289225-S08899818802008062700000) .

Scheme 40

1. Check ventilation channels to both ventilation frames - A - in luggage compartment (left and right) for throughput.

1. Sealing lips - B - in air extraction outlets - A - must move freely and close automatically.
2. Blocked channels or jammed sealing lips may cause windows to fog up.

Scheme 41

Note. In this illustration, ventilation frame is depicted with rear bumper removed. One vent frame is installed on left and right for forced air extraction. So that sealing lips - B - close correctly, ventilation frame - A - must be installed on proper side (smaller radius - C - at top). To ensure proper function of passenger compartment ventilation, vent openings - A - in luggage compartment trim on left and right must not be sealed. Air from passenger compartment flows via vent slits in rear shelf and through slits incorporated in upper trim - B - into luggage compartment.

Scheme 42

Note. The draining of water from plenum chamber may be impaired by deposits (leaves, diverse tree needles etc.) accumulating in plenum chamber water drains. When in an automatic car wash or during heavy rainfall, water level will rise in plenum chamber and water will ingress into air conditioner through openings - A - (right and left next to fresh air blower) which are actually intended for water drainage, and will be blown through fresh air blower onto evaporator together with air conveyed. The two water drain sockets - A - and - B - in plenum chamber can only be replaced when removing transmission or air conditioner. Without removing air conditioner, transmission, pump valve unit and brake booster, drains and area beneath air conditioner can be cleaned from coarse dirt e.g. with a commercially available flexible grip tool. Fine deposits and sludge can be removed e.g. using a thin water hose or pressure-fed spray gun V.A.G 1538 and flexible nylon probe V.A.G 1538/2. Removal of stubborn dirt can be facilitated by e.g. removing pump valve unit. If water drain sockets - A - and - B - 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. Metal clips are inserted from above into both water drain grommets - A - and - B -. These tabs hold the grommets in place in the opening on the bottom of the plenum chamber .

Removing

1. Remove left and right plenum chamber covers.
2. Remove dust and pollen filter --> «Dust and pollen filter, removing and installing»(ref-289225-S02097241612008062700000) .
3. Remove dome brace with reinforcement to cowl panel trim. --> «40 - FRONT SUSPENSION»(ref-289219-S31806228072008062700000)
4. Switch on ignition and set air conditioner to fresh-air mode (e.g. by "Defrost" setting on Climatronic Control Module J255)

Note. To gain access to bolts - A - , air flow flap must be open.

Scheme 43

1. Remove bolts - A -.
2. Switch off ignition.
3. Now remove the remaining screws - arrows -.

Scheme 44

1. Release fasteners for wiring harness - A - on left and right of air conditioner.
2. Take off air intake shroud with air flow flap.
3. If necessary for further work, open remaining wiring harness fasteners at air conditioner.

Scheme 45

1. Remove bolts - A -.
2. Remove cover - B -.
3. Remove temperature sensor from intake housing --> «Fresh Air Intake Duct Temperature Sensor G89 removing and installing»(ref-289225-S40864103962008062700000)
4. Remove Air Flow Flap Motor V71 --> «Air Flow Flap Motor V71 with Back Pressure Flap Motor Position Sensor G113 , removing and installing»(ref-289225-S28604062512008062700000) .

Installing

Installation is carried out in the reverse order, when doing this note the following

Scheme 46

1. Before installing air intake housing, seal housing joint at areas marked - C - and - D - thoroughly with silicone sealant D 176 001 A3 .
2. Seal grommet through which wiring harness is routed into air conditioner (to Fresh Air Blower Control Module J126) with silicone sealant D 176 001 A3 (to prevent ingress of water into air conditioner through grommet or past grommet).
3. Install the removed components again in reverse order.

Scheme 47

Note. If there are complaints about moisture (evaporator on windshield, odor), a sponge rubber strip 3 mm - A - should be inserted in addition to sealing measures described, starting and finishing at area - B -. In the area marked - B - , in which the groove is narrower, there should be no sponge rubber strip. Use commercially available sponge rubber strip, soft type 3 mm.

1. Check DTC memory of Climatronic Control Module J255 and erase DTCs displayed if necessary. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
2. Perform basic setting and output Diagnostic Test Mode (DTM) on the A/C system. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Air Flow Flap Motor V71 with Back Pressure Flap Motor Position Sensor G113 , removing and installing

Note. Mark motor/flap connecting elements when removing (danger of swapping with connecting elements of the other actuator motors). In the event of fault "Upper or lower limit value exceeded" , check connecting element of engine/flap, it must be attached to engine accurate to side and there must not be any clearance between actuator mount and connecting element.

1. Remove air intake housing with air flow flap --> «Intake housing with air flow flap, removing and installing»(ref-289225-S35130398122008062700000) .

Scheme 48

1. Remove bolts - A -.
2. Remove grommet - C - from mount.
3. Remove actuator.
4. Disconnect harness connector from actuator - B -.

Scheme 49

1. Check back pressure flap position before installing actuator.
2. Remove connecting piece - A - from shaft of air flow flap and position on actuator -B- as shown in illustration.

Note. Actuator shaft - B - does not have a stop, it rotates continuously when voltage is applied to terminals 5 and 6. Therefore, when actuator is removed, voltage is only to be applied if connecting element - B - is attached. If connecting element - A - cannot be inserted into actuator without pretension, actuator may be incorrectly positioned. If shaft is so awkwardly positioned that connecting element cannot be attached, connect terminals 5 and 6 of actuator via a 5A fuse to a 12 V battery e.g. using adapter lead --> Preparing adapter cables for control motor actuation or an adapter lead from connector test kit V.A.G 1594/C. Rotate actuator for only as long until connecting element can be attached without pretension, the turning direction can be reversed by swapping B+ and Ground. Check seating of connecting element, there must be no play between actuator mount and connecting element.

1. Install connecting element - A - onto air flow flap shaft.
2. Install actuator - B -.

1. Hand-tighten mounting bolts - A - (10 Ncm).
2. Before installing cover, check correct positioning of connector - B - , routing of wiring as illustrated and position of grommet - C -.
3. Seal grommet through which wiring harness is routed beneath cover to actuator with silicone sealant D 176 001 A3 (to prevent ingress of water to connector or actuator through grommet or past grommet).
4. Install the removed components again in reverse order.

1. Check DTC memory of Climatronic Control Module J255 and erase DTCs displayed if necessary. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
2. Perform basic setting and output Diagnostic Test Mode (DTM) on the A/C system. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Scheme 50

1. Connect one wire with a cross section of0.25 mm 2 each to terminals - 5 - and - 6 - of one connector - A - (part number 6Q0 972 706).

Note. Part numbers are for reference only. Always check with your Parts Department for the latest part number information

1. Connect the other end of each wire to a commercially available banana connector - B -.

Fresh Air Intake Duct Temperature Sensor G89 removing and installing

1. Remove left and right plenum chamber covers.
2. Remove dust and pollen filter --> «Dust and pollen filter, removing and installing»(ref-289225-S02097241612008062700000) .

Scheme 51

1. Remove temperature sensor - A - from intake housing - B

Recirculation Flap Motor V113 removing and installing

Note. Mark motor/flap connecting elements when removing (danger of swapping with connecting elements of the other actuator motors). In the event of fault "Upper or lower limit value exceeded" , check connecting element of engine/flap, it must be attached to engine accurate to side and there must not be any clearance between actuator mount and connecting element. Position of Recirculation Flap Motor V113 beneath cowl panel trim is such that rainwater may drip onto cover - B - and ingress via separation point between air conditioner and cover into housing and onto actuator or connector at actuator. To prevent ingress of water, connection between housing components has been sealed at factory as of 02.03 with silicone sealant D 176 001 A3 and/or round butyl packing (diameter 3 mm). Packing is inserted in joint between cover - B - for actuator and cover with recirculated-air flap to provide a seal. The introduction of a modified cover for actuator - B - (with 4 instead of 2 bolt points), a suitably adapted cover with recirculated-air flap and a wiring harness with modified grommet - C - is planned as of 12.03 (gradual introduction) . If water has increased into the connector - B - or actuator, the recirculated-air flap can no longer be adjusted and faults may be stored in the fault memory for this actuator.

1. Switch off ignition.
2. Remove left and right plenum chamber covers.
3. Remove dust and pollen filter --> «Dust and pollen filter, removing and installing»(ref-289225-S02097241612008062700000) .
4. Remove dome brace with reinforcement to cowl panel trim --> «40 - FRONT SUSPENSION»(ref-289219-S31806228072008062700000) .

1. Remove windshield wipers and scuttle panel trim. --> «92 - WINDSHIELD WIPER AND WASHER SYSTEM»(ref-289227-S11612981612008062700000)

Scheme 52

1. Remove bolts - A -.
2. Remove cover - B -.

Scheme 53

1. Remove bolts - A -.
2. Remove grommet - C - from mount.
3. Remove actuator.
4. Disconnect harness connector from actuator - B -.

Installation is carried out in the reverse order, when doing this note the following

1. Remove any residual black silicone sealant or round packing at cover for actuator or air conditioner.

1. Check recirculated-air flap position before installing actuator.
2. Remove connecting element - A - from shaft of recirculated-air flap and position on actuator - B - as shown in illustration.

Note. Actuator shaft - B - does not have a stop, it rotates continuously when voltage is applied to terminals 5 and 6. Therefore, when actuator is removed, voltage is only to be applied if intermediate piece - B - is attached. If connecting element - A - cannot be inserted into actuator without pretension, actuator may be incorrectly positioned. If shaft is so awkwardly positioned that connecting element cannot be attached, connect terminals 5 and 6 of actuator via a 5A fuse to a 12 V battery e.g. using adapter lead --> Preparing adapter cables for control motor actuation or an adapter lead from connector test kit V.A.G 1594/C. Rotate actuator for only as long until connecting element can be attached without pretension, the turning direction can be reversed by swapping B+ and Ground. Check seating of connecting element, there must be no play between actuator mount and connecting element.

1. Install intermediate piece - A - onto shaft of recirculated-air flap.
2. Install actuator - B -.

1. Hand-tighten mounting bolts - A - (10 Ncm).
2. Before inserting grommet - C - , fill groove of cover with recirculated-air flap (at air conditioner, tongue-and-groove joint to cover) and of grommet - C - all around with exactly the amount of silicone sealant D 176 001 A3 required to reliably seal connection with cover.
3. Connect connector - B - to actuator.
4. Before installing cover, check correct positioning of connector - B - , routing of wiring as illustrated and position of grommet - C -.

1. Also, fill open groove of grommet - C - with exactly the amount of silicone sealant D 176 001 A3 required to reliably seal connection with cover.

Note. The introduction of a modified cover for actuator (with 4 instead of 2 bolt points), a suitably adapted cover with recirculated-air flap and a wiring harness with modified grommet - C - is planned as of 12.03 (gradual introduction) . However, additionally seal connection between air conditioner, cover and grommet with silicone sealant.

1. Install cover - B -.
2. Check connection between air conditioner and cover - B - (reliable sealing is only provided if silicone sealant emerges all around).
3. Also seal location at which wiring harness enters grommet - C - (see illustration above) with silicone sealant D 176 001 A3 .
4. Remove sealant emerging at connections to air conditioner when installing cover - B -.

1. Install the removed components again in reverse order.
2. Check DTC memory of Climatronic Control Module J255 and erase DTCs displayed if necessary. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
3. Perform basic setting and output Diagnostic Test Mode (DTM) on the A/C system. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Note. In the event of problems with moisture in passenger compartment, additionally check recirculated-air flap (must close completely).

Cover with recirculated-air flap, removing and installing

Note. The introduction of a modified cover for actuator (with 4 instead of 2 bolt points), a suitably adapted cover with recirculated-air flap and a wiring harness with modified grommet - C - is planned as of 12.03 (gradual introduction) .

1. Remove left and right plenum chamber covers.
2. Remove dust and pollen filter --> «Dust and pollen filter, removing and installing»(ref-289225-S02097241612008062700000) .
3. Remove dome brace with reinforcement to cowl panel trim --> «40 - FRONT SUSPENSION»(ref-289219-S31806228072008062700000) .
4. Remove windshield wipers and scuttle panel trim. --> «92 - WINDSHIELD WIPER AND WASHER SYSTEM»(ref-289227-S11612981612008062700000)

Scheme 54

1. Remove bolts - A -.
2. Release fasteners for wiring harness - C - on left and right of air conditioner.
3. Remove cover - B -.

Note. If cover must be completely removed, actuator for recirculated-air flap must also be removed --> Recirculation Flap Motor V113 removing and installing .

Fresh Air Blower V2 , removing and installing

Note. Deposits in water drain openings (in area beneath the two blower fans of Fresh Air Blower V2) in air conditioner may cause whistling noise in recirculated-air mode. Therefore, air conditioners with slightly larger drain openings - A - have been installed as of 06.03.

1. Remove left and right plenum chamber covers.
2. Remove dust and pollen filter --> «Dust and pollen filter, removing and installing»(ref-289225-S02097241612008062700000) .
3. Remove air intake housing with air flow flap --> «Intake housing with air flow flap, removing and installing»(ref-289225-S35130398122008062700000) .
4. Remove windshield wipers and scuttle panel trim. --> «92 - WINDSHIELD WIPER AND WASHER SYSTEM»(ref-289227-S11612981612008062700000)

1. Remove cover with recirculation flap --> «Cover with recirculated-air flap, removing and installing»(ref-289225-S30509580512008062700000) .

Scheme 55

1. Remove bolts - A - and remove two air guide rings - B - (left and right).
2. Remove bolts - C -.
3. Remove air guide - D -.

Scheme 56

1. Remove bolts - A - and remove bracket - B -.
2. Disconnect connector - C - from Fresh Air Blower Control Module J126.
3. Remove Fresh Air Blower V2.

Installation is carried out in the reverse order, when doing this note the following

1. When installing, ensure wiring is routed correctly to connector - C -.

1. Remove left and right plenum chamber covers.
2. Remove dust and pollen filter --> «Dust and pollen filter, removing and installing»(ref-289225-S02097241612008062700000) .
3. Remove dome brace with reinforcement to cowl panel trim. --> «40 - FRONT SUSPENSION»(ref-289219-S31806228072008062700000)
4. Remove air intake housing with air flow flap --> «Intake housing with air flow flap, removing and installing»(ref-289225-S35130398122008062700000) .

Scheme 57

1. Remove bolts - A - and - B -.

Note. To remove bolt - B - , use e.g. 1/4 inch socket wrench set. Should it not be possible to remove bolt - B - with cover with recirculated-air flap installed, cover must also be removed --> Cover with recirculated-air flap, removing and installing

1. Disconnect connectors - C - and - D - from Fresh Air Blower Control Module J126.

1. Remove Fresh Air Blower Control Module J126.

Install in reverse order.

Pump/valve unit, removing and installing

Note. For complaint "poor heating performance" , before removing pump-valve unit, check: - Connection to coolant circuit (proper connection of supply and return to engine). - Wiring to pump for possible interchange ("+" and "-"). Bleed coolant circuit again, observe notes for this while doing this --> A/C system heat output and pump valve unit, checking . If Coolant Pump V50 causes noise, check cooling system for complete bleeding (air in coolant circuit may cause noise) before removing pump-valve unit: --> 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM 19 - ENGINE - COOLING SYSTEM for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM 19 - COOLING SYSTEM for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB Valves of pump valve unit are open when de-energized. If power supply or valve connection to Climatronic Control Module J255 is interrupted, heat output of air conditioner cannot be regulated.

Special tools, testers and other items required

1. Hose clamps 3090 bow. 3094
2. Compressed air gun, commercially available
3. Cooling system tester V.A.G 1274 (and corresponding adapter)

1. Switch off ignition.
2. Remove plenum chamber cover on right.
3. Dissipate pressure in coolant circuit by opening cap at coolant expansion tank. --> «19 - ENGINE - COOLING SYSTEM»(ref-289203-S15357943982008062700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM «19 - ENGINE - COOLING SYSTEM»(ref-289204-S03664241582008062700000) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM «19 - COOLING SYSTEM»(ref-289206-S27114819052008062700000) for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB

Scheme 58

1. Mark the arrangement of coolant hoses - A - (supply to pump valve unit) and - B - (return to engine).
2. Clamp two coolant hoses from engine to pump valve unit (e.g. using hose clamps V.A.G 3094).
3. Remove coolant hoses - A - and - B - from connections.

Scheme 59

1. Connect one hose piece - A - and - B - to each of two connections.
2. Place container - C - beneath hose - B -.
3. Using compressed-air gun, carefully blow coolant out of heater core and pump valve unit (into container).

Scheme 60

1. Disconnect connectors - A - (to Right Heat Regulating Valve N176), - B - (to Left Heat Regulating Valve N175) and - C - (to Coolant Pump V50) from pump valve unit.

Note. The connectors are designed so as to prevent interchange

1. Mark arrangement of coolant hoses - D - (supply to pump valve unit) and - E - (return to engine).
2. Remove coolant hoses - D - and - E - from pump valve unit.

Scheme 61

1. Remove two hex nuts - A -.

Scheme 62

1. Mark coolant hoses to heater cores (- A - , supply to drivers heater core, - B - , return from front passengers heater core, - C - , supply to front passengers heater core and - D - , return from front passengers heater core).
2. Release pump-valve unit from rubber elements - E -.
3. Remove coolant hoses from pump valve unit.
4. Remove pump valve unit.

Scheme 63

Note. On left-hand drive vehicles, coolant hoses are connected to pump valve unit as follows: Supply from engine to pump valve unit - A - Return from pump valve unit to engine - B - Supply to front passengers heater core - C - Return from front passengers heater core - D - Supply to drivers heater core - E - Return from drivers heater core - F - For removal, hex nuts at bracket - G - must also be removed on these vehicles.

Installation is carried out in the reverse order, when doing this note the following

Note. Coolant pump V50 of pump-valve unit must only be operated after coolant circuit has been vented. Dry running of pump in pump valve unit leads to destruction.

1. Connect 2-pin harness connector - C - to pump only after bleeding coolant circuit: --> «19 - ENGINE - COOLING SYSTEM»(ref-289203-S15357943982008062700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM «19 - ENGINE - COOLING SYSTEM»(ref-289204-S03664241582008062700000) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM «19 - COOLING SYSTEM»(ref-289206-S27114819052008062700000) for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB
2. After installation, check grommet between engine compartment and plenum chamber for proper seating.

Pump valve unit, replacing

1. Remove pump valve unit --> «Pump/valve unit, removing and installing»(ref-289225-S19938788502008062700000) .

Scheme 64

1. Remove bolts - A - (tightening torque 2 Nm).
2. Remove coolant lines

1. Lines - C - to front passengers heater core
2. Lines - D - to drivers heater core

Note. Replace O-ring seals - B -. Coat O-ring seals with refrigerant before inserting. Insert rubber bushings - E - into pump valve unit and into bracket - F - (Scheme 71)

Scheme 65

Note. Solar ventilation function only works when the sunroof is either closed or in raised position (the solar sunroof - C - converts solar energy into electrical energy which then passes into the vehicle electrical system via terminals - A - (on the front of the sunroof) and terminals - B - (on the frame of the sunroof). Solar operation is not possible with ignition switched on and with auxiliary heater/auxiliary ventilation mode (Fresh Air Blower Control Module J126 interrupts link between solar roof and Fresh Air Blower V2). --> Electrical Wiring Diagrams, Troubleshooting and Component Locations If solar operation of fresh-air blower is not desired, function can be deactivated at Climatronic Control Module J255 or in MMI (Multi Media Interface). Owners Manual Measured value block of Climatronic Control Module J255 (display group 044), indicates operating time of Fresh Air Blower V2 in solar mode in hours. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. Temperature where "solar roof" function is switched on or off can be entered via "adaptation" function --> Climatronic Control Module J255 , adaptation Design of Fresh Air Blower Control Module J126 is such that in solar mode, Fresh Air Blower V2 is only actuated if there is sufficient energy for solar operation (minimum voltage with Fresh Air Blower V2 actuated must be greater than 2 V at present). The energy supplied by the Solar Cells C20 is conveyed directly to the Fresh Air Blower V2 via Fresh Air Blower Control Module J126. The fresh-air blower converts the generated electrical energy into blower output. On vehicles without sunroof, all A/C system actuators remain standing in their current positions at the moment when the ignition is switched off. However, in order to ventilate the vehicle interior when the system is in solar ventilation mode, the fresh air/recirculated air flap must be in the "fresh air" position. Therefore on vehicles with solar roof, Climatronic Control Module J255 is informed via coding that the vehicle is equipped with solar cells. Climatronic Control Module J255 then moves the flaps in the A/C unit to "fresh air mode" position after ignition is switched off. With ignition switched off (no signal detected from Climatronic Control Module J255), the Fresh Air Blower Control Module J126 checks the voltage at the input of the solar cells in regular intervals and converts the voltage generated by the solar cells in such a way that the fresh-air blower runs at the highest possible speed when there is sufficient solar energy. The electrical energy transferred from the solar roof at a solar radiation level of 500 W/m 2 is approx. 12 W

500 W/m 2 (solar irradiation) x 0.21 m 2 (solar cell surface area on sunroof) x 0.13 (efficiency of Solar Cells C20) x 0.9 (efficiency of Fresh Air Blower Control Module J126).

1. Terminals - A - and - B - (on the sunroof and sunroof frame) are used to transfer the electrical energy generated, and must always be clean and free of conventional lubricating grease.
2. If necessary, terminals - A - and - B - can be lightly coated with contact grease (electrically conductive protective lubricant, available from suppliers of electronic equipment).

Components for control and regulation of air conditioner located in passenger compartment

Note. If there is a malfunction in the system, first check DTC memory of Climatronic Control Module J255 (and of Rear A/C Control Head (Climatronic) E265). Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. If no fault is displayed, read out measured value block of Climatronic Control Module J255 (and Rear A/C Control Head (Climatronic) E265) (pay particular attention to measured value blocks "001" , "002" , "034 " "030" and "050" of Climatronic Control Module J255 and actuate any problematic component via "output Diagnostic Test Mode (DTM)" function. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. Repair work on refrigerant circuit --> A/C Refrigerant Circuit, servicing . Perform the following work on completion of repair operations

1. Check DTC memory of Climatronic Control Module J255 (and of Rear A/C Control Head (Climatronic) E265) and erase DTCs displayed if necessary.
2. Check coding of A/C control head Climatronic Control Module J255
3. If necessary, check adaptation of Climatronic Control Module J255 and Rear A/C Control Head (Climatronic) E265 (not installed on all vehicles).
4. Perform air conditioner basic setting. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

1. Electrical checking of the various control motors, potentiometers and senders is described in the guided fault-finding. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Scheme 66

1 - Diagnostic socket

1. Perform On Board Diagnostic (OBD) on A/C system Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

2 - Instrument cluster

1. With Outside Air Temperature Display G106
2. Ambient temperature sent by Climatronic Control Module J255 is displayed
3. Check temperature sensor measured values if temperature display is malfunctioning. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
4. Measured value of Outside Air Temperature Sensor G17 is evaluated by Instrument Cluster Control Module and transmitted via CAN-Bus Comfort to Climatronic Control Module J255. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

3 - Instrument panel vent with Left Center Air Outlet Sensor G347

1. Potentiometer is installed in instrument panel vent.
2. Removing and installing instrument panel vent --> «70 - INTERIOR TRIM»(ref-289222-S30170627502008062700000)

4 - Left Center Vent Motor V110

1. With Left Center Vent Motor Position Sensor G136
2. Removing and installing --> «Left Center Vent Motor V110 , removing and installing»(ref-289225-S06618623582008062700000)

5 - Humidity Sensor G355

1. Function of Humidity Sensor G355 is described in relevant self-study program for this vehicle Self Study Program
2. Humidity Sensor G355 is installed in area of interior mirror at windshield and connected to Roof Electronics Control Module J528. --> «64 - GLASS, WINDOWS»(ref-289221-S30390656582008062700000)
3. Removing and installing --> «96 - LIGHTS, SWITCHES - INTERIOR, ANTI-THEFT»(ref-289227-S40096413892008062700000)
4. Humidity Sensor G355 determines temperature of windshield by means of infrared signal and humidity level by built-in condenser. Climatronic Control Module J255 uses measuring values to calculate temperature or humidity level at which windows start to fog up and alters setting (vent temperature of air, vent direction of air and air flow rate). Sensor measured values are displayed in measured value block of Climatronic Control Module J255. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

6 - Center Outlet Temperature Sensor G191

1. Removing and installing --> «Center Outlet Temperature Sensor G191 , removing and installing»(ref-289225-S24524932702008062700000)

7 - Multi Media Interface (MMI)

1. Functions selected (and various additional A/C system functions) on Climatronic Control Module J255 are indicated via MMI display.
2. Various additional A/C system functions can be called up and their settings modified via "Set-up" button on Climatronic Control Module J255 Owners Manual.
3. Depending on coding and adaptation of front Climatronic Control Module J255 , respective setting does not always appear on Multi Media Interface (MMI) display (on vehicles as of model year 2007) when turning rotary temperature control (with USA coding, indication appears e.g. only when rotary temperature control has been briefly pressed beforehand).

8 - Sunlight Photo Sensor G107

1. Removing and installing --> «Sunlight Photo Sensor G107 , removing and installing»(ref-289225-S40179134262008062700000)

9 - Right Center Vent Motor V111

1. With Right Center Vent Motor Position Sensor G137
2. Removing and installing --> «Right Center Vent Motor V111 , removing and installing»(ref-289225-S14882750802008062700000)

10 - Instrument panel vent with Right Center Air Outlet Sensor G348

1. Potentiometer is installed in instrument panel vent
2. Removing and installing instrument panel vents --> «70 - INTERIOR TRIM»(ref-289222-S30170627502008062700000)

11 - Air conditioner unit

1. Different versions on vehicles with and without Rear A/C Control Head (Climatronic) E265 --> «Air distribution system, block diagram»(ref-289225-S08694407202008062700000) and --> «Heating and A/C unit, disassembling and assembling»(ref-289225-S34809723892008062700000)
2. Air guide in air conditioner and in vehicle --> «Air distribution system, block diagram»(ref-289225-S08694407202008062700000)
3. Components of A/C unit in passenger compartment --> «Air conditioner unit components located in passenger compartment»(ref-289225-S05879408382008062700000)
4. Removing and installing --> «Heating and A/C unit, removing and installing»(ref-289225-S13172352362008062700000)

12 - Evaporator drain hose

1. Right (front passenger side)
2. Checking, removing and installing --> «Evaporator drain hose, removing, checking and installing»(ref-289225-S28528887042008062700000)

13 - Climatronic Control Module J255

1. Different versions (with or without seat heater, seat heater with or without seat ventilation)
2. Removing and installing --> «Climatronic Control Module J255 , removing and installing»(ref-289225-S36563865272008062700000)
3. Instrument Panel Interior Temperature Sensor G56 is integrated in Climatronic Control Module J255.
4. Interior Temperature Sensor Fan V42 is installed in Climatronic Control Module J255 , however it cannot be replaced individually --> «Interior Temperature Sensor Fan V42 , removing and installing»(ref-289225-S13696985862008062700000) .

1. Also heed additional notes on A/C control head --> «Climatronic Control Module J255 , removing and installing»(ref-289225-S36563865272008062700000)
2. On Board Diagnostic (OBD) of Climatronic Control Module J255 is to be performed as described in Guided Fault Finding Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
3. Buttons and display fields are illuminated by Light Emitting Diodes (LED), cannot be replaced
4. Two rotary buttons are attached, they can be removed and replaced individually

1. Climatronic Control Module J255 with software number "026" installed in model year 2003: With these front A/C control heads Climatronic Control Module J255 , settings assigned to a specific person by fingerprint are lost when starting the vehicle via "One-touch memory". Service installation of front A/C control heads Climatronic Control Module J255 with this software number is therefore not permitted on vehicles with "one-touch memory".

14 - Interior Temperature Sensor Fan V42

1. Installed in Climatronic Control Module J255
2. Removing and installing blower --> «Interior Temperature Sensor Fan V42 , removing and installing»(ref-289225-S13696985862008062700000)

15 - Instrument Panel Interior Temperature Sensor (006785-3211) G56

1. Installed in Climatronic Control Module J255 , cannot be replaced individually

16 - Right Rear Footwell Heater Z43

1. Removing and installing --> «Left Rear Footwell Heater Z42/Right Rear Footwell Heater Z43 , removing and installing»(ref-289225-S03272162302008062700000)
2. Only installed on vehicles with Rear A/C Control Head (Climatronic) E265 (optional equipment)

17 - Right Front Seat Temperature Sensor G345 and Right Front Heated Seat Z46

1. Seat heater and seat ventilation are not installed in all vehicles (optional equipment)
2. Activation of seat heater and seat ventilation are displayed in measured value block of Climatronic Control Module J255 , checking Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
3. Servicing seat heater and seat ventilation --> «74 - SEATS - UPHOLSTERY, COVERS»(ref-289222-S14110830172008062700000)

18 - Right Rear Warm/Cold Flap Air Outlet Motor V221

1. With Right Center Vent Motor Position Sensor G352
2. Removing and installing --> «Right Rear Warm/Cold Flap Air Outlet Motor V221 , removing and installing»(ref-289225-S12889842302008062700000)
3. Only installed on vehicles with Rear A/C Control Head (Climatronic) E265 (optional equipment)
4. On vehicles without Rear A/C Control Head (Climatronic) E265 (without Right Rear Warm/Cold Flap Air Outlet Motor V221), flaps for right side are moved via a joint shaft by Left Rear Warm/Cold Flap Air Outlet Motor V220 --> «Air distribution system, block diagram»(ref-289225-S08694407202008062700000) .

1. Connecting element between flap and motor is "blue" colored

19 - Rear A/C Control Head (Climatronic) E265

1. Not installed in all vehicles (optional equipment)
2. Different versions (with or without rear seat heater, rear seat heater with or without seat ventilation)
3. Removing and installing --> «Rear A/C Control Head (Climatronic) E265 , removing and installing»(ref-289225-S33910017952008062700000) and --> «Climatronic Control Module J255 , removing and installing»(ref-289225-S36563865272008062700000)
4. Also heed additional notes on rear A/C control head --> «Climatronic Control Module J255 , removing and installing»(ref-289225-S36563865272008062700000) and --> «Rear A/C Control Head (Climatronic) E265 , removing and installing»(ref-289225-S33910017952008062700000)

1. On Board Diagnostic (OBD) of Rear A/C Control Head (Climatronic) E265 is to be performed as described in Guided Fault Finding Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
2. Adaptation of Rear A/C Control Head (Climatronic) E265 is checked as described in Guided Fault Finding and altered if necessary Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
3. Buttons and display fields are illuminated by Light Emitting Diodes (LED), cannot be replaced
4. Two rotary buttons are attached, they can be removed and replaced individually

20 - Actuation of rear seat heater and seat ventilation

1. Rear seat heater and seat ventilation are not installed in all vehicles (optional equipment)
2. On vehicles without Rear A/C Control Head (Climatronic) E265 , rear seat heater is actuated via 2 rotary switches --> Electrical Wiring Diagrams, Troubleshooting and Component Locations
3. Measuring values of Left Rear Heated Seat Temperature Sensor G94 and Right Rear Heated Seat Temperature Sensor G95 are displayed in measured value block of Rear A/C Control Head (Climatronic) E265 Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
4. Actuation of rear seat heater (Left Rear Seat Heating Element Z10 to Right Rear Backrest Heating Element Z13) and seat ventilation is displayed in measured value block of Rear A/C Control Head (Climatronic) E265 , checking Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

1. Servicing rear seat heater and rear seat ventilation --> «74 - SEATS - UPHOLSTERY, COVERS»(ref-289222-S14110830172008062700000)

21 - Left Rear Footwell Heater Z42

1. Removing and installing --> «Left Rear Footwell Heater Z42/Right Rear Footwell Heater Z43 , removing and installing»(ref-289225-S03272162302008062700000)
2. Only installed on vehicles with Rear A/C Control Head (Climatronic) E265 (optional equipment)

22 - Left Front Seat Temperature Sensor G344 and Left Front Heated Seat Z45

1. Seat heater and seat ventilation not installed in all vehicles (optional equipment)
2. Activation of seat heater and seat ventilation are displayed in measured value block of Climatronic Control Module J255 , checking Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
3. Servicing seat heater and seat ventilation --> «74 - SEATS - UPHOLSTERY, COVERS»(ref-289222-S14110830172008062700000)

23 - Left Rear Warm/Cold Flap Air Outlet Motor V220

1. With Right Center Vent Motor Position Sensor G351
2. Removing and installing --> «Left Rear Warm/Cold Flap Air Outlet Motor V220 , removing and installing»(ref-289225-S41569496482008062700000)
3. Only actuates flaps for left side on vehicles with Rear A/C Control Head (Climatronic) E265 (optional equipment)
4. Connecting element between flap and motor is "red" colored

1. On vehicles without Rear A/C Control Head (Climatronic) E265 (without Right Rear Warm/Cold Flap Air Outlet Motor V221), flaps for right side are also moved via a joint shaft by Left Rear Warm/Cold Flap Air Outlet Motor V220 --> «Air distribution system, block diagram»(ref-289225-S08694407202008062700000) .

24 - Right Rear Center Console Temperature Sensor G312

1. Only installed on vehicles with Rear A/C Control Head (Climatronic) E265 (optional equipment)
2. On vehicles without Right Rear Center Console Temperature Sensor G312 , mounting hole is sealed with plug
3. Removing and installing --> «Left Rear Center Console Temperature Sensor G311 and Right Rear Center Console Temperature Sensor G312 removing and installing»(ref-289225-S30233265942008062700000)

25 - Left Rear Center Console Temperature Sensor G311

1. Only installed on vehicles with Rear A/C Control Head (Climatronic) E265 (optional equipment)
2. On vehicles without Left Rear Center Console Temperature Sensor G311 , mounting hole is sealed with plug
3. Removing and installing --> «Left Rear Center Console Temperature Sensor G311 and Right Rear Center Console Temperature Sensor G312 removing and installing»(ref-289225-S30233265942008062700000)

26 - Evaporator drain hose

1. Left (driver side)
2. Checking, removing and installing --> «Evaporator drain hose, removing, checking and installing»(ref-289225-S28528887042008062700000)

27 - Accelerator mechanism

1. Kick down switch-off of compressor by Climatronic Control Module J255 (via A/C Compressor Regulator Valve N280) is performed by request from Engine Control Module -ECM- (data is exchanged over the CAN-Bus system). Current status can be read out in measured value block of Climatronic Control Module J255 (display group "002"). Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Left Center Vent Motor V110 , removing and installing

Note. Mark motor/flap connecting elements when removing (danger of swapping with connecting elements of the other actuator motors). In the event of fault "Upper or lower limit value exceeded" , check connecting element of engine/flap, it must be attached to engine accurate to side and there must not be any clearance between actuator mount and connecting element. If a "clicking noise" is determined from area of actuator, check connection of lug of connecting element at actuator to vent adjustment levers. Such noise may be produced if lug does not engage properly between the two adjustment levers.

1. Remove storage compartment beneath left instrument panel --> «70 - INTERIOR TRIM»(ref-289222-S30170627502008062700000) .
2. Switch ignition on.
3. Set air distribution at Climatronic Control Module J255 to instrument panel vents and open two instrument panel vents - A - and - B -.

Scheme 67

1. Pull left center instrument panel - A - out of instrument panel --> «70 - INTERIOR TRIM»(ref-289222-S30170627502008062700000)
2. Close center instrument panel vents on left - A - and right - B - using corresponding knurled wheels.
3. Set air distribution on Climatronic Control Module J255 to footwell.

Scheme 68

1. Wait until lug - D - is positioned such that bolt - B - can be removed.
2. Switch off ignition.
3. Disconnect wire connection to left center instrument panel vent and remove entire vent --> «70 - INTERIOR TRIM»(ref-289222-S30170627502008062700000)
4. Remove bolts - A - and - B -.

Note. If actuator cannot be moved and lug - D - is positioned such that bolt - B - cannot be removed: Disconnect plug-in coupling attached to air conditioner in wiring to actuator. Connect terminal 5 and 6 of actuator to 12 V battery by means of 5 A fuse using e.g. adapter cable --> Preparing adapter cables for control motor actuation or auxiliary wire from connector test set V.A.G 1594/C. Rotate actuator until bolt - B - can be removed, turning direction can be reversed by swapping B+ and Ground.

1. Disconnect electrical connection wire to actuator - C - at attachment points.
2. Tilt actuator - C - with bracket in direction of arrow out of mount in instrument panel.

Scheme 69

1. Remove connector - A -.
2. Remove bolts - B -.
3. Remove bracket - C -.
4. Pry off connecting element - D - using 2 screwdrivers.

Scheme 70

1. Attach connecting element - A - onto actuator shaft.

Note. Check connecting element for proper seating, it must engage in motor shaft and there must not be any clearance between actuator shaft and connecting element. Connecting element must be attached only in the position in which it engages without using force. If pretension is necessary to insert connecting element, check mount of motor, it can be turned by 180°. Actuator shaft - B - does not have a stop, it rotates continuously when voltage is applied between terminals 5 and 6. Therefore, when actuator is removed, voltage is only to be applied if connecting element -A- is attached. If connecting element - A - cannot be inserted into actuator without pretension, actuator may be incorrectly positioned. If shaft is so awkwardly positioned that connecting piece cannot be attached, connect terminals 5 and 6 of actuator via a 5A fuse to a 12 V battery e.g. using adapter lead --> Preparing adapter cables for control motor actuation or an adapter lead from connector test kit V.A.G 1594/C. Rotate actuator for only as long until connecting element can be attached without pretension, the turning direction can be reversed by swapping B+ and Ground.

1. Install positioning motor.
2. Slightly lubricate guide in instrument panel vent using grease (e.g. G 000 150)
3. After installing actuator, perform "basic setting" function in On Board Diagnostic of air conditioner; if connecting element has not been installed properly, fault will be displayed. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
4. Switch ignition on.

1. Set air distribution on Climatronic Control Module J255 to instrument panel vents.

1. Wait until lug - D - has reached position shown.
2. Install instrument panel vent, make sure lug - D - is inserted between two levers - E - of shut-off flaps. --> «70 - INTERIOR TRIM»(ref-289222-S30170627502008062700000)
3. Install the removed components again in reverse order.
4. Check DTC memory of Climatronic Control Module J255 and erase DTCs displayed if necessary. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

1. Perform basic setting and output Diagnostic Test Mode (DTM) on the A/C system. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Right Center Vent Motor V111 , removing and installing

Note. Mark motor/flap connecting elements when removing (danger of swapping with connecting elements of the other actuator motors). In the event of fault "Upper or lower limit value exceeded" , check connecting element of engine/flap, it must be attached to engine accurate to side and there must not be any clearance between actuator mount and connecting element. If a "clicking noise" is determined from area of actuator, check connection of lug of connecting element at actuator to vent adjustment levers. Such noise may be produced if lug does not engage properly between the two adjustment levers.

1. Remove glove compartment --> «68 - INTERIOR EQUIPMENT»(ref-289222-S37995085722008062700000) .
2. Switch ignition on.
3. Set air distribution at Climatronic Control Module J255 to instrument panel vents and open two instrument panel vents - A - and - B -.

1. Pull right center instrument panel - B - out of instrument panel --> «70 - INTERIOR TRIM»(ref-289222-S30170627502008062700000)
2. Remove and install right instrument panel vent and actuator in same manner as described for left instrument panel vent --> «Left Center Vent Motor V110 , removing and installing»(ref-289225-S06618623582008062700000) .

Center Outlet Temperature Sensor G191 , removing and installing

1. Switch off ignition.
2. Remove center console. --> «70 - INTERIOR TRIM»(ref-289222-S30170627502008062700000)
3. Remove storage compartment beneath left instrument panel and steering column support to center tunnel --> «68 - INTERIOR EQUIPMENT»(ref-289222-S37995085722008062700000)

Scheme 71

1. Disconnect connector - A -.
2. Turn vent temperature sensor - B - approx. 90° in direction of arrow.
3. Remove vent temperature sensor out of air guide.

Note. Depending on design of air duct, sensor may also be installed at different location in air duct.

Sunlight Photo Sensor G107 , removing and installing

1. Switch off ignition.

Scheme 72

1. Carefully pry cover - A - out of windshield defroster vent.
2. Carefully pry sunlight photo sensor - B - out of front windshield defroster vent.
3. Disconnect connector - C -.

Interior Temperature Sensor Fan V42 , removing and installing

1. Remove Climatronic Control Module J255 --> «Climatronic Control Module J255 , removing and installing»(ref-289225-S36563865272008062700000) .

Scheme 73

1. Remove bolts - A -.
2. Pull Interior Temperature Sensor Fan V42 - B - out of Climatronic Control Module J255.

Note. When installing Interior Temperature Sensor Fan V42 , do not press on motor - C - , hold fan firmly at housing instead.

Climatronic Control Module J255 , removing and installing

1. Removing and installing Climatronic Control Module J255

Note. Front A/C control heads can no longer be cross-exchanged in the familiar way; as soon as a the Climatronic control module J255 has been adapted in a vehicle, component protection takes effect. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. If a Climatronic Control Module J255 with active component protection (anti-theft system) is installed in a different vehicle, only the functions necessary for vehicle safety can be selected, comfort functions can no longer be selected. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. Component protection can only be canceled by entering specific vehicle data Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. Climatronic Control Module J255 may also be designated "Climatronic Control Module -J255-" in wiring diagrams. Follow allocation exactly when replacing Climatronic Control Module J255 Different versions of Climatronic Control Module J255 on vehicles with or without seat heater, seat heating with or without seat ventilation. Part number index must therefore be heeded. After installing Climatronic Control Module J255 , perform basic setting for A/C system according to specifications. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. If a new one was installed and basic setting was not performed, controls of Climatronic Control Module J255 are restricted and this is displayed as a malfunction in DTC memory. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. Climatronic Control Module J255 can be set into operation for a certain period of time (up to approx. 30 minutes) after switching off ignition by operating the "On/Off" button (the operating time depends on the battery charge state, it is approx. 10 minutes). Owners Manual Display fields and control buttons on Climatronic Control Module J255 are illuminated by light emitting diodes (LEDs, cannot be replaced). If Instrument Panel Interior Temperature Sensor G56 sends incorrect measurements, check intake grille on panel of Climatronic Control Module J255 (must not be sealed) and function of Interior Temperature Sensor Fan V42.. The selected functions are displayed by illuminated LEDs in the various buttons of Climatronic Control Module J255. Always perform the following work after replacing Climatronic Control Module J255 : - Check coding. - Perform basic setting. - Check adaptation. - Check DTC memory. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. Display unit (°C or °F) of temperature display of Climatronic Control Module J255 , is specified by MMI (Multi Media Interface) via Comfort CAN-Bus system and determined by setting entered there. In model year 2003, Climatronic Control Module J255 was installed with software number "026". With these Climatronic Control Module J255 , settings assigned to a specific person via fingerprint may be lost when starting the vehicle via "one-touch memory". Service installation of Climatronic Control Module J255 with this software number is therefore not permitted on vehicles with "one-touch memory". Climatronic Control Module J255 is not connected to terminal "15" , therefore after voltage supply interruption (via connector - E -), it is necessary to wait at least 30 seconds to protect electronics until remaining connections are disconnected . Two rotary buttons are attached, they can be carefully removed and replaced individually

Climatronic Control Module J255 , removing

1. Check coding and adaptation of Climatronic Control Module J255 via the "Replace control module" function of Guided Fault Finding (in the event that Climatronic Control Module J255 is to be replaced). Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
2. Switch off ignition.
3. Remove trim for front center instrument panel section and ashtray. --> «68 - INTERIOR EQUIPMENT»(ref-289222-S37995085722008062700000)

Scheme 74

1. Remove two bolts - A -.
2. Remove Climatronic Control Module J255 from center console.

Scheme 75

1. Disengage catches of connector - E - by pressing retaining tabs - G - and disconnect this connector.
2. Wait 30 seconds (to protect electronics in Climatronic Control Module J255).
3. Disengage catches of connectors - A - to - D - by pressing retaining tabs - G - and disconnect them.
4. Disengage connector - F - and disconnect it.

1. Installing

Install in reverse order of removal.

1. Check DTC memory of Climatronic Control Module J255 and erase DTCs displayed if necessary. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
2. Perform basic setting, coding, adaptation and output Diagnostic Test Mode (DTM) on A/C system. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Left Rear Footwell Heater Z42/Right Rear Footwell Heater Z43 , removing and installing

Note. Left Rear Footwell Heater Z42 and Right Rear Footwell Heater Z43 are actuated by Climatronic Control Module J255 via data wire, actuation is displayed in measured value block (display group "041" and "042"). Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. Heater element consists of control module, temperature sensor and, at present, 4 transistors with heat sinks which generate heat and supply it to the passing air flow. Heater element is installed only on vehicles with Rear A/C Control Head (Climatronic) E265 in vent - C - (optional equipment).

1. Switch off ignition.
2. Remove left or right seat --> «72 - SEAT - FRAMES»(ref-289222-S36188513802008062700000)

Scheme 76

1. Remove cover - A -.
2. Lift floor covering - B -.
3. Disconnect harness connector to heater element.
4. Remove vent - C - with heater element.

1. Installing

Install in reverse order of removal.

Left Rear Center Console Temperature Sensor G311 and Right Rear Center Console Temperature Sensor G312 removing and installing

1. Switch off ignition.
2. Remove rear center console cover. --> «68 - INTERIOR EQUIPMENT»(ref-289222-S37995085722008062700000)

Scheme 77

1. Disconnect connector from temperature sensor - A - or - B -.
2. Rotate - A - (Left Rear Center Console Temperature Sensor G311) or - B - (Right Rear Center Console Temperature Sensor G312) approx. 90° in direction of arrow.
3. Remove appropriate temperature sensor from air guide.

Note. Left Rear Center Console Temperature Sensor G311 and Right Rear Center Console Temperature Sensor G312 are installed only on vehicles with Rear A/C Control Head (Climatronic) E265 (optional equipment). On vehicles without Rear A/C Control Head (Climatronic) E265 , openings in air guide are sealed with plugs. Observe connector arrangement to Left Rear Center Console Temperature Sensor G311 and Right Rear Center Console Temperature Sensor G312 and mark them if necessary to avoid possible interchange. In cases of doubt about correct connector assignment, disconnect connector e.g. from temperature sensor and then check DTC memory of Rear A/C Control Head (Climatronic) E265. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Left Rear Warm/Cold Flap Air Outlet Motor V220 , removing and installing

Note. On vehicles with Rear A/C Control Head (Climatronic) E265 (optional equipment), this actuator operates only left flap in rear air guide. On vehicles without Rear A/C Control Head (Climatronic) E265 , this actuator operates flaps for left and right side in rear air guide (shafts of flaps are connected). Observe connector arrangement on vehicles with Rear A/C Control Head (Climatronic) E265 to the two actuators - A - (Left Rear Warm/Cold Flap Air Outlet Motor V220) with connecting element - C - ("red" color) and actuator - B - (Right Rear Warm/Cold Flap Air Outlet Motor V221) with connecting element - D - ("blue" color) and mark them if necessary to avoid possible interchange. In cases of doubt about correct connector assignment, disconnect connector e.g. from actuator and then check DTC memory of Climatronic Control Module J255. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

1. Switch off ignition.
2. Remove center console. --> «70 - INTERIOR TRIM»(ref-289222-S30170627502008062700000)
3. Remove air duct from center console --> «68 - INTERIOR EQUIPMENT»(ref-289222-S37995085722008062700000)

Scheme 78

1. Remove bolts - A -.
2. Remove actuator - B -.
3. Pry off connecting element - D - using 2 screwdrivers - C -.

1. Attach connecting element - A - onto actuator shaft.

Perform remaining installation operations in reverse order of removal.

Note. Check connecting element for proper seating, it must engage in motor mount and there must not be any clearance between actuator mount and connecting element. Observe correct assignment of connecting element (color "red" for left actuator and color "blue" for right actuator). Connecting piece must be attached only in the position in which it engages without using force. If pretension is necessary to insert connecting piece, check mount of motor, it may be turned by 180°. Actuator shaft - B - does not have a stop, it rotates continuously when voltage is applied between terminals 5 and 6. Therefore, when actuator is removed, voltage is only to be applied if connecting element -A- is attached. If connecting piece - A - cannot be inserted into actuator without pretension, actuator may be incorrectly positioned. If shaft is so awkwardly positioned that connecting piece cannot be attached, connect terminals 5 and 6 of actuator via a 5A fuse to a 12 V battery e.g. using adapter lead --> Preparing adapter cables for control motor actuation or an adapter lead from connector test kit V.A.G 1594/C. In the event of fault "Upper or lower limit value exceeded" , check connecting element of engine/flap, it must be attached to engine accurate to side and there must not be any clearance between actuator mount and connecting element. Rotate actuator until intermediate piece can be attached without pretension, turning direction can be reversed by swapping B+ and Ground.

1. Install the removed components again in reverse order.
2. Check DTC memory of Climatronic Control Module J255 and erase DTCs displayed if necessary. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
3. Perform basic setting and output Diagnostic Test Mode (DTM) on the A/C system. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Right Rear Warm/Cold Flap Air Outlet Motor V221 , removing and installing

Note. On vehicles with Rear A/C Control Head (Climatronic) E265 , Left Rear Warm/Cold Flap Air Outlet Motor V220 actuates flaps for left and right side in rear air guide (shafts of flaps are connected, no Right Rear Warm/Cold Flap Air Outlet Motor V221 is installed. Observe connector arrangement on vehicles with Rear A/C Control Head (Climatronic) E265 to the two actuators - A - (Left Rear Warm/Cold Flap Air Outlet Motor V220) with connecting element - C - ("red" color) and actuator - B - (Right Rear Warm/Cold Flap Air Outlet Motor V221) with connecting element - D - ("blue" color) and mark them if necessary to avoid possible interchange. In cases of doubt about correct connector assignment, disconnect connector e.g. from actuator and then check DTC memory of Climatronic Control Module J255. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. In the event of fault "Upper or lower limit value exceeded" , check connecting element of engine/flap, it must be attached to engine accurate to side and there must not be any clearance between actuator mount and connecting element.

1. Switch off ignition.

Scheme 79

1. Remove and install Right Rear Warm/Cold Flap Air Outlet Motor V221 - B - in the same manner as described for Left Rear Warm/Cold Flap Air Outlet Motor V220 --> «Left Rear Warm/Cold Flap Air Outlet Motor V220 , removing and installing»(ref-289225-S41569496482008062700000) .

Rear A/C Control Head (Climatronic) E265 , removing and installing

1. Rear A/C Control Head (Climatronic) E265 , removing and installing.

Note. At present, Rear A/C Control Head (Climatronic) E265 can still be exchanged in the familiar manner; component protection is currently not active for this component (introduction of component protection not yet finalized). Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. Front A/C control heads can no longer be cross-exchanged in the familiar way; as soon as a , the Climatronic control module J255 has been adapted in a vehicle, the component protection takes effect. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. If a Climatronic Control Module J255 with active component protection (anti-theft system) is installed in a different vehicle, only the functions necessary for vehicle safety can be selected, comfort functions can no longer be selected; this also applies to functions of Rear A/C Control Head (Climatronic) E265. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. Follow assignment exactly when replacing Rear A/C Control Head (Climatronic) E265 Different versions of Rear A/C Control Head (Climatronic) E265 on vehicles with or without rear seat heating, rear seat heating with or without seat ventilation. Part number index must therefore be heeded. After installing Rear A/C Control Head (Climatronic) E265 , perform basic setting for A/C system according to specifications. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. The selected functions are displayed by illuminated LEDs in the various buttons of Rear A/C Control Head (Climatronic) E265. If information "child safety system for rear doors activated" is received via data bus system, Rear A/C Control Head (Climatronic) E265 is switched off, and, depending on version, display of Rear A/C Control Head (Climatronic) E265 shows e.g. "Passive" (air conditioner can then only be operated by Climatronic Control Module J255). Owners Manual Display unit of temperature display of Rear A/C Control Head (Climatronic) E265 in °C or °F is transmitted by MMI (Multi Media Interface) via Comfort CAN-Bus system and determined by setting entered there. Display fields and control buttons on Rear A/C Control Head (Climatronic) E265 are illuminated by light emitting diodes (LEDs, cannot be replaced). Always perform the following work after replacing Rear A/C Control Head (Climatronic) E265 : - Perform basic setting. - Check adaptation. - Check DTC memory. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. Two rotary buttons are attached, they can be carefully removed and replaced individually

Note. At present, Rear A/C Control Head (Climatronic) E265 can still be exchanged in the familiar manner, no component protection is active (introduction of component protection not yet finalized) Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Removing

1. Check adaptation of Rear A/C Control Head (Climatronic) E265 via "Replace control module" function of Guided Fault Finding (in the event Rear A/C Control Head (Climatronic) E265 is to be replaced). Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
2. Switch off ignition.

Scheme 80

1. Remove vents from rear center console - A -. --> «68 - INTERIOR EQUIPMENT»(ref-289222-S37995085722008062700000)

Scheme 81

1. Disengage catch of connector - A - by lifting clip - B - and disconnect connector.
2. Disengage connector - C - and disconnect it.
3. Pull Rear A/C Control Head (Climatronic) E265 - B - out of center console vent - A - (clipped in).

Installing

Install in reverse order of removal.

1. Check DTC memory of Rear A/C Control Head (Climatronic) E265 and of Climatronic Control Module J255 and erase DTCs displayed if necessary. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
2. Perform basic setting, adaptation and output Diagnostic Test Mode (DTM) on A/C system. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Removing, checking

1. Remove storage compartment on drivers side, glove compartment and center console. --> «68 - INTERIOR EQUIPMENT»(ref-289222-S37995085722008062700000)

Scheme 82

1. Carefully fold back floor mat far enough that evaporator drain - A - is visible.
2. Disengage clamp - B
3. Cover area beneath evaporator drain - C - with absorbent paper (so that any water present does not flow under carpet).
4. Remove foam pipe - D -.

1. Remove evaporator drain - C -.

Scheme 83

1. Check gap between lower floor panel - F - and insulation mat - G - installed in center tunnel; there must be sufficient space for evaporator to drain out of evaporator drain -C-.

Scheme 84

1. Check evaporator water drain of A/C unit - A - for soiling (e.g. using a piece of wire).

1. Installing

Install in reverse order, paying attention to the following.

1. Insert evaporator drain into opening in lower floor plate - B - , observe locking element while doing so.
2. Insert foam pipe - D - into opening of upper floor plate - E - such that cross-section of evaporator drain is not constricted.

Air conditioner unit components located in passenger compartment

Note. Different versions of air conditioner on vehicles with and without Rear A/C Control Head (Climatronic) E265 --> Heating and A/C unit, disassembling and assembling and --> Air distribution system, block diagram Air guide in air conditioner and in vehicle --> Air distribution system, block diagram Heating and A/C unit, removing and installing --> Heating and A/C unit, removing and installing

Scheme 85

1 - Defroster Flap Motor V107

1. With Right Center Vent Motor Position Sensor G135
2. Removing and installing --> «Defroster Flap Motor V107 removing and installing»(ref-289225-S42572212272008062700000)

2 - Left Front Defrost/Upper Body Shut-off Flap Motor V200

1. With Right Center Vent Motor Position Sensor G318
2. Removing and installing --> «Left Front Defrost/Upper Body Shut-off Flap Motor V200 removing and installing»(ref-289225-S40486847262008062700000)

3 - Center Vent Adjustment Motor V102

1. With Right Center Vent Motor Position Sensor G138
2. This actuator operates cold-air flap (flap in air duct which bypasses heater core) --> «Air distribution system, block diagram»(ref-289225-S08694407202008062700000)
3. Removing and installing --> «Center Vent Adjustment Motor V102 , removing and installing»(ref-289225-S21014432372008062700000)

4 - Left Rear Air Outlet Motor V218

1. With Right Center Vent Motor Position Sensor G349
2. Installed only on vehicles with Rear A/C Control Head (Climatronic) E265.
3. Removing and installing --> «Left Rear Air Outlet Motor V218 and Right Rear Air Outlet Motor V219 , removing and installing»(ref-289225-S31122125862008062700000)

5 - Left Footwell Flap Motor V108

1. With Right Center Vent Motor Position Sensor G139
2. Removing and installing --> «Left Footwell Flap Motor V108 , removing and installing»(ref-289225-S31021624902008062700000)

6 - Flange for left evaporator drain

7 - Left Vent Temperature Sensor G150

1. Removing and installing --> «Left Vent Temperature Sensor G150 , removing and installing»(ref-289225-S27189746682008062700000) .

8 - Heater core for heater unit

1. Left
2. Removing and installing --> «Left (drivers side) heater core, removing and installing»(ref-289225-S42140079472008062700000)

9 - Evaporator Vent Temperature Sensor G263

1. Removing and installing --> «Evaporator Vent Temperature Sensor G263 , removing and installing»(ref-289225-S39880614912008062700000)

10 - Heater core for heater unit

1. Right
2. Removing and installing --> «Right (front passengers side) heater core, removing and installing»(ref-289225-S28144043302008062700000)

11 - Right Front Defrost/Upper Body Shut-off Flap Motor V199

1. With Right Center Vent Motor Position Sensor G317
2. Removing and installing --> «Right Front Defrost/Upper Body Shut-off Flap Motor V199 removing and installing»(ref-289225-S11364670872008062700000)

12 - Temperature Regulator Flap Motor V68

1. With Right Center Vent Motor Position Sensor G92
2. This actuator operates warm-air flap (flap in air duct starting in mixing chamber downstream heater core) --> «Air distribution system, block diagram»(ref-289225-S08694407202008062700000)
3. Removing and installing --> «Temperature Regulator Flap Motor V68 , removing and installing»(ref-289225-S41322577942008062700000)

13 - Right Rear Air Outlet Motor V219

1. With Right Center Vent Motor Position Sensor G350
2. Installed only on vehicles with Rear A/C Control Head (Climatronic) E265.
3. Removing and installing --> «Left Rear Air Outlet Motor V218 and Right Rear Air Outlet Motor V219 , removing and installing»(ref-289225-S31122125862008062700000)

14 - Right Vent Temperature Sensor G151

1. Removing and installing --> «Right Vent Temperature Sensor G151 , removing and installing»(ref-289225-S01873010522008062700000)

15 - Right Footwell Flap Motor V109

1. With Right Center Vent Motor Position Sensor G140
2. Removing and installing --> «Right Footwell Flap Motor V109 , removing and installing»(ref-289225-S27518629242008062700000)

16 - Flange for right evaporator drain

Defroster Flap Motor V107 removing and installing

Note. Mark motor/flap connecting elements when removing (danger of swapping with connecting elements of the other actuator motors). In the event of fault "Upper or lower limit value exceeded" , check connecting element of engine/flap, it must be attached to engine accurate to side and there must not be any clearance between actuator mount and connecting element.

1. Remove dash panel complete with dash panel cross member. --> «70 - INTERIOR TRIM»(ref-289222-S30170627502008062700000)
2. Remove left footwell vent (drivers side).

Scheme 86

1. Remove bolts - A - and remove air guide - B -.
2. Mark connector - C - to control motor (danger of interchange with other connectors of same construction).
3. Disconnect connector - C - from Left Front Defrost/Upper Body Shut-Off Flap Motor V200.

Scheme 87

1. Carefully pry off connecting element - C - from actuator using 2 screwdrivers.

Note. Connecting element - C - and linkage - D - with lever remains at air conditioner.

1. Remove bolts - A -.
2. Mark connector - B - to actuator (danger of interchange with other connectors of same construction).
3. Disconnect connector - B - from actuator.
4. Remove control motor.

Install in reverse order, paying attention to the following.

1. Attach connecting element - A - onto actuator shaft.

Note. Check connecting element for proper seating, it must engage in motor shaft and there must not be any clearance between actuator shaft and connecting element. Connecting element must be attached only in the position in which it engages without using force. If pretension is necessary to insert connecting element, check mount of motor, it can be turned by 180°. Actuator shaft - B - does not have a stop, it rotates continuously when voltage is applied between terminals 5 and 6. Therefore, when actuator is removed, voltage is only to be applied if connecting element - A - is attached. If connecting piece - A - cannot be inserted into actuator without pretension, actuator may be incorrectly positioned. If shaft is so awkwardly positioned that connecting piece cannot be attached, connect terminals 5 and 6 of actuator via a 5A fuse to a 12 V battery e.g. using adapter lead --> Preparing adapter cables for control motor actuation or an adapter lead from connector test kit V.A.G 1594/C. Rotate actuator for only as long until connecting element can be attached without pretension, the turning direction can be reversed by swapping B+ and Ground.

1. Install the removed components again in reverse order.
2. Check DTC memory of Climatronic Control Module J255 and erase DTCs displayed if necessary. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
3. Perform basic setting and output Diagnostic Test Mode (DTM) on the A/C system. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

1. Switch off ignition.
2. Remove center console. --> «68 - INTERIOR EQUIPMENT»(ref-289222-S37995085722008062700000)
3. Remove storage compartment beneath left instrument panel and steering column support to center tunnel --> «68 - INTERIOR EQUIPMENT»(ref-289222-S37995085722008062700000)

Scheme 88

1. Carefully pry off connecting element - C - from actuator, e.g. using 2 screwdrivers.
2. Mark connector - B - to actuator (danger of interchange with other connectors of same construction).
3. Disconnect connector - B - from actuator.
4. Remove bolts - A -.

1. Remove control motor.

Install in reverse order, paying attention to the following.

1. Lightly lubricate guide of lever - C - or lug at flap lever with grease (e.g. G 000 150)

1. Attach connecting element - A - onto actuator shaft.

Note. Check connecting element for proper seating, it must engage in motor shaft and there must not be any clearance between actuator shaft and connecting element. Connecting element must be attached only in the position in which it engages without using force. If pretension is necessary to insert connecting element, check mount of motor, it can be turned by 180°. Actuator shaft - B - does not have a stop, it rotates continuously when voltage is applied between terminals 5 and 6. Therefore, when actuator is removed, voltage is only to be applied if connecting element - A - is attached. If connecting piece - A - cannot be inserted into actuator without pretension, actuator may be incorrectly positioned. If shaft is so awkwardly positioned that connecting piece cannot be attached, connect terminals 5 and 6 of actuator via a 5A fuse to a 12 V battery e.g. using adapter lead --> Preparing adapter cables for control motor actuation or an adapter lead from connector test kit V.A.G 1594/A. Rotate actuator for only as long until connecting element can be attached without pretension, the turning direction can be reversed by swapping B+ and Ground.

1. Install the removed components again in reverse order.
2. Check DTC memory of Climatronic Control Module J255 and erase DTCs displayed if necessary. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
3. Perform basic setting and output Diagnostic Test Mode (DTM) on the A/C system. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Left Front Defrost/Upper Body Shut-off Flap Motor V200 removing and installing

Note. Mark motor/flap connecting elements when removing (danger of swapping with connecting elements of the other actuator motors). In the event of fault "Upper or lower limit value exceeded" , check connecting element of engine/flap, it must be attached to engine accurate to side and there must not be any clearance between actuator mount and connecting element.

1. Switch off ignition.
2. Remove center console. --> «68 - INTERIOR EQUIPMENT»(ref-289222-S37995085722008062700000)
3. Remove storage compartment beneath left instrument panel and steering column support to center tunnel --> «68 - INTERIOR EQUIPMENT»(ref-289222-S37995085722008062700000)

Scheme 89

1. Remove bolts - A -.
2. Mark connector - B - to actuator (danger of interchange with other connectors of same construction).
3. Disconnect connector - B - from actuator.
4. Remove control motor.

1. Carefully pry off cam disk - C - from actuator, e.g. using 2 screwdrivers.
2. Remove bolts - D -.

1. Attach metal bracket to actuator.

1. Attach cam disk - A - to actuator shaft.

Note. Check cam disk for proper seating, it must engage in motor shaft and there must not be any clearance between actuator shaft and cam disk. Cam disk must be attached only in the position in which it engages without using force. If pretension is necessary to insert cam disk, check mount of motor, it may be turned by 180°. Actuator shaft - B - does not have a stop, it rotates continuously when voltage is applied between terminals 5 and 6. Therefore, when actuator is removed, voltage is only to be applied if cam disk - A - is attached. If cam disk - A - cannot be inserted into actuator without pretension, actuator may be incorrectly positioned. If shaft is so awkwardly positioned that cam disk cannot be attached, connect terminals 5 and 6 of actuator via a 5A fuse to a 12 V battery e.g. using adapter lead --> Preparing adapter cables for control motor actuation or an adapter lead from connector test kit V.A.G 1594/C. Rotate actuator for only as long until connecting element can be attached without pretension, the turning direction can be reversed by swapping B+ and Ground.

Scheme 90

1. Lightly lubricate guides of cam disk - C - and lugs at flap levers - A - and - B - with grease G 000 150 .
2. Move levers - A - and - B - of flaps to position shown.
3. Insert lugs of levers as shown into guides of cam disk - C -.
4. Attach actuator to air conditioner.

1. Connect terminal 5 and 6 of actuator to 12 V battery by means of 5 A fuse using e.g. adapter cable --> «Preparing adapter cables for control motor actuation»(ref-289225-S04241360192008062700000) .
2. Turn actuator until it reaches end position, interchange B+ and Ground on actuator and let actuator move to other end position.
3. Install the removed components again in reverse order.
4. Check DTC memory of Climatronic Control Module J255 and erase DTCs displayed if necessary. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

1. Perform basic setting and output Diagnostic Test Mode (DTM) on the A/C system. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Right Front Defrost/Upper Body Shut-off Flap Motor V199 removing and installing

Note. Mark motor/flap connecting elements when removing (danger of swapping with connecting elements of the other actuator motors). In the event of fault "Upper or lower limit value exceeded" , check connecting element of engine/flap, it must be attached to engine accurate to side and there must not be any clearance between actuator mount and connecting element.

1. Switch off ignition.
2. Remove glove box. --> «68 - INTERIOR EQUIPMENT»(ref-289222-S37995085722008062700000)

Scheme 91

1. Remove bolts - A -.
2. Mark connector - B - to actuator (danger of interchange with other connectors of same construction).
3. Disconnect connector - B - from actuator.
4. Remove control motor.

1. Carefully pry off cam disk - C - from actuator, e.g. using 2 screwdrivers.
2. Remove bolts - D -.

Install in reverse order, paying attention to the following.

1. Attach metal bracket - E - to actuator.

1. Attach cam disk - A - to actuator shaft.

Note. Check cam disk for proper seating, it must engage in motor shaft and there must not be any clearance between actuator shaft and cam disk. Cam disk must be attached only in the position in which it engages without using force. If pretension is necessary to insert cam disk, check mount of motor, it may be turned by 180°. Actuator shaft - B - does not have a stop, it rotates continuously when voltage is applied between terminals 5 and 6. Therefore, when actuator is removed, voltage is only to be applied if cam disk - A - is attached. If cam disk - A - cannot be inserted into actuator without pretension, actuator may be incorrectly positioned. If shaft is so awkwardly positioned that cam disk cannot be attached, connect terminals 5 and 6 of actuator via a 5A fuse to a 12 V battery e.g. using adapter lead --> Preparing adapter cables for control motor actuation or an adapter lead from connector test kit V.A.G 1594/C. Rotate actuator for only as long until connecting element can be attached without pretension, the turning direction can be reversed by swapping B+ and Ground.

Scheme 92

1. Lightly lubricate guides of cam disk - C - and lugs at flap levers - A - and - B - with grease G 000 150 .
2. Move levers - A - and - B - of flaps to position shown.
3. Insert lugs of levers as shown into guides of cam disk - C -.
4. Attach actuator to air conditioner.

1. Connect terminal 5 and 6 of actuator to 12 V battery by means of 5 A fuse using e.g. adapter cable --> «Preparing adapter cables for control motor actuation»(ref-289225-S04241360192008062700000) .
2. Turn actuator until it reaches end position, interchange B+ and Ground on actuator and let actuator move to other end position.
3. Install the removed components again in reverse order.
4. Check DTC memory of Climatronic Control Module J255 and erase DTCs displayed if necessary. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

1. Perform basic setting and output Diagnostic Test Mode (DTM) on the A/C system. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Left Footwell Flap Motor V108 , removing and installing

Note. Mark motor/flap connecting elements when removing (danger of swapping with connecting elements of the other actuator motors). In the event of fault "Upper or lower limit value exceeded" , check connecting element of engine/flap, it must be attached to engine accurate to side and there must not be any clearance between actuator mount and connecting element.

1. Switch off ignition.
2. Remove storage compartment beneath left instrument panel. --> «68 - INTERIOR EQUIPMENT»(ref-289222-S37995085722008062700000)
3. Remove center console. --> «68 - INTERIOR EQUIPMENT»(ref-289222-S37995085722008062700000)
4. Remove left footwell vent (drivers side).

Scheme 93

1. Carefully fold back floor covering in area of actuator.
2. Remove bolts - A -.
3. Mark connector - B - to actuator (danger of interchange with other connectors of same construction).
4. Remove control motor.

1. Disconnect connector - B - from actuator.
2. Carefully pry off cam disk - C - from actuator, e.g. using 2 screwdrivers.
3. Remove bolts - D -.

Install in reverse order, paying attention to the following.

1. Attach metal bracket - E - to actuator.

1. Attach cam disk - A - to actuator shaft.

Note. Check cam disk for proper seating, it must engage in motor shaft and there must not be any clearance between actuator shaft and cam disk. Cam disk must be attached only in the position in which it engages without using force. If pretension is necessary to insert cam disk, check mount of motor, it may be turned by 180°. Actuator shaft - B - does not have a stop, it rotates continuously when voltage is applied between terminals 5 and 6. Therefore, when actuator is removed, voltage is only to be applied if cam disk - A - is attached. If cam disk - A - cannot be inserted into actuator without pretension, actuator may be incorrectly positioned. If shaft is so awkwardly positioned that cam disk cannot be attached, connect terminals 5 and 6 of actuator via a 5A fuse to a 12 V battery e.g. using adapter lead --> Preparing adapter cables for control motor actuation or an adapter lead from connector test kit V.A.G 1594/C. Rotate actuator for only as long until connecting element can be attached without pretension, the turning direction can be reversed by swapping B+ and Ground.

Scheme 94

1. Lightly lubricate guides of cam disk - C - and lugs at flap levers - A - and - B - with grease G 000 450 .
2. Move levers - A - and - B - of flaps to position shown.
3. Insert lugs of levers as shown into guides of cam disk - C -.
4. Attach actuator to air conditioner.

1. Switch on ignition and check operation of actuator (by changing settings on , actuator must reach both end positions).
2. Check DTC memory of Climatronic Control Module J255 and erase DTCs displayed if necessary. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
3. Perform basic setting and output Diagnostic Test Mode (DTM) on the A/C system. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
4. Install the removed components again in reverse order.

Right Footwell Flap Motor V109 , removing and installing

Note. Mark motor/flap connecting elements when removing (danger of swapping with connecting elements of the other actuator motors). In the event of fault "Upper or lower limit value exceeded" , check connecting element of engine/flap, it must be attached to engine accurate to side and there must not be any clearance between actuator mount and connecting element.

1. Switch off ignition.
2. Remove glove box. --> «68 - INTERIOR EQUIPMENT»(ref-289222-S37995085722008062700000)
3. Remove center console. --> «68 - INTERIOR EQUIPMENT»(ref-289222-S37995085722008062700000)
4. Remove right footwell vent (passengers side).

Scheme 95

1. Carefully fold back floor covering in area of actuator.
2. Remove bolts - A -.
3. Mark connector - B - to actuator (danger of interchange with other connectors of same construction).
4. Disconnect connector - B - from actuator.

1. Remove control motor.
2. Carefully pry off cam disk - C - from actuator, e.g. using 2 screwdrivers.
3. Remove bolts - D -.

Install in reverse order, paying attention to the following.

1. Attach metal bracket - E - to actuator.

1. Attach cam disk - A - to actuator shaft.

Note. Check cam disk for proper seating, it must engage in motor shaft and there must not be any clearance between actuator shaft and cam disk. Cam disk must be attached only in the position in which it engages without using force. If pretension is necessary to insert cam disk, check mount of motor, it may be turned by 180°. Actuator shaft - B - does not have a stop, it rotates continuously when voltage is applied between terminals 5 and 6. Therefore, when actuator is removed, voltage is only to be applied if cam disk - A - is attached. If cam disk - A - cannot be inserted into actuator without pretension, actuator may be incorrectly positioned. If shaft is so awkwardly positioned that cam disk cannot be attached, connect terminals 5 and 6 of actuator via a 5A fuse to a 12 V battery e.g. using adapter lead --> Preparing adapter cables for control motor actuation or an adapter lead from connector test kit V.A.G 1594/C. Rotate actuator for only as long until connecting element can be attached without pretension, the turning direction can be reversed by swapping B+ and Ground.

Scheme 96

1. Lightly lubricate guides of cam disk - C - and lugs at flap levers - A - and - B - with grease G 000 450 .
2. Move levers - A - and - B - of flaps to position shown.
3. Insert lugs of levers as shown into guides of cam disk - C -.
4. Attach actuator to air conditioner.

1. Switch on ignition and check operation of actuator (by changing settings on , actuator must reach both end positions).
2. Check DTC memory of Climatronic Control Module J255 and erase DTCs displayed if necessary. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
3. Perform basic setting and output Diagnostic Test Mode (DTM) on the A/C system. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
4. Install the removed components again in reverse order.

Temperature Regulator Flap Motor V68 , removing and installing

Note. Mark motor/flap connecting elements when removing (danger of swapping with connecting elements of the other actuator motors). In the event of fault "Upper or lower limit value exceeded" , check connecting element of engine/flap, it must be attached to engine accurate to side and there must not be any clearance between actuator mount and connecting element. This actuator operates the warm-air flap (flap in air duct from heater core) --> Air distribution system, block diagram

1. Switch off ignition.
2. Remove glove box. --> «68 - INTERIOR EQUIPMENT»(ref-289222-S37995085722008062700000)
3. Remove right footwell vent (passengers side).

Scheme 97

1. Carefully pry off connecting element - C - from actuator (e.g. using 2 screwdrivers, in case one of the bolts - A - is not accessible.
2. Remove bolts - A -.
3. Remove control motor.
4. Mark connector - B - to actuator (danger of interchange with other connectors of same construction).

1. Disconnect connector - B - from actuator.
2. Carefully pry off connecting element - C - from actuator, e.g. using 2 screwdrivers.

Install in reverse order, paying attention to the following.

1. Attach connecting element - A - onto actuator shaft.

Note. Check connecting element for proper seating, it must engage in motor shaft and there must not be any clearance between actuator shaft and connecting element. Connecting element must be attached only in the position in which it engages without using force. If pretension is necessary to insert connecting element, check mount of motor, it can be turned by 180°. Actuator shaft - B - does not have a stop, it rotates continuously when voltage is applied between terminals 5 and 6. Therefore, when actuator is removed, voltage is only to be applied if connecting element - A - is attached. If connecting piece - A - cannot be inserted into actuator without pretension, actuator may be incorrectly positioned. If shaft is so awkwardly positioned that connecting piece cannot be attached, connect terminals 5 and 6 of actuator via a 5A fuse to a 12 V battery e.g. using adapter lead --> Preparing adapter cables for control motor actuation or an adapter lead from connector test kit V.A.G 1594/C. Rotate actuator for only as long until connecting element can be attached without pretension, the turning direction can be reversed by swapping B+ and Ground.

1. Lightly lubricate guide of lever - C - or lug at flap lever with grease G 000 150.
2. Attach actuator to air conditioner.
3. Switch on ignition and check operation of actuator (by changing settings on , actuator must reach both end positions).
4. Check DTC memory of Climatronic Control Module J255 and erase DTCs displayed if necessary. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

1. Perform basic setting and output Diagnostic Test Mode (DTM) on the A/C system. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
2. Install the removed components again in reverse order.

Left Vent Temperature Sensor G150 , removing and installing

1. Switch off ignition.
2. Remove driver s storage compartment. --> «70 - INTERIOR TRIM»(ref-289222-S30170627502008062700000)
3. Remove left footwell vent (drivers side).

Scheme 98

1. Disconnect harness connector - A - from temperature sensor.
2. Turn temperature sensor - 1 - in direction of arrow approx. 90°.
3. Take temperature sensor out of heating and A/C unit.

1. Install in reverse order of removal.

Right Vent Temperature Sensor G151 , removing and installing

1. Switch off ignition.
2. Remove glove box. --> «70 - INTERIOR TRIM»(ref-289222-S30170627502008062700000)
3. Remove right footwell vent (passengers side).

Scheme 99

1. Disconnect harness connector - A - from temperature sensor.
2. Turn temperature sensor - 1 - in direction of arrow approx. 90°.
3. Take temperature sensor out of heating and A/C unit.

1. Install in reverse order of removal.

Evaporator Vent Temperature Sensor G263 , removing and installing

1. Switch off ignition.
2. Remove glove box. --> «68 - INTERIOR EQUIPMENT»(ref-289222-S37995085722008062700000)
3. Remove right footwell vent (passengers side).

Scheme 100

1. Disconnect harness connector - A - from sensor.
2. Turn sensor - 1 - in direction of arrow approx. 90°.
3. Take temperature sensor out of heating and A/C unit.

1. Install in reverse order of removal.

Left Rear Air Outlet Motor V218 and Right Rear Air Outlet Motor V219 , removing and installing

Note. Mark motor/flap connecting elements when removing (danger of swapping with connecting elements of the other actuator motors). In the event of fault "Upper or lower limit value exceeded" , check connecting element of engine/flap, it must be attached to engine accurate to side and there must not be any clearance between actuator mount and connecting element. These actuators are installed only on vehicles with Rear A/C Control Head (Climatronic) E265. On vehicles without Rear A/C Control Head (Climatronic) E265 , there are no flaps installed in air duct of air conditioner. In cases of doubt about correct connector assignment after installation of actuators, disconnect connector e.g. from actuator and then check DTC memory of Rear A/C Control Head (Climatronic) E265. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

1. Switch off ignition.
2. Remove center console. --> «68 - INTERIOR EQUIPMENT»(ref-289222-S37995085722008062700000)

Scheme 101

1. Mark connector - B - to Left Rear Air Outlet Motor V218 and - C - to Right Rear Air Outlet Motor V219 to prevent possible interchange of identical connectors.
2. Remove bolts - A -.
3. Disconnect connector - B - and - C - from actuators.
4. Remove bracket - D - with both actuators.

Scheme 102

1. Remove bolts - A - from actuator to be removed.
2. Mark actuators (e.g. - B - and - C - , due to different position of actuator shaft).
3. Remove respective actuator from bracket - F -.
4. Mark cam disk - D - , e.g. - D - (to Left Rear Air Outlet Motor V218) and - E - , e.g. - E - (to Right Rear Air Outlet Motor V219) to prevent possible interchange (allocation --> «Heating and A/C unit, disassembling and assembling»(ref-289225-S34809723892008062700000) ).

1. Carefully pry off cam disk - C - or - E - from respective actuator, e.g. using 2 screwdrivers.

Install in reverse order, paying attention to the following.

1. Attach actuators - B - and - C - to bracket - F -.
2. Attach cam disk - D - and - E - onto shaft of respective actuator (observe correct assignment --> «Heating and A/C unit, disassembling and assembling»(ref-289225-S34809723892008062700000) ).

Note. Check cam disk for proper seating, it must engage in motor shaft and there must not be any clearance between actuator shaft and cam disk. Cam disk must be attached only in the position in which it engages without using force. If pretension is necessary to insert cam disk, check mount of motor, it may be turned by 180°. Actuator shaft - B - does not have a stop, it rotates continuously when voltage is applied between terminals 5 and 6. Therefore, when actuator is removed, voltage is only to be applied if cam disk - A - is attached. If cam disk - A - cannot be inserted into actuator without pretension, actuator may be incorrectly positioned. If shaft is so awkwardly positioned that cam disk cannot be attached, connect terminals 5 and 6 of actuator via a 5A fuse to a 12 V battery e.g. using adapter lead --> Preparing adapter cables for control motor actuation or an adapter lead from connector test kit V.A.G 1594/C. Rotate actuator for only as long until connecting element can be attached without pretension, the turning direction can be reversed by swapping B+ and Ground.

Scheme 103

1. Lightly lubricate guides of cam disk - E - and - F - and lugs at flap levers - A - to - D - with grease G 000 150 .
2. Move levers - A - and - B - of flaps for left side and - C - and - D - of flaps for right side to position shown.
3. Insert lugs of levers - A - to - D - into guides of cam disks - E - and - F - as shown.
4. Attach bracket with actuators to air conditioner.

1. Install the removed components again in reverse order.
2. Check DTC memory of Rear A/C Control Head (Climatronic) E265 (and of Climatronic Control Module J255) and erase DTCs displayed if necessary. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
3. Perform basic setting and output Diagnostic Test Mode (DTM) on the A/C system. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Heater Core, removing and installing

Special tools, testers and other items required

1. Hose clamps 3093 bow. 3094
2. Compressed air gun, commercially available
3. Cooling system tester V.A.G 1274 (and corresponding adapter)

1. Perform preparatory work for removing heater core --> «Preparation for heater core removal»(ref-289225-S10717798852008062700000)
2. Remove glove compartment: --> «68 - INTERIOR EQUIPMENT»(ref-289222-S37995085722008062700000)
3. Remove footwell vent.
4. Cover carpet in area under heater core with waterproof foil and water absorbing paper.

1. Lightly coat contact surface of both coolant lines - D - and - E - at boot - C - with silicone lubricant from inside as well (so that lines can be moved without changing position of boot, this illustration shows lines viewed from plenum chamber).

Scheme 104

1. Remove clamps - A - and - B -.
2. Take both coolant lines out of heater core.
3. Push both coolant lines in direction of "plenum chamber".

Note. As grommet has been moistened slightly with silicone lubricant in area of coolant pipe penetration, lines can be moved without grommet being pushed out of air conditioner unit.

1. Remove bolts - C -.
2. Detach holder.
3. Pull heater core - D - out of air conditioner.

Scheme 105

1. Before installing heater core, check openings - A - of evaporator drain for soiling and clean if necessary.

Note. Evaporator drain must not be blocked by dirt or other deposits. Drain openings in illustration are depicted with heater cores installed.

Cleaning evaporator drain

1. Heater core removed: Insert illuminated angled mirror into opening for heater core and check both drain openings. Clean evaporator drains if necessary using a piece of wire, for example.
2. Heater core in installed: With evaporator hose detached, clean evaporator drains from outside using a piece of wire, for example.

Perform further installation in reverse order, paying attention to the following

1. Before installing heater core, check attached foam seal

Note. An incorrectly glued seal can roll up into air conditioner when sliding in heater core. Cold air may flow past heater core if seal is damaged or not properly fitted.

1. Secure all connections with standard clamps or with retainers approved for these connections.

Note. Clamps - A - and - B - can only be mounted with difficulty in installed position. To be able to replace heater core in customer service with air conditioner installed, clamping brackets - A - and - C - must be used

Scheme 106

1. Check both coolant lines - B - and heater core connections - C - for soiling or damage.

Note. Sealing rings must always be replaced.

1. Lightly coat sealing ring - A - with coolant and place on coolant pipe - B -.
2. Place clamping bracket - A - (with studs) according to illustration onto connection at heater core - B -.
3. Place clamping bracket - C - (with holes) onto coolant pipe - D - according to illustration.
4. Insert coolant line - D - (with sealing ring) into connection of heater core - B -.

Scheme 107

1. Secure coolant pipe with two clamping brackets - C - and - D - in heater core.
2. Tighten both hex nuts - A - and - B - alternately and uniformly (tightening torque 3 Nm).

Note. Clamping brackets - C - and - D - must be installed as illustrated (observe outer contour). When tightening hexagon nuts, take care not to tilt retainers. After securing coolant lines, check position of retainers. They must not make contact with other components.

1. Install second coolant pipe in the same way.
2. Before installing glove box, check cooling system for leaks. --> «19 - ENGINE - COOLING SYSTEM»(ref-289203-S15357943982008062700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM «19 - ENGINE - COOLING SYSTEM»(ref-289204-S03664241582008062700000) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM «19 - COOLING SYSTEM»(ref-289206-S27114819052008062700000) for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB
3. Before installing glove box and plenum chamber cover, check position of grommet in coolant pipe penetration to plenum chamber.
4. Connect 2-pin harness connector to Coolant Pump V50 of pump valve unit only after venting coolant circuit --> «Pump/valve unit, removing and installing»(ref-289225-S19938788502008062700000) and. --> «19 - ENGINE - COOLING SYSTEM»(ref-289203-S15357943982008062700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM «19 - ENGINE - COOLING SYSTEM»(ref-289204-S03664241582008062700000) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM «19 - COOLING SYSTEM»(ref-289206-S27114819052008062700000) for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB

Note. Coolant pump V50 of pump valve unit must only be operated after coolant circuit has been vented, dry running of pump in pump valve unit leads to destruction. When bleeding coolant circuit, take special care to ensure complete bleeding of heat exchangers. If air bubbles remain in heater cores, there may be complaints made by customers about insufficient heating performance in winter, or different air temperature from vents at same setting in regulated mode --> A/C system heat output and pump valve unit, checking .

1. Remove right heater core (passengers side) --> «Right (front passengers side) heater core, removing and installing»(ref-289225-S28144043302008062700000) .
2. Remove drivers storage compartment. --> «68 - INTERIOR EQUIPMENT»(ref-289222-S37995085722008062700000)
3. Completely remove gas pedal module --> «20 - FUEL SUPPLY»(ref-289211-S22315802802008062700000) for 4.2 LITER V8 4V GENERIC SCAN TOOL, ENGINE CODE(S): BVJ 20 - FUEL SUPPLY for 4.2 LITER V8 5V GENERIC SCAN TOOL, ENGINE CODE(S): BFM «20 - FUEL SUPPLY»(ref-289210-S16335687652008062700000) for 5.2 LITER 10-CYL. 4V GENERIC SCAN TOOL, ENGINE CODE(S): BSM «20 FUEL SUPPLY»(ref-289213-S27849435172008062700000) for 6.0 LITER 12-CYL. 4V GENERIC SCAN TOOL, ENGINE CODE(S): BSB
4. Remove left footwell vent.

1. Cover carpet in area under heater core with waterproof foil and water absorbing paper.

Scheme 108

1. Remove clamps - A - and - B -.
2. Remove coolant lines - C - and - D - from heater core - E -.
3. Slide heater core - E - in direction of passenger side (perpendicular through air conditioner).

1. Before installing heater core, check attached foam seal

Note. An incorrectly glued seal can roll up into air conditioner when sliding in heater core. Cold air may flow past heater core if seal is damaged or not properly fitted.

Installation is carried out in the reverse order, when doing this note the following

Note. Sealing rings must always be replaced.

1. To prevent heater core from sliding back into air conditioner, it is appropriate to insert heater core for passenger side into air conditioner and to secure bracket with bolt - C -.

1. Push heater core from front passenger s side sideways through air conditioner unit.
2. Install O-rings, coolant lines and brackets in same manner as described for left heater core.

Scheme 109

1. Before installing glove compartment, storage compartment on passengers side and plenum chamber cover, check position of boots - C - and - D - in coolant pipe penetration to plenum chamber.
2. Check coolant system for proper seal before installing glove compartment and storage compartment on drivers side: --> «19 - ENGINE - COOLING SYSTEM»(ref-289203-S15357943982008062700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM «19 - ENGINE - COOLING SYSTEM»(ref-289204-S03664241582008062700000) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM «19 - COOLING SYSTEM»(ref-289206-S27114819052008062700000) for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB
3. Further installation work steps are to be performed in same manner as described for heater core on passengers side.

Air distribution system, block diagram

Note. Air routing and air distribution in passenger compartment --> Air routing and air distribution in passenger compartment Component locations of individual components --> Components not located in passenger compartment , --> Components located in passenger compartment and --> Air conditioner unit components located in passenger compartment .

Scheme 110

I - Engine compartment (plenum chamber)

1. In fresh-air mode, air is drawn in via dust and pollen filter

II - Passenger compartment

1. In recirculated-air mode, air is drawn in beneath instrument panel

III - Air conditioner unit

A - Fresh-air intake from plenum chamber

1. In fresh-air mode

B - Dust and pollen filter

C - Air intake beneath instrument panel

1. In recirculated-air mode

D - Evaporator

E1 - Left heater core

1. For heater

E2 - Right heater core

1. For heater

E3 - Left mixing chamber

E4 - Right mixing chamber

F1 - To left indirect ventilation vent

1. Via air guides in instrument panel to windshield

F2 - To left instrument panel vent

G1 - To right indirect ventilation vent

1. Via air guides in instrument panel to windshield

G2 - To right instrument panel vent

H1 - To left front footwell vent

1. To left rear footwell vent on right-hand drive vehicles

H2 - To left rear footwell vent

1. To left front footwell vent on right-hand drive vehicles

J1 - To right rear footwell vent

1. To right front footwell vent on right-hand drive vehicles

J2 - To right front footwell vent

1. To right rear footwell vent on right-hand drive vehicles

K1 - To left center instrument panel vent

K2 - To right center instrument panel vent

L - To defroster vent in instrument panel

1. Via air guides in instrument panel to windshield

M1 - Left rear warm air duct

M2 - Left rear cold air duct

1. Only on vehicles with Rear A/C Control Head (Climatronic) E265.
2. On vehicles without Rear A/C Control Head (Climatronic) E265 , opening in air conditioner is sealed

N1 - Right rear cold air duct

1. Only on vehicles with Rear A/C Control Head (Climatronic) E265.
2. On vehicles without Rear A/C Control Head (Climatronic) E265 , opening in air conditioner is sealed

N2 - Right rear warm air duct

1 - Air Flow Flap Motor V71

1. Flap closes completely in recirculated-air mode and partially at higher vehicle speed (program-controlled)

2 - Recirculation Flap Motor V113

1. Flap opens in recirculated-air mode and partial recirculated-air mode

3 - Fresh Air Blower V2

4 - Evaporator Vent Temperature Sensor G263

5 - Left Vent Temperature Sensor G150

6 - Right Vent Temperature Sensor G151

7 - Left Front Defrost/Upper Body Shut-off Flap Motor V200

8 - Right Front Defrost/Upper Body Shut-off Flap Motor V199

9 - Left Footwell Flap Motor V108

10 - Right Footwell Flap Motor V109

11 - Defroster Flap Motor V107

12 - Center Vent Adjustment Motor V102

1. Flap in cold air duct

13 - Temperature Regulator Flap Motor V68

1. Flap in warm air duct

14 - Left Rear Air Outlet Motor V218

1. Installed only on vehicles with Rear A/C Control Head (Climatronic) E265.

15 - Right Rear Air Outlet Motor V219

1. Installed only on vehicles with Rear A/C Control Head (Climatronic) E265.

Air routing and air distribution in passenger compartment

Note. Air intake and air guide in air conditioner --> Air intake and air routing in air conditioner unit Component locations of individual components --> Components not located in passenger compartment , --> Components located in passenger compartment and --> Air conditioner unit components located in passenger compartment . Description of items "F1" to "N2" --> Air intake and air routing in air conditioner unit

Scheme 111

1 - Air guide and left front footwell vent

2 - Air duct to rear left footwell vent

3 - Air duct to rear left footwell vent

4 - Left rear footwell vent

1. Vehicles with Rear A/C Control Head (Climatronic) E265 are equipped with Left Rear Footwell Heater Z42.

5 - Air guide and right front footwell vent

6 - Air duct to rear right footwell vent

7 - Air duct to rear right footwell vent

8 - Right rear footwell vent

1. Vehicles with Rear A/C Control Head (Climatronic) E265 are equipped with Right Rear Footwell Heater Z43.

9 - Air duct to left footwell vents

10 - Air duct to right footwell vents

11 - Rear air vent distribution

1. Different versions on vehicles with and without Rear A/C Control Head (Climatronic) E265

12 - Left Rear Warm/Cold Flap Air Outlet Motor V220

1. Only actuates flaps for left side on vehicles with Rear A/C Control Head (Climatronic) E265
2. Connecting element between flap and motor is "red" colored
3. On vehicles without Rear A/C Control Head (Climatronic) E265 (without Right Rear Warm/Cold Flap Air Outlet Motor V221), flaps for right side are also moved via a joint shaft by Left Rear Warm/Cold Flap Air Outlet Motor V220.

13 - Right Rear Warm/Cold Flap Air Outlet Motor V221

1. Installed only on vehicles with Rear A/C Control Head (Climatronic) E265.
2. Connecting element between flap and motor is "blue" colored
3. On vehicles without Rear A/C Control Head (Climatronic) E265 (without Right Rear Warm/Cold Flap Air Outlet Motor V221), flaps for right side are moved via a joint shaft by Left Rear Warm/Cold Flap Air Outlet Motor V220.

14 - Air duct to vents in left B-pillar

15 - Air duct to vents in right B-pillar

16 - Air duct in left B-pillar

17 - Air duct in right B-pillar

18 - Air duct to vent for dehumidifying door window in left B-pillar

1. Installed only on vehicles with Rear A/C Control Head (Climatronic) E265.

19 - Air duct to vent for dehumidifying door window in right B-pillar

1. Installed only on vehicles with Rear A/C Control Head (Climatronic) E265.

20 - Cap

1. Installed on vehicles without Rear A/C Control Head (Climatronic) E265 instead of air guide to vents for dehumidifying door window in B-pillar.

A/C cooling output, checking

Special tools, testers and other items required

1. Diagnostic operation system VAS 5051 A (or Vehicle Diagnosis Service Syst. VAS 5052)
2. Standard thermometer (for temperature measurements, if necessary a thermometer with 2 measuring probes for simultaneous measurement e.g. for temperature at right and left)

1. Measure ambient temperature (must be greater than 15°C).
2. Close doors, hood, windows and sun roof.
3. Open all dash panel vents.
4. Switch ignition on.

1. Set "Econ" mode on MMI.
2. Close vents in "B" pillar.
3. Set handwheel for variable temperature center vent to "Warm".
4. Start engine.

1. Initiate On Board Diagnostic (OBD) of A/C system Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
2. Select the "Read measuring value block" function display group "001" in Climatronic Control Module J255. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
3. Check display in display zones
4. Display field "2" shows 0% (compressor is switched off)

1. Display field "4" shows that the pressure in the refrigerant circuit measured at ambient temperature is the same or greater as the table value.

Note. In terms of absolute pressure, 0 bar corresponds to an absolute vacuum. Normal ambient pressure equals approx. 1 bar absolute pressure. On the scales of most pressure gauges, 0 bar corresponds to an absolute pressure of one bar (can be seen from -1 mark below 0). Pressure in refrigerant circuit is governed by ambient temperature. On account of heat given off by components (e.g. radiator), pressure displayed with warm engine will be slightly higher than that given for the respective ambient temperature. If pressure displayed is below that indicated in table: Check signal of High Pressure Sensor G65 --> Pressure signal of High Pressure Sensor G65 , checking If no malfunction can be detected at High Pressure Sensor G65 , there is insufficient refrigerant in circuit, deliver vehicle to an A/C system service point workshop (insufficient refrigerant in circuit).

If pressure in refrigerant circuit is OK

1. Switch on compressor, select "Auto" mode on Climatronic Control Module J255 or on MMI (Multi Media Interface) to do so.
2. Select temperature preselect for drivers and front passengers side to "Lo" on Climatronic Control Module J255.
3. Set direction of air flow to "instrument panel vents" on Climatronic Control Module J255.
4. Select display group "001" in function "Read Measuring Value Block". Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

1. Check display in display zones
2. Display field "2" shows a duty cycle greater than 30% (A/C Compressor Regulator Valve N280 is activated, compressor is switched on)
3. Display field "1" shows a current greater than 0.3 A (current flows via A/C Compressor Regulator Valve N280 , compressor is switched on)
4. The displayed pressure in display field "4" rises above the value with the compressor switched off.

Note. A/C Compressor Regulator Valve N280 is activated by Climatronic Control Module J255 such that temperature of air downstream of evaporator reaches specified value (approx. 2 to 5°C): After starting vehicle, value greater than 75 % (0.55A) is displayed depending on measured temperature, engine speed and electrical system voltage. As soon as the temperature measured by Evaporator Vent Temperature Sensor G263 approximates the specified value, activation is reduced and thus the compressor output is reduced. The connector to A/C Compressor Regulator Valve N280 and the connector to the electric engine mounts are identical in construction. If connectors are interchanged (e.g. possible on vehicles with 4.2 l engine), no entry is made in DTC memory, however since the compressor is continuously actuated, the evaporator may ice up. Under certain operating conditions, residual moisture in refrigerant circuit can lead to an ice build-up at compressor regulator valve. This impedes compressor regulation. Evaporator is excessively cooled and ices up. The freeze-up of the evaporator can be the cause for the following customer complaints: - After a long drive, A/C system repeatedly or sporadically fails (no cooling or heating performance), after switching off vehicle and after a short time, A/C function is OK again. - After a long drive, windows fog up from inside, windows are also not cleared by then pressing the "Defrost" button, after switching off vehicle and after a short time, A/C function is OK again. Corrective action: Check measured value of Evaporator Vent Temperature Sensor G263 , (function "Read measuring value block" display group "018"). Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. If measured value of sensor is too high under operating conditions reported by customer (even though A/C system is operating without difficulty at greater than e.g. 10°C), check Evaporator Vent Temperature Sensor G263 (incorrect measured value may cause evaporator to ice up). If measured value of the sensor is too low under operating conditions reported by customer (at an ambient temperature above 0°C, colder than 0°C for a long period of time), transfer vehicle to an authorized service shop for A/C systems. Check refrigerant line from evaporator to accumulator (thick tube, low pressure side) with engine running. If this line is thickly iced up when complaint occurs (a very thin layer of ice is permitted), this also indicates that temperature in evaporator is too low, take vehicle to an authorized service shop for A/C systems. Bring the determined deficiency to the attention of the authorized service shop for A/C systems, the necessary work can only be performed there (draining refrigerant circuit, replacing reservoir and then evacuating refrigerant circuit for minimum of 3 hours). If no or very little current is displayed in display field "1" , check actuation of A/C Compressor Regulator Valve N280 --> A/C Compressor Regulator Valve N280 cut-in signal, checking . If pressure displayed in display group "4" does not change and compressor actuation is OK (display field "1" and "2"), there is a malfunction in refrigerant circuit, take vehicle to A/C system service point workshop.

1. Press button for recirculating-air mode on Climatronic Control Module J255 (symbol for "recirculating-air mode" lights up in button).
2. Set engine speed of 2000 RPM (start of time measurement).
3. Select display group "018" in "Read measuring value block" function Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Scheme 112

1. Compare displayed measuring value (of Evaporator Vent Temperature Sensor G263) in display field "1" with values in diagram.

A - Measured air temperature of Evaporator Vent Temperature Sensor G263

B - Ambient temperature

C - Permissible tolerance range

Depending on ambient temperature, air temperature measured must be within stated tolerance range after 5 minutes.

Note. If the requested values are not obtained, check measured value of Evaporator Vent Temperature Sensor G263 , compare measured values displayed in display group "018" , display fields "1" and "017" with display fields "1" and "2" : If measured value in both display fields "1" or "2" of display group "017" deviates only slightly from measured value of display group "018" : Perform "Identifying malfunctions if specified values are not obtained" --> Measures to be taken if readout does not match specification . If measured value of Evaporator Vent Temperature Sensor G263 is greater than measured value of Left Vent Temperature Sensor G150 and Right Vent Temperature Sensor G151 , check Evaporator Vent Temperature Sensor G263 for proper installation and perform electrical test for this sensor --> Evaporator Vent Temperature Sensor G263 , removing and installing Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. The function of the air conditioning is recognizable, e.g. the refrigerant pipe on the low pressure side (thick line) cools off.

If measuring value of Evaporator Vent Temperature Sensor G263 (and therefore cooling performance of A/C system) is OK.

1. Compare displayed measured value (of Evaporator Vent Temperature Sensor G263) in display field "1" of display group "018" with measured values of display group "017" display field "1" and "2" (Left Vent Temperature Sensor G150 and Right Vent Temperature Sensor G151).
2. After 5 minutes, measured values in display group "017" display field "1" and "2" (Left Vent Temperature Sensor G150 and Right Vent Temperature Sensor G151) must not be more than 3°C higher than value in display field "1" of display group "018" (of Evaporator Vent Temperature Sensor G263).

Note. If required values are not obtained, compare displayed measuring values in display group "017" display fields "1" and "2" with each other: - If measured value in one of the two display fields "1" or "2" is OK, check activation and function of Left Heat Regulating Valve N175 , Right Heat Regulating Valve N176 and Coolant Pump V50 --> A/C system heat output and pump valve unit, checking . Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. - If measured value in display fields "1" or "2" of display group "017" is less than that in display field "1" of display group "018". Check Evaporator Vent Temperature Sensor G263 , Left Vent Temperature Sensor G150 and Right Vent Temperature Sensor G151 for correct installation and their electrical connections for contact resistance, replace malfunctioning sensor if necessary. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. - If no fault is found at Left Vent Temperature Sensor G150 and Right Vent Temperature Sensor G151 as well as at Left Heat Regulating Valve N175 , Right Heat Regulating Valve N176 and Coolant Pump V50 , perform "Identifying malfunctions at temperature increase downstream of evaporator". Temperature of air flowing out of "center" instrument panel vents can also be measured e.g. using a standard thermometer. If air flowing out of variable temperature center vent in "Lo" setting for drivers and passengers side on , Climatronic Control Module J255) is cooled in "Cold" setting and not cooled in "Warm" setting, check operation of Left Heat Regulating Valve N175 and Right Heat Regulating Valve N176. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. If cooling output on front passengers side is still adequate but values on drivers side are no longer attained, this is an indication for insufficient refrigerant in refrigerant circuit (stratification in evaporator due to lack of refrigerant). Problems relating to differences between temperature of air emitted by vents with identical setting in air conditioner control mode may be due to the following: - Cold-air flaps or warm-air flaps in air ducts do not close completely or do not reach their end positions --> Air intake and air routing in air conditioner unit and Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. - There is air in one or both heater cores (effecting different flow through heater cores and uneven heat distribution) --> A/C system heat output and pump valve unit, checking - A foam seal has loosened during installation of heater cores and air may flow past heater core.

Measures to be taken in the event of temperature increase downstream of evaporator

1. Clamp two coolant hoses from engine to pump valve unit using hose clamps 3093 bow. 3094.
2. Repeat cooling performance test --> «A/C cooling output, checking»(ref-289225-S08271818162008062700000) .

A/C system heat output and pump valve unit, checking

Note. If coolant circuit is not completely bled after filling, air may accumulate in heater cores of A/C unit, thus reducing heating performance of air conditioner, additional noises may occur or customer may complain of different air temperatures flowing out of vents at drivers side and front passengers side despite identical setting. Corrective action: - Set air conditioner for drivers and front passengers side to maximum heat output (temperature preselect "Hi") on Climatronic Control Module J255 - Perform long road test at increased engine speed (at least 10 minutes, engine speed greater than 2500 RPM). In doing so, select a low gear to prevent excessive vehicle speed. - If customer complains of poor heating performance at specific engine speeds, check incorporation of pump valve unit in coolant circuit. If both coolant hoses (supply and return) between engine to pump valve unit have been interchanged, engine coolant pump works in opposition to pump in pump valve unit, and at certain engine speeds coolant no longer flows into heater core --> Pump/valve unit, removing and installing and --> 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM 19 - ENGINE - COOLING SYSTEM for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM 19 - COOLING SYSTEM for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB

Special tools, testers and other items required

1. Diagnostic operation system VAS 5051 A (or Vehicle Diagnosis Service Syst. VAS 5052)

1. Close hood.
2. Close doors, windows and sun roof.
3. Start engine and let it run for several minutes with maximum cooling performance (compressor is switched on, temperature preselect "LO" for left and right sides).
4. Switch off ignition.

1. With ignition switched off, connect diagnostic operation system VAS 5051 A with diagnostic cable VAS 5051/5A to 16-pin Data Link Connector (DLC) in vehicle and select address word "08" A/C/Heating Electronics --> «Vehicle Diagnostic, Testing and Information System VAS 5051 A , connecting and selecting functions»(ref-289225-S22299735562008062700000) .
2. Switch ignition on.

Starts operation, Coolant Pump V50 is not actuated and does not run, Left Heat Regulating Valve N175 and Right Heat Regulating Valve N176 are activated and are closed).

1. Read out measured value block, display groups "034" and "035" , no shut-off must be effected by Energy Management Control Module J644. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
2. Read out measuring value block, display group "017". Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
3. Check indication in display fields "1" and "2".

1. Specification: Ambient temperature plus max. 15°C

1. Set temperature preselect for left side (drivers side) onto "Hi".
2. Read out display in display field "1" (temperature value increases).

1. Specification: approx. engine temperature (operation of Coolant Pump V50 , Left Heat Regulating Valve N175 open)

1. Read out display in display field "2" (temperature value remains roughly constant).

1. Temperature increase less than 15°C (Right Heat Regulating Valve N176 closed)

1. Set temperature preselect for right side (passengers side) onto "Hi".
2. Read out display in display field "2" (temperature value increases).

1. Specification: approx. engine temperature (operation of Coolant Pump V50 , Left Heat Regulating Valve N175 and Right Heat Regulating Valve N176 open)

1. Set temperature preselect for drivers side and passengers side onto "Lo".
2. Read indication shown in display fields "1" and "2".

1. Specified values: Temperature drops within 5 minutes to ambient temperature (plus max. 15°C), (operation of Coolant Pump V50 , Left Heat Regulating Valve N175 and Right Heat Regulating Valve N176 closed).

Note. Refrigerant in refrigerant circuit is never to be topped up (drain, evacuate and refill circuit). Compressor is always driven when engine is running; there is no magnetic clutch. Engine is therefore not to be started unless refrigerant circuit has been properly assembled. If for example the refrigerant lines are not connected to the compressor and the engine is started then the compressor may be destroyed by the build-up of internal heat. Such internal heat generation results from the fact that - even with delivery approaching 0 % - the compressor is confronted with a fixed resistance (sealed circuit). To stop the compressor being destroyed when the refrigerant circuit is empty, it is designed such that delivery is reduced to roughly 0 % and lubrication is maintained by way of an internal oil circuit with the oil left in the compressor. Replacement compressors contain the full quantity of refrigerant oil required for the refrigerant circuit. --> 87 - AIR CONDITIONING Zexel, Sanden and Denso compressors require different refrigerant oils: --> 87 - AIR CONDITIONING Depending on compressor type ("6 SEU 14" , "7 SEU 16" or "7 SEU 17") different refrigerant oil fill capacities are designated for the refrigerant circuit --> 87 - AIR CONDITIONING Coat O-ring seals lightly with refrigerant oil before installing --> Refrigerant circuit O-rings . The specified diameters for O-rings seals and the tightening torques pertain also to the threaded connections of the refrigerant lines or hoses between the separate components. Only install O-rings seals that are approved for Refrigerant R134a: --> 87 - AIR CONDITIONING Check cooling performance --> A/C cooling output, checking . Checking pressures in refrigerant circuit --> 87 - AIR CONDITIONING For all other refrigerant circuit servicing and testing work not described in this article, refer to --> 87 - AIR CONDITIONING

Servicing refrigerant circuit

HD = High-pressure end

ND = Low-pressure end

1 - A/C Compressor Regulator Valve N280

1. Do not remove
2. Check activation and function --> «A/C Compressor Regulator Valve N280 cut-in signal, checking»(ref-289225-S39143243932008062700000) .

Note. A/C Compressor Regulator Valve N280 is activated by Climatronic Control Module J255 , it controls pressure on low pressure side of refrigerant circuit

2 - Compressor

1. Removing compressor from bracket and installing in vehicles with 8-cyl. MPI engine --> «Removing compressor from bracket and installing in vehicles with 8-cyl. MPI engine»(ref-289225-S14195474132008062700000)
2. Removing compressor from bracket and re-installing in vehicles with 12-cyl. engine --> «Compressor, removing from bracket and re-installing - vehicles with 12-cyl. engine»(ref-289225-S11543673622008062700000)
3. Refrigerant line, disconnecting from compressor and connecting --> «Refrigerant lines, disconnecting and connecting at compressor»(ref-289225-S01947645402008062700000)
4. To protect compressor, refrigerant circuit must have been completely assembled before starting engine

1. Remove ribbed belt --> «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-289203-S16488527182008062700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-289204-S09096153412008062700000) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-289206-S19139229562008062700000) for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB
2. Compressor, removing and installing (basics) --> «A/C compressor, removing and installing (basic guidelines)»(ref-289225-S08499229282008062700000)
3. Compressor, removing and installing in vehicles with 8-cyl. FSI engine --> «A/C compressor, removing and installing - vehicles with 8-cyl. FSI engine»(ref-289225-S28803055272008062700000)
4. Compressor, removing and installing in vehicles with 10-cyl. engine --> «Compressor, removing and installing - vehicles with 10-cyl. engine (Audi S8)»(ref-289225-S40754187942008062700000)

1. Type of compressor differs depending on engine (8, 10 or 12-cyl. engine)
2. After fitting new compressor or pouring in fresh refrigerant oil (e.g. after blowing out refrigerant circuit), crank compressor 10 times by hand following installation and prior to initial start-up so as to prevent compressor damage
3. Depending on compressor type ("6 SEU 14" , "7 SEU 16" or "7 SEU 17") different refrigerant oil fill capacities are designated for the refrigerant circuit --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000)

3 - Compressor belt pulley/drive unit

1. Replacing compressor pulley --> «A/C Compressor Pulley»(ref-289225-S14146475182008062700000)
2. Ribbed belt, removing and installing --> «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-289203-S16488527182008062700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-289204-S09096153412008062700000) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-289206-S19139229562008062700000) for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB
3. Replacing compressor drive unit (vehicles with 8-cyl. FSI or 10-cyl. engine) --> «Compressor drive unit, checking, replacing»(ref-289225-S40868384782008062700000)

4 - Oil drain plug

1. Denso compressors have sealing ring installed which are always to be replaced
2. Torque specification: 30 Nm
3. Should only be unscrewed to drain refrigerant oil and with the compressor removed. Turn compressor via belt pulley, to speed up refrigerant oil drainage.

5 - Pressure relief valve, 10 Nm

1. Do not remove

6 - Connection with valve

7 - High Pressure Sensor for air conditioner G65

1. Removing and installing --> «High Pressure Sensor G65 , removing and installing»(ref-289225-S12705460112008062700000)
2. Checking signal --> «Pressure signal of High Pressure Sensor G65 , checking»(ref-289225-S00982019582008062700000)

8 - Condenser

1. Refrigerant lines, disconnecting and reconnecting --> «Detaching refrigerant lines from condenser/re-attaching»(ref-289225-S05971395372008062700000)
2. Condenser, removing and installing --> «Condenser, removing and installing»(ref-289225-S12724682252008062700000)

9 - Cap

1. With seal
2. Always to be screwed on

10 - Service connection

1. High pressure side
2. For service station for measuring, discharging and recharging

11 - Bolts in refrigerant line

1. Replace O-ring seal, version
2. Torque specification: 15 Nm

12 - Restrictors

1. O-ring seal: 7.5 mm/1.5 mm
2. Replace restrictor with O-ring
3. Removing and installing --> «Restrictors, removing and installing»(ref-289225-S10549892742008062700000)
4. Coat O-ring lightly with refrigerant oil before installing --> «Refrigerant circuit O-rings»(ref-289225-S00601433862008062700000)

13 - Evaporator

1. Replace O-ring seals, version
2. Torque specification: Socket head bolt 25 Nm
3. Removing and installing refrigerant line --> «Refrigerant lines, disconnecting from evaporator connection and connecting»(ref-289225-S03941563262008062700000)
4. Removing and installing --> «Evaporator, removing and installing»(ref-289225-S10206257522008062700000)

14 - Service connection

1. Low pressure side
2. For service-station for measuring and discharging

15 - Cap

1. With seal
2. Always to be screwed on

16 - Accumulator

1. Coat O-ring seals lightly with refrigerant oil before installing --> «Refrigerant circuit O-rings»(ref-289225-S00601433862008062700000) .
2. Replace O-ring seals, version
3. Torque specification: Socket hex bolt at block connection 10 Nm
4. Removing and installing --> «Accumulator, removing and installing»(ref-289225-S17523221382008062700000)

Refrigerant lines, disconnecting and connecting at compressor

Note. Compressor is always driven when engine is running; there is no magnetic clutch. Engine is therefore not to be started unless refrigerant circuit has been properly assembled. If for example the refrigerant lines are not connected to the compressor and the engine is started then the compressor may be destroyed by the build-up of internal heat. The following illustrations show a compressor installed on left of engine, refrigerant lines with compressor installed at other locations (e.g. at top) are to be removed the same way. Seal open lines and connections at compressor with suitable caps (to prevent ingress of dirt and moisture).

1. Drain refrigerant circuit: --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000)
2. On vehicles with 8-cyl. FSI engine, perform preparatory work described --> «A/C compressor, removing and installing - vehicles with 8-cyl. FSI engine»(ref-289225-S28803055272008062700000)
3. On vehicles with 10-cyl. engine, perform the preparatory work described --> «Compressor, removing and installing - vehicles with 10-cyl. engine (Audi S8)»(ref-289225-S40754187942008062700000)
4. On vehicles with 12-cyl. engine, perform the preparatory work described --> «Compressor, removing from bracket and re-installing - vehicles with 12-cyl. engine»(ref-289225-S11543673622008062700000)

Scheme 113

1. Remove bolts - A -.
2. Disconnect refrigerant lines - B - and - C -.

Installation is carried out in the reverse order, when doing this note the following

1. Replace O-rings seals - D - and - E - , version.
2. Tighten bolts - B - to 25 Nm.

Note. Do not use the O-rings from the shipping caps that are installed on the connections of replacement compressor when installing lines. Coat O-ring seals lightly with refrigerant oil before installing --> Refrigerant circuit O-rings . Following attachment of refrigerant lines to compressor (and installation of compressor) check routing of lines. They must be inserted in holders provided and not make contact with other components.

1. Evacuate refrigerant circuit and recharge again. --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000)

A/C compressor, removing and installing (basic guidelines)

Note. Mark connector to A/C Compressor Regulator Valve N280 due to risk of interchange with connector to electric engine mount (if connectors are interchanged, no DTC is entered in DTC memory, however the evaporator may ice-up since the compressor is actuated continuously). Compressor as replacement part has different oil fill capacities, therefore note the exact part number --> 87 - AIR CONDITIONING . The reason for the different oil capacities in the compressor lies in the design of the compressor itself, note these oil capacities. Too much oil in the circuit leads to higher pressures and reduces cooling performance of the system. Too little oil may lead to lubrication problems in the compressor. Depending on compressor type ("6 SEU 14" , "7 SEU 16" or "7 SEU 17") different refrigerant oil fill capacities are designated for the refrigerant circuit --> 87 - AIR CONDITIONING

1. Drain refrigerant circuit: --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000)
2. Remove compressor from bracket --> «Removing compressor from bracket and installing in vehicles with 8-cyl. MPI engine»(ref-289225-S14195474132008062700000) .
3. On vehicles with 12-cyl. engine, perform the preparatory work described --> «Compressor, removing from bracket and re-installing - vehicles with 12-cyl. engine»(ref-289225-S11543673622008062700000)
4. Disconnect refrigerant lines from compressor --> «Refrigerant lines, disconnecting and connecting at compressor»(ref-289225-S01947645402008062700000) .

Installation is carried out in the reverse order, when doing this note the following

Before installing compressor: --> 87 - AIR CONDITIONING

1. Tightening torques --> «Removing compressor from bracket and installing in vehicles with 8-cyl. MPI engine»(ref-289225-S14195474132008062700000) and --> «Refrigerant lines, disconnecting and connecting at compressor»(ref-289225-S01947645402008062700000) .
2. Replace the O-ring seals on opened connection points

1. Start engine first after reconnecting refrigerant circuit.
2. If a new compressor has been installed or fresh refrigerant oil has been filled into the compressor before installing ribbed belt (e.g. after blowing through refrigerant circuit), the compressor must be turned by hand approx. 10 revolutions. This ensures that the compressor will not be damaged when engine is first started.
3. If possible start engine only with a filled refrigerant circuit.

Note. Different compressors, depending on country version, production time period and on engine --> A/C Refrigerant Circuit, servicing Coat O-ring seals lightly with refrigerant oil before installing --> Refrigerant circuit O-rings . Compressor is always driven by pulley (there is no magnetic clutch). The compressor has an "internal oil circuit" to ensure the compressor is not damaged when refrigerant circuit is empty. Prerequisite for the internal lubrication is residual refrigerant oil in compressor. The engine may only be started when the refrigerant circuit is installed correctly. If for example the refrigerant lines are not connected to the compressor and the engine is started then the compressor may be destroyed by the build-up of internal heat. An uncertain quantity of refrigerant oil remains in a removed compressor, therefore observe notes for replacing the compressor. --> 87 - AIR CONDITIONING A/C Compressor Regulator Valve N280 is not activated when the refrigerant circuit is empty and the compressor idles with the engine. As there is no refrigerant in the circuit the oil required to lubricate is not fed to the compressor. To prevent damage to the compressor the compressor is lubricated by an "internal oil circuit". If it is necessary to start the engine with a discharged refrigerant circuit: - Refrigerant circuit must be completely assembled. - At least one quarter of refrigerant oil specified for this refrigerant circuit must be in the compressor. - Engine speed should not exceed 2500 RPM. - Engine should only run as long as absolutely necessary

1. Note the following when starting engine for first time after filling refrigerant circuit
2. Start engine with compressor switched off ("Econ" mode set on MMI) and wait until idling speed stabilizes.
3. Open an instrument cluster vent.
4. Set temperature preselect for drivers and front passengers side to "Lo" on A/C front control head Climatronic Control Module J255.

1. Now, switch compressor on ("Auto" mode selected and "Econ" switched off) and allow engine to run for 5 minutes at idling speed.

Scheme 114

Note. Compressor is driven via a toothed gear and an drive shaft - B -. Compressor bracket, removing from engine and installing. --> 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB To remove the compressor on vehicles with an 8-cyl. FSI engine, refrigerant circuit must be drained and then both refrigerant lines must be removed from compressor --> Refrigerant lines, disconnecting and connecting at compressor and --> 87 - AIR CONDITIONING .

Special tools, testers and auxiliary items required

Scheme 115

1. Engine Support Bridge 10 - 222 A

Scheme 116

1. Adapter 10 - 222 A/21

Scheme 117

1. Used Oil Collection and Extraction Device V.A.G 1782

Scheme 118

1. Engine Support Supplement Set T40093

Removing

Scheme 119

1. Discharge refrigerant circuit --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000) .
2. Extract power-steering hydraulic oil from reservoir using Used Oil Collecting and Extracting Device V.A.G 1782.
3. Remove rear engine cover - arrows -.
4. Drain coolant --> «19 - ENGINE - COOLING SYSTEM»(ref-289203-S15357943982008062700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM «19 - ENGINE - COOLING SYSTEM»(ref-289204-S03664241582008062700000) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM «19 - COOLING SYSTEM»(ref-289206-S27114819052008062700000) for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB .

1. Remove front coolant pipe --> «19 - ENGINE - COOLING SYSTEM»(ref-289203-S15357943982008062700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM «19 - ENGINE - COOLING SYSTEM»(ref-289204-S03664241582008062700000) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM «19 - COOLING SYSTEM»(ref-289206-S27114819052008062700000) for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB .
2. Remove coolant pump --> «19 - ENGINE - COOLING SYSTEM»(ref-289203-S15357943982008062700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM «19 - ENGINE - COOLING SYSTEM»(ref-289204-S03664241582008062700000) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM «19 - COOLING SYSTEM»(ref-289206-S27114819052008062700000) for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB .

Scheme 120

1. Remove hydraulic fluid line bolt - arrow -.

Scheme 121

1. Remove oil dipstick - 10 - from guide tube.
2. Remove bolts - 2 - and - 5 -.
3. Disconnect electrical connectors - 1, 3, 4, 6, 8 - and free up wiring harness.
4. Remove Hall sensor - 9 -.

1. Remove crankcase ventilation hose - 7 - by pressing release buttons.
2. Lay wiring harness on engine.

Scheme 122

1. Remove bolt - 1 - and remove oil dipstick guide tube upward.
2. Remove bolts - 2 - and - 3 - and pull left coolant pipe up slightly.

Note. Ignore - items 4, 5 and arrows -.

Scheme 123

1. Remove rubber seal - 1 - and remove plenum chamber covers - 2 - and - 3 -.

Scheme 124

1. Remove tower brace rear bolts - 3 -.
2. Secure Adapter 10 - 222 A/21 without crossbeam to suspension strut towers.

1. The supports are marked for the left and right vehicle sides.
2. Center support point - 2 - of supports is attached to front bolts for suspension strut dome.
3. Adapters 10 - 222 A/21 are tightened using rear mounting bolts - 3 - for suspension strut dome.
4. Knurled-head screw - 1 - must be turned downward far enough so that supporting plate makes contact on suspension strut dome.

Scheme 125

1. Install crossbraces with 2 adapters T40093/6 on adapters 10 - 222 A/21.
2. Secure spindles 10 - 222 A/11 on engine lifting eyes.
3. Slightly pre-tension engine using spindles on engine support bridge.

Scheme 126

1. Remove left and right stabilizer mount bolts - 1 - and - 2 -.

Scheme 127

1. Remove bolts - 3 - and - 4 -.

Note. Ignore items - 1 and 2 - in illustration.

Scheme 128

1. Remove left and right engine mount bolts - arrows - evenly.
2. Remove engine carrier.

Scheme 129

Note. In order to collect escaping hydraulic fluid, lay a cloth under the separating point.

1. Remove banjo fitting - 2 -.

Note. Ignore items - 1, 3, 4 - in illustration.

Scheme 130

1. Disconnect electrical connection on engine bracket - 1 -.
2. Remove bolts - arrows - and remove engine support with engine bracket.

Scheme 131

1. Remove bolts - 1 and 2 -.
2. Disconnect refrigerant lines from A/C compressor --> «Refrigerant lines, disconnecting and connecting at compressor»(ref-289225-S01947645402008062700000) .

Note. To prevent dirt and moisture from entering, seal open lines and connections with clean plugs or protective caps.

Scheme 132

1. Counterhold compressor drive shaft - A - using an open-end wrench and turn compressor drive unit - B - in - direction of arrow C -.

Note. Compressor drive shaft - A - must not be turned. Compressor drive shaft - A - can be slid into drive wheel through boot - E - after loosening threaded connection.

Scheme 133

1. Remove electrical connection - 1 - for A/C Compressor Regulator Valve N280 out of bracket and disconnect it.
2. Remove bolt - arrows -.
3. Remove A/C compressor.

Installing

Scheme 134

Installation is done is reverse order, observe the following

1. Check whether alignment sleeves - F - are installed in compressor.

1. Tighten bolts - arrows -.

1. Torque specification: 25 Nm.

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

Note. Check refrigerant lines and their bracket for sufficient distances to other components.

1. Attach refrigerant lines --> «Refrigerant lines, disconnecting and connecting at compressor»(ref-289225-S01947645402008062700000) .

1. Before installing compressor drive shaft - A - , install compressor drive unit - B - on compressor by rotating 10 turns by hand in - direction of arrow C - in order to avoid damage to compressor when switching on for the first time.

Note. By rotating, refrigerant oil which has accumulated in the compressor compression chamber in the removed compressor or after adding fresh refrigerant oil (e.g. after blowing through the refrigerant circuit) is forced out of the compression chamber.

1. Counterhold compressor drive shaft - A - using an open-end wrench and turn compressor drive unit - B - in - direction of arrow D -.

1. Torque specification: 60 Nm.

Note. Compressor drive shaft - A - must not be turned when tightening. After installing, check installation position of grommet - E - on drive wheel.

1. Install engine support with left engine mount --> «10 - ENGINE - ASSEMBLY»(ref-289203-S09080036082008062700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 10 - ENGINE - ASSEMBLY for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM 10 - ENGINE - ASSEMBLY for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM «10 - ENGINE - ASSEMBLY»(ref-289206-S27923578852008062700000) for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB .
2. Install subframe and engine carrier --> «40 - FRONT SUSPENSION»(ref-289219-S31806228072008062700000) .
3. Install stabilizer --> «40 - FRONT SUSPENSION»(ref-289219-S31806228072008062700000) .
4. Install coolant pump --> «19 - ENGINE - COOLING SYSTEM»(ref-289203-S15357943982008062700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM «19 - ENGINE - COOLING SYSTEM»(ref-289204-S03664241582008062700000) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM «19 - COOLING SYSTEM»(ref-289206-S27114819052008062700000) for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB .

1. Install front and left coolant pipe --> «19 - ENGINE - COOLING SYSTEM»(ref-289203-S15357943982008062700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM «19 - ENGINE - COOLING SYSTEM»(ref-289204-S03664241582008062700000) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM «19 - COOLING SYSTEM»(ref-289206-S27114819052008062700000) for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB .
2. Fill coolant and bleed coolant circuit --> «19 - ENGINE - COOLING SYSTEM»(ref-289203-S15357943982008062700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM «19 - ENGINE - COOLING SYSTEM»(ref-289204-S03664241582008062700000) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM «19 - COOLING SYSTEM»(ref-289206-S27114819052008062700000) for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB .
3. Evacuate and fill refrigerant circuit --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000) .

Torque specification

Compressor, removing from bracket and re-installing - vehicles with 12-cyl. engine

Special tools, testers and auxiliary items required

Scheme 135

1. Hose clamps up to Ø 25 mm 3094

1. Discharge refrigerant circuit --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000) .
2. Bring lock carrier into service position --> «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-289206-S19139229562008062700000) .
3. Remove left front wheel.

Note. Secure brake discs using wheel bolts. Heed notes for removal and installation, as well as commissioning of compressor --> A/C compressor, removing and installing (basic guidelines)

1. Remove front part of wheel housing liner at front left --> «66 - EXTERIOR EQUIPMENT»(ref-289221-S23584739002008062700000) .

Scheme 136

1. Use hose clamp 3094 to clamp vane pump return hose.
2. Pull off return hose - 1 - from vane pump.

Note. Ignore - item 2 -.

Scheme 137

1. Press release buttons and pull both air guide hoses - arrows - at bottom off lower left air filter housing.

Scheme 138

1. Disconnect electrical harness connector - 3 - for Mass Air Flow (MAF) Sensor 2 G246.
2. Disconnect hose - 2 - from air guide hose.
3. Disconnect air guide hose - 1 - at intake manifold.
4. Remove bolts - arrows -.

1. Remove left upper section of air filter housing.

Scheme 139

1. Remove air duct - 1 -.
2. Remove bolts - arrows -.
3. Remove left lower section of air filter housing.

Note. Place a rag beneath hydraulic pipe to catch escaping hydraulic fluid.

1. Remove hydraulic pressure pipe - 2 - at vane pump and put down on top of longitudinal member.

Note. Ignore - item 1 -.

Scheme 140

1. Carefully remove engine cover upward starting at rear and in center - arrows 1 -.
2. Then pull engine cover forward off intake manifold - arrows 2 -.

Scheme 141

1. Move tensioner in - direction of arrow - to release tension on ribbed belt.
2. Remove ribbed belt from vane pump pulley, release tensioner.

Note. Ribbed belt remains in position on other pulleys.

Scheme 142

1. Remove belt pulley for power steering vane pump - arrows -.

Scheme 143

1. Unscrew bolts - arrows - and remove vane pump.

Scheme 144

1. Remove bracket for vane pump - arrows -.

Scheme 145

Note. Do not bend or stretch lines or hoses as A/C compressor and refrigerant lines/hoses may be damaged.

1. Disconnect refrigerant lines from A/C compressor - arrows - --> «Refrigerant lines, disconnecting and connecting at compressor»(ref-289225-S01947645402008062700000) .
2. Seal openings in A/C compressor.

Scheme 146

1. Disconnect electrical connector - 1 -.
2. Unscrew bolts - arrows - and remove A/C compressor.

Installation is carried out in the reverse order, when doing this note the following

Note. Heed notes for removal and installation, as well as commissioning of compressor --> A/C compressor, removing and installing (basic guidelines) Replace seals and O-rings. Note alignment bushings. Secure all hose connections with hose clamps used in series production .

1. Install vane pump --> «48 - STEERING»(ref-289219-S07076849872008062700000) .
2. Install ribbed belt --> «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-289206-S19139229562008062700000) .
3. Install lock carrier with attachments --> «50 - BODY - FRONT»(ref-289221-S10914933722008062700000) .
4. Fill refrigerant circuit --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000) .

1. Check headlamp adjustment 4E.

Compressor, removing and installing - vehicles with 10-cyl. engine (Audi S8)

Note. Compressor is driven via a toothed gear and an drive shaft - B -. Compressor bracket, removing from engine and installing. --> 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB To remove the compressor on vehicles with an 10-cyl. engine, refrigerant circuit must be drained and then both refrigerant lines must be removed from compressor --> Refrigerant lines, disconnecting and connecting at compressor and --> 87 - AIR CONDITIONING .

Special tools, testers and auxiliary items required

1. Engine Support Bridge 10 - 222 A
2. Adapter 10 - 222 A/21
3. Used Oil Collection and Extraction Device V.A.G 1782
4. Hose clamp pliers V.A.G 1921

1. Spring type clip pliers VAS 5024A

Removing

1. Discharge refrigerant circuit --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000) .
2. Drain coolant --> «19 - ENGINE - COOLING SYSTEM»(ref-289203-S15357943982008062700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM «19 - ENGINE - COOLING SYSTEM»(ref-289204-S03664241582008062700000) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM «19 - COOLING SYSTEM»(ref-289206-S27114819052008062700000) for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB .

Scheme 147

1. Remove engine cover at front - 1 - and at rear - 2 - - arrows -.
2. Remove left air filter housing --> «24 - MULTIPORT FUEL INJECTION (MFI)»(ref-289205-S08445194072008062700000) for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BVJ 24 MULTIPORT FUEL INJECTION (MFI) for 4.2 LITER V8 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): BFM «24 - MULTIPORT FUEL INJECTION (MFI)»(ref-289209-S01888638322008062700000) for 5.2 LITER 10-CYL. 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BSM «24 FUEL INJECTION SYSTEM»(ref-289212-S05463344962008062700000) for 6.0 LITER 12-CYL. 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BSB .
3. Extract hydraulic oil for power-steering from reservoir using old oil collecting and extracting device V.A.G 1782 --> «48 - STEERING»(ref-289219-S07076849872008062700000) .

Scheme 148

1. Remove bolts - 2 - and - 3 -.
2. Pull guide tube for oil dipstick off upward - arrow -.

Note. Ignore - item 1 - and - item 4 -.

1. Remove rubber seal - 1 - and remove plenum chamber covers - 2 - and - 3 -.

Scheme 149

1. Remove bracket for refrigerant line from left suspension strut dome - arrow -.

Scheme 150

1. Remove clip - 1 -.
2. Disengage fuel line - 2 - and line to EVAP canister from bracket at right suspension strut dome.

1. Remove rear bolts - 3 - for suspension strut.
2. Secure engine support bridge 10 - 222 A with adapters 10 - 222 A/21 to suspension strut domes without cross-beam.

1. The supports are marked for the left and right vehicle sides.
2. Center support point - 2 - of supports is attached to front bolts for suspension strut dome.
3. Adapters 10 - 222 A/21 are tightened using rear mounting bolts - 3 - for suspension strut dome.
4. Knurled-head screw - 1 - must be turned downward far enough so that supporting plate makes contact on suspension strut dome.

Scheme 151

1. Secure spindles of engine support bridge 10 - 222 A to rear engine lifting eyelets.
2. Pre-tension engine slightly using spindles on engine support bridge.

Scheme 152

1. Remove bolts - arrows - uniformly at left and right.
2. Remove stabilizer --> «40 - FRONT SUSPENSION»(ref-289219-S31806228072008062700000) .

Scheme 153

1. Remove bolts - 1 through 3 - on left and right and remove engine carrier.

Scheme 154

1. Remove nut - 1 - and bolt - 6 - and pull coolant pipe at lower left off coolant hoses - 2 through 5 -.

Scheme 155

1. Disconnect electrical harness connector - 1 - (mark connector to avoid possible interchange).
2. Remove coolant hose - 2 -.
3. Remove bolts - arrows -.
4. Swing After-Run Coolant Pump V51 and disconnect from coolant hose - 3 -.

Scheme 156

1. Disconnect coolant hose - 1 - from radiator.

Note. Ignore - item 2 -.

Scheme 157

1. Disconnect electrical harness connector - arrow - at Engine Coolant Temperature (ECT) Sensor (on Radiator) G83.

Scheme 158

1. Remove coolant hose - 2 - from coolant thermostat housing at bottom.
2. Remove bolts - arrows -.
3. Remove coolant thermostat housing and remove coolant hose - 1 - from coolant thermostat housing at top.

Note. Do not bend, kink or stretch lines or hoses as refrigerant lines and refrigerant hoses may be damaged.

1. Remove bolts - 1 - and - 2 -.
2. Disconnect 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).

Scheme 159

1. Disconnect electrical harness connector - 2 - and remove engine mount from engine support.

Scheme 160

1. Unscrew bolts - arrows - and remove engine support.

Scheme 161

1. Remove supply hose.
2. Remove pressure line banjo fitting - 2 -.

Scheme 162

1. Remove coolant hose - arrows - and place coolant pipe upward.

1. Counterhold compressor drive shaft - A - using an open-end wrench and turn compressor drive unit - B - in - direction of arrow C -.

Note. Compressor drive shaft - A - must not be turned. Compressor drive shaft - A - can be slid into drive wheel through boot - E - after loosening threaded connection.

Scheme 163

1. Disconnect electrical harness connector - 1 - to A/C Compressor Regulator Valve N280 (mark connector to prevent possible interchange with connector to engine mount).
2. Remove bolts - arrows -.
3. Remove A/C compressor.

Installing

Installation is done is reverse order, observe the following

Note. Secure all hose connections with hose clamps used in series production . An uncertain quantity of refrigerant oil remains in a removed compressor, therefore observe notes for replacing the compressor. --> 87 - AIR CONDITIONING

1. Install compressor drive shaft - A - (into drive wheel of engine) and check seating as well as corresponding boot - E - --> «Compressor drive shaft, loosening and tightening»(ref-289225-S38025576562008062700000) .

1. Thoroughly clean contact surfaces at bracket (and contact surfaces at compressor), if necessary remove bushings - F - from compressor bracket or compressor.
2. Check connections of compressor and of refrigerant lines for damage or soiling --> «Refrigerant lines, disconnecting and connecting at compressor»(ref-289225-S01947645402008062700000) .
3. Make sure bushings - F - are inserted in A/C compressor or in bracket.

Note. Ensure bushings - F - are properly seated and contact surfaces are clean. Sockets installed incorrectly and dirty or damaged contact surfaces can lead to alignment irregularities between the compressor and engine. Alignment irregularities over operating time lead to damage to input shaft or compressor.

1. Attach compressor to bracket with bolts - D - and washers - E - (tightening torque 25 Nm).
2. Attach refrigerant lines to compressor --> «Refrigerant lines, disconnecting and connecting at compressor»(ref-289225-S01947645402008062700000) (tightening torque of bolts - A - 25 Nm), dimensions of O-rings - B - and - C - and further notes --> «Refrigerant lines, disconnecting and connecting at compressor»(ref-289225-S01947645402008062700000) .

1. Before screwing in drive shaft, rotate compressor 10 rotations by hand (after installing) via compressor drive unit - B - in direction of arrow - C - (to prevent damage to compressor with first switch-on).

Note. By rotating, refrigerant oil which has accumulated in the compressor compression chamber in the removed compressor or after adding fresh refrigerant oil (e.g. after blowing through the refrigerant circuit) is forced out of the compression chamber.

1. Tighten drive shaft, hold compressor drive shaft - A - in place using open-end wrench and turn compressor drive unit - B - in direction of arrow - D - (tightening torque 60 Nm).

Note. Drive shaft - A - must not be turned. After installing drive shaft - A - , check installation position of boot - E -. Boot - E - is secured against slipping by clamp on power steering pump flange

1. Install engine support --> «10 - ENGINE - ASSEMBLY»(ref-289203-S09080036082008062700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 10 - ENGINE - ASSEMBLY for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM 10 - ENGINE - ASSEMBLY for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM «10 - ENGINE - ASSEMBLY»(ref-289206-S27923578852008062700000) for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB .
2. Install coolant thermostat housing --> «19 - ENGINE - COOLING SYSTEM»(ref-289203-S15357943982008062700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM «19 - ENGINE - COOLING SYSTEM»(ref-289204-S03664241582008062700000) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM «19 - COOLING SYSTEM»(ref-289206-S27114819052008062700000) for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB .
3. Install engine carrier --> «10 - ENGINE - ASSEMBLY»(ref-289203-S09080036082008062700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 10 - ENGINE - ASSEMBLY for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM 10 - ENGINE - ASSEMBLY for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM «10 - ENGINE - ASSEMBLY»(ref-289206-S27923578852008062700000) for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB .
4. Install stabilizer --> «40 - FRONT SUSPENSION»(ref-289219-S31806228072008062700000) .

1. Install left air filter housing --> «24 - MULTIPORT FUEL INJECTION (MFI)»(ref-289205-S08445194072008062700000) for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BVJ 24 MULTIPORT FUEL INJECTION (MFI) for 4.2 LITER V8 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): BFM «24 - MULTIPORT FUEL INJECTION (MFI)»(ref-289209-S01888638322008062700000) for 5.2 LITER 10-CYL. 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BSM «24 FUEL INJECTION SYSTEM»(ref-289212-S05463344962008062700000) for 6.0 LITER 12-CYL. 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BSB .
2. Fill hydraulic fluid into power steering reservoir --> «48 - STEERING»(ref-289219-S07076849872008062700000)
3. Fill up coolant --> «19 - ENGINE - COOLING SYSTEM»(ref-289203-S15357943982008062700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM «19 - ENGINE - COOLING SYSTEM»(ref-289204-S03664241582008062700000) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM «19 - COOLING SYSTEM»(ref-289206-S27114819052008062700000) for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB .
4. Re-install remaining components removed.

1. Empty and fill refrigerant circuit. --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000)
2. Check DTC memory of Climatronic Control Module J255 and erase DTCs displayed if necessary. Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function.
3. Pay attention to notes concerning first operation of A/C system after installing compressor (installing compressor)

Compressor drive unit, checking, replacing

Note. If drive plate overload protection activates, check compressor for ease of motion before replacing the drive unit. If compressor creates friction, replace it completely.

Scheme 164

1 - Compressor drive unit

1. Check, drive shaft must be seated free of play in splines of engine drive wheel with thread tightened --> «Compressor drive shaft, removing and installing»(ref-289225-S24212533462008062700000) .
2. Tightening torque 60 Nm
3. Loosening and tightening --> «Compressor drive shaft, loosening and tightening»(ref-289225-S38025576562008062700000)
4. Removing and installing --> «Compressor drive shaft, removing and installing»(ref-289225-S24212533462008062700000)

1. Lubricate splines of engine drive wheel using G 000 100 clutch splining grease .

2 - Hex socket head bolt

1. Tightening torque 10 Nm

3 - Drive plate

1. With overload safeguard, triggers when torque is too-high (e.g. compressor produces friction) and drive shaft runs freely without driving the compressor.
2. Run-out, checking and adjusting --> «Drive plate with overload protection, checking run-out and adjusting»(ref-289225-S28879057872008062700000) .
3. Removing and installing --> «Drive plate with overload protection, removing and installing»(ref-289225-S27234834422008062700000)

4 - Drive plate

1. Attached to compressor input shaft
2. With overload safeguard, triggers when torque is too-high (e.g. compressor produces friction) and drive shaft runs freely without driving the compressor.
3. Tightening torque 30 Nm
4. Removing and installing --> «Drive plate, removing from compressor and installing»(ref-289225-S38075963832008062700000)

5 - Rubber element

1. Decouples drive unit, dampens vibrations and noises.
2. When installing, coat rubber element lightly e.g. using soapy water (as sliding compound).
3. Removing and installing --> «Drive plate, removing from compressor and installing»(ref-289225-S38075963832008062700000)

6 - Spacer

1. The original disc must be installed
2. Dimensions: 17.5 x 10 x 3 mm

7 - Circlip

1. Replace
2. Install on proper side (level side to compressor)
3. Removing and installing --> «Drive plate with roller bearing, removing and installing»(ref-289225-S31581665702008062700000)

8 - Drive plate

1. With roller bearing.
2. Removing and installing --> «Drive plate with roller bearing, removing and installing»(ref-289225-S31581665702008062700000)
3. Clean compressor flange before sliding on drive plate.

9 - Compressor

1. Different versions may be installed, depending on engine version and country version of vehicle.

Compressor drive shaft, loosening

1. Remove components that prevent access to drive shaft --> «Compressor, removing and installing - vehicles with 10-cyl. engine (Audi S8)»(ref-289225-S40754187942008062700000) (Compressor, removing and installing on vehicles with 10-cyl. engine) or --> «A/C compressor, removing and installing - vehicles with 8-cyl. FSI engine»(ref-289225-S28803055272008062700000) (Compressor, removing and installing on vehicles with 8-cyl. FSI engine)

1. Hold compressor drive shaft - A - in place using an open-end wrench and turn compressor drive unit - B - in direction of arrow - C -.

Note. Drive shaft - A - must not be turned. Drive shaft - A - can be slid into drive wheel through the boot - E - after loosening threaded connection. After installing drive shaft - A - , check installation position of boot - E -.

1. Remove compressor --> «Compressor, removing and installing - vehicles with 10-cyl. engine (Audi S8)»(ref-289225-S40754187942008062700000) .

1. Remove boot - A
2. Remove drive shaft - B - from splines of drive pinion - C

Installation is carried out in the reverse order, when doing this note the following

1. Check drive shaft - B - , splines must show no traces of wear and must be seated free of play in splines of drive wheel - C -.
2. Coat splines of drive shaft - B - using clutch splining grease G 000 100 before installing .

1. Insert drive shaft - B - before installing compressor and slide it into drive wheel - C - up to stop.
2. After installing compressor, check installation position of boot - A -.

Boot - A - is secured against slipping by a clamp on power steering pump flange .

Drive plate with overload protection, removing and installing

1. Remove compressor --> «Compressor, removing and installing - vehicles with 10-cyl. engine (Audi S8)»(ref-289225-S40754187942008062700000) .

Scheme 165

1. Remove bolts - A -.

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

Attaching

1. Position drive plate with overload safeguard - B - onto drive plate - C -.
2. Insert bolts - A - and tighten them by hand.
3. Check run-out of drive plate - B - --> «Drive plate with overload protection, checking run-out and adjusting»(ref-289225-S28879057872008062700000) .
4. Tighten bolts - A - (tightening torque 10 Nm).

1. Check run-out of drive plate - B - again --> «Drive plate with overload protection, checking run-out and adjusting»(ref-289225-S28879057872008062700000) .

Drive plate with overload protection, checking run-out and adjusting

1. Remove compressor --> «Compressor, removing and installing - vehicles with 10-cyl. engine (Audi S8)»(ref-289225-S40754187942008062700000) .

Scheme 166

1. Clean flange at drive plate - A
2. Secure a dial gauge - B - using a dial gauge holder - C - (e.g. using dial gauge holder VW 387) on compressor.
3. Set probe of dial gauge - D - on flange of drive plate - A - with a pre-tension of approx. 1.0 mm.
4. Turn compressor drive unit - E - several rotations.

Specification: Run-out deviation is less than 0.21 mm (run-out of dial indicator, difference between smallest and largest measured value 0.2 mm maximum)

1. If run-out deviation is greater than 0.2 mm, loosen bolts on drive plate --> «Drive plate with overload protection, removing and installing»(ref-289225-S27234834422008062700000) and re-adjust drive plate.

Drive plate, removing from compressor and installing

1. Remove drive plate with overload safeguard --> «Drive plate with overload protection, removing and installing»(ref-289225-S27234834422008062700000) .

Scheme 167

1. Loosen 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 -.

Note. Depending on compressor version (compressor shaft varies), a ring wrench or e.g. a socket wrench T10001/10 from shock absorber set T10001 or retainer 3079 must be used to counterhold.

Scheme 168

1. When installing, coat rubber element - B - lightly e.g. using soapy water (as sliding compound).
2. Insert rubber element - B - in drive plate - A - according to illustration.
3. Insert drive plate - A - with rubber elements - B - onto drive plate - C - according to illustration until it makes contact with 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.

1. Screw drive plate - C - onto compressor shaft - A - by rotating in direction of arrow - E -.
2. Tighten drive plate - C - by turning using a conventional band wrench (with webbed band) in - direction of arrow E - to 30 Nm, counterhold compressor shaft - A - using a retainer - B - on compressor shaft - A -.

Note. Depending on compressor version (compressor shaft varies), a ring wrench or e.g. a socket wrench T10001/10 from shock absorber set T10001 or retainer 3079 must be used to counterhold.

Drive plate with roller bearing, removing and installing

1. Remove drive plate from compressor shaft --> «Drive plate, removing from compressor and installing»(ref-289225-S38075963832008062700000) .

Scheme 169

1. Remove circlip - A -.
2. Remove drive plate - B -.

Note. Replace circlip - A -. Clean 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 proper side, the side with beveled insertion edge - C - faces away from compressor (install flat side facing compressor).

Detaching refrigerant lines from condenser/re-attaching

Note. Condenser is available in different versions (e.g. with and without power steering oil cooler) depending on vehicle model.

Detaching

1. Drain refrigerant circuit: --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000)
2. Remove noise insulation: --> «50 - BODY - FRONT»(ref-289221-S10914933722008062700000)
3. Remove front bumper: --> «63 - BUMPERS»(ref-289221-S15322224352008062700000)

Scheme 170

1. Remove bolts - A - (tightening torque 10 Nm).
2. Detach refrigerant lines from condenser.

Note. Seal open lines and connections at condenser with suitable caps (to prevent ingress of dirt and moisture).

Installation is carried out in the reverse order, when doing this note the following

1. Replace O-ring seals - B - and - C -. Version.

Note. Coat O-ring seals lightly with refrigerant oil before installing --> Refrigerant circuit O-rings .

1. Following attachment, check routing of refrigerant lines. They must be inserted in holders provided and not make contact with other components.
2. Evacuate and re-charge refrigerant circuit. --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000)

Condenser, removing and installing

Note. Condenser is available in different versions (e.g. with and without power steering oil cooler) depending on vehicle model. Removed condenser contains refrigerant oil which must be restored to the refrigerant system. --> 87 - AIR CONDITIONING

1. Drain refrigerant circuit: --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000)

1. Clamp both hoses to power steering oil cooler - D - and - E - e.g. using one hose clamp 3093 each and remove from condenser.
2. Disconnect refrigerant lines from condenser --> «Detaching refrigerant lines from condenser/re-attaching»(ref-289225-S05971395372008062700000) .

Scheme 171

1. Disconnect connector - A - from High Pressure Sensor G65.
2. Remove bolts - B - and - C - (tightening torque 5 Nm).
3. Remove condenser downward.

Install in reverse order of removal.

Restrictorss, removing and installing

Note. This vehicle is only to be equipped with a red colored restrictors (depending on manufacturer, color may also tend towards orange) --> 87 - AIR CONDITIONING Differently colored replacement restrictor (restrictors "yellow" colored, diameter of bore/constriction 1.54 mm, restrictors "red" colored, diameter of bore/constriction 1.42 mm), therefore heed assignment (different matching of refrigerant circuit). Refrigerant lines from evaporator to compressor/reservoir are available in different versions, depending on vehicle model.

1. Drain refrigerant circuit: --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000)

Scheme 172

1. Disconnect refrigerant line at threaded connection - A - (seal open connections).
2. Pull restrictor - B - out of refrigerant line using needle nose pliers.

Note. Only install restrictors of same type; restrictors with different colors have different bore diameters

1. Check O-ring - C - (7.5 mm; 1.5 mm) for correct seating in groove.
2. Coat O-ring (of restrictor and at threaded connection) lightly with refrigerant oil before installation --> «Refrigerant circuit O-rings»(ref-289225-S00601433862008062700000) .
3. Install restrictor - B - accurate to side (arrow on restrictor faces evaporator).
4. Check seating of restrictor, it must seat in refrigerant line free of play

1. Replace O-ring - D - (11.1 mm; 1.8 mm).
2. Install refrigerant lines such that they are not strained.
3. Tighten threaded connection - A - to 15 Nm.

Note. Check position of refrigerant lines after tightening union. Lines must not make contact with other components.

1. Evacuate and re-charge refrigerant circuit. --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000)

Accumulator, removing and installing

Note. Depending on vehicle model, accumulator is available in different versions and for different component locations.

1. Evacuate refrigerant circuit: --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000)
2. Remove front bumper. --> «63 - BUMPERS»(ref-289221-S15322224352008062700000)
3. Bring lock carrier to service position. --> «50 - BODY - FRONT»(ref-289221-S10914933722008062700000)
4. If necessary, remove charge air cooler or secondary air injection pump motor (not required on all vehicles). --> «24 - MULTIPORT FUEL INJECTION (MFI)»(ref-289205-S08445194072008062700000) for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BVJ 24 MULTIPORT FUEL INJECTION (MFI) for 4.2 LITER V8 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): BFM «24 - MULTIPORT FUEL INJECTION (MFI)»(ref-289209-S01888638322008062700000) for 5.2 LITER 10-CYL. 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BSM «24 FUEL INJECTION SYSTEM»(ref-289212-S05463344962008062700000) for 6.0 LITER 12-CYL. 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BSB .

Scheme 173

1. Remove bolts - A - and disconnect refrigerant lines - B - and - C -.
2. Remove bolts - D -.
3. Remove accumulator.

Note. Seal open line connections. Attachment of refrigerant lines differs depending on engine version. Keep accumulator closed as long as possible; only remove caps immediately prior to installation (accumulator contains a desiccant bag which soon becomes saturated with moisture and thus unusable when accumulator is open). Removed accumulator contains refrigerant oil which must be restored to refrigerant circuit. --> 87 - AIR CONDITIONING

Installation is carried out in the reverse order, when doing this note the following

Before installing accumulator: --> 87 - AIR CONDITIONING

Note. Connection at accumulator can be marked with "IN" (from evaporator) and "OUT" (to compressor). Accumulator removed contains refrigerant oil which must be returned to refrigerant circuit (with new reservoir). Adjustment of oil quantity depends on nature of complaint. If the accumulator was damaged, e.g. during an accident (no refrigerant escaped, no moisture or dirt entered refrigerant circuit), A/C system can be serviced without the need for extensive repair work by weighing old and new accumulator. Pour refrigerant oil into new accumulator until it weighs the same as the reservoir removed. If an indeterminate amount of refrigerant oil has escaped or dirt and moisture have entered into refrigerant circuit, it must be cleaned using compressed air and nitrogen. --> 87 - AIR CONDITIONING

1. Replace O-rings - E -.

Note. Coat O-ring seals lightly with refrigerant oil before installing --> Refrigerant circuit O-rings .

1. Insert refrigerant lines - B - and - C - in accumulator free of tension. In doing so, pay attention to correct assignment of connections.
2. Install bolts - D - and tighten (tightening torque 10 Nm).
3. Mount refrigerant line on accumulator using bolt - A - (tightening torque 10 Nm).
4. Re-install remaining components removed.

1. Evacuate and re-charge refrigerant circuit. --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000)

Disconnecting

1. Drain refrigerant circuit: --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000)
2. Remove brake master cylinder and brake booster. --> «47 - BRAKES - HYDRAULIC COMPONENTS»(ref-289218-S12193944372008062700000)

Scheme 174

1. Disconnect refrigerant lines at suspension strut dome by removing bolt - A -.

Scheme 175

1. Remove socket head bolt - A - (tightening torque 25 Nm).
2. Disconnect refrigerant lines - B - and - C - from evaporator and seal open connections.

Note. To seal open connections on evaporator and lines, use e.g. cap from replacement evaporator to prevent ingress of dirt and moisture.

Connecting

Installation is carried out in the reverse order, when doing this note the following

Scheme 176

1. Replace O-rings - A - and - B -. Version.

Note. Coat O-ring seals lightly with refrigerant oil before installing --> Refrigerant circuit O-rings .

1. Install refrigerant lines such that they are not strained.

Scheme 177

1. After securing refrigerant lines and installing brake master cylinder, check whether lines are guided properly - A -.
2. Check position of refrigerant lines with respect to evaporator.
3. Re-install remaining components removed.
4. Evacuate and re-charge refrigerant circuit. --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000)

1. Drain refrigerant circuit: --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000)
2. Remove cover with recirculation flap --> «Cover with recirculated-air flap, removing and installing»(ref-289225-S30509580512008062700000) .
3. Take out Fresh Air Blower V2 --> «Fresh Air Blower V2 , removing and installing»(ref-289225-S24370298332008062700000) .

Scheme 178

1. Remove bolts - A -.
2. Remove bolt - C - and remove appropriate bracket for refrigerant lines.
3. Remove bolt - B - together with bracket for refrigerant lines.
4. Remove evaporator cover - D -.

1. Disconnect refrigerant lines from evaporator connection --> «Refrigerant lines, disconnecting from evaporator connection and connecting»(ref-289225-S03941563262008062700000) .

Scheme 179

1. Remove bolts - A -.
2. Remove connecting pipe - B -.
3. Remove evaporator.

Installation is carried out in the reverse order, when doing this note the following

Before installing evaporator: --> 87 - AIR CONDITIONING

1. Before installing evaporator, check holes - A - of evaporator drain for dirt, clean if necessary.

1. Replace O-rings - C - and - D - between connecting pipe in A/C unit - B - and to evaporator - E - , version.

Note. Coat O-ring seals lightly with refrigerant oil before installing --> Refrigerant circuit O-rings .

1. Install bolts - A - (tightening torque 5 Nm).

Note. Make sure O-rings - C - and - D - are seated properly in groove in connecting lines to evaporator - E -. Make sure grommet - B - is properly seated to A/C unit and at connecting pipe for evaporator - A -. Removed evaporator contains refrigerant oil which must be restored to refrigerant circuit. --> 87 - AIR CONDITIONING

1. Re-install remaining components removed.
2. Evacuate and re-charge refrigerant circuit. --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000)

Heating and A/C unit, removing and installing

Special tools, testers and other items required

1. Hose clamps 3093 bow. 3094
2. Cooling system tester V.A.G 1274 (and corresponding adapter)
3. Compressed air gun, commercially available

Note. On removal, note down bolt lengths and assignment for re-installation. 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.

1. Drain refrigerant circuit: --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000)
2. Switch ignition on.
3. Move power seats to rearmost position.
4. Switch off ignition.

1. Remove dust and pollen filter --> «Dust and pollen filter, removing and installing»(ref-289225-S02097241612008062700000) .
2. Remove E-box cover and engine control module. --> «97 - WIRING»(ref-289227-S18739568652008062700000)
3. Remove dome brace with reinforcement to cowl panel trim --> «40 - FRONT SUSPENSION»(ref-289219-S31806228072008062700000) .
4. Remove windshield wiper completely --> «92 - WINDSHIELD WIPER AND WASHER SYSTEM»(ref-289227-S11612981612008062700000) .

1. Remove pump valve unit --> «Pump/valve unit, removing and installing»(ref-289225-S19938788502008062700000) .
2. Protect driver and passenger seat using seat cover.
3. Disconnect negative terminal clamp from Battery A. --> «27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(ref-289227-S36040774962008062700000)

Note. Before disconnecting Battery A , obtain anti-theft radio security code if necessary. On vehicles with electrically adjustable seats, move the seats back as far as possible before disconnecting the Battery A.

1. Remove dash panel complete with dash panel cross member. --> «70 - INTERIOR TRIM»(ref-289222-S30170627502008062700000)
2. Remove brake master cylinder and brake booster. --> «47 - BRAKES - HYDRAULIC COMPONENTS»(ref-289218-S12193944372008062700000)
3. Remove complete foot pedal assembly with mounting bracket. --> «46 - BRAKES - MECHANICAL COMPONENTS»(ref-289218-S25306293062008062700000)
4. Disconnect refrigerant lines from evaporator connection --> «Refrigerant lines, disconnecting from evaporator connection and connecting»(ref-289225-S03941563262008062700000) .

1. Remove Rotation Rate Sensor G202 --> «45 - ANTI-LOCK BRAKE SYSTEM»(ref-289218-S14499523772008062700000)

Scheme 180

1. Remove brackets - A - and - B - (depending on A/C unit version, only brackets - B - or - A - are installed).
2. Remove air guides to footwell vents.
3. Disconnect evaporator drain hoses from heating and A/C unit --> «Evaporator drain hose, removing, checking and installing»(ref-289225-S28528887042008062700000) .
4. Disconnect harness connectors to heating and A/C unit.

Scheme 181

1. Remove bolts - A -.
2. Remove bolts - B -.
3. Remove A/C unit toward vehicle interior.

Installation is carried out in the reverse order, when doing this note the following

Scheme 182

1. Replace seal - A - between plenum chamber and A/C unit.

Note. Check other seals, replace if necessary Connect coolant hoses to heater core accurate to side --> Pump/valve unit, removing and installing . Secure all hose connections with standard hose clamps or clips as used in series production, or approved replacement parts When inserting A/C unit, make sure that wiring to actuators (in plenum chamber) and seal - A - is not jammed or damaged by studs.

Scheme 183

1. Check damper element - A - for proper seating.
2. After installation, check grommet between engine compartment and plenum chamber for proper seating.

Scheme 184

1. Seal 4 bolts - A - (left and right) in plenum chamber (e.g. using Terolan D 511 500 A2 ).
2. Check the evaporator drain hoses for proper seating --> «Evaporator drain hose, removing, checking and installing»(ref-289225-S28528887042008062700000) .

Scheme 185

1. Before installing instrument panel, check foam seals - A - to - D - , replace damaged seals if necessary.
2. Install removed components, except drivers storage compartment and glove compartment, in reverse order.
3. Check coolant hoses to heater cores are secured --> «Left (drivers side) heater core, removing and installing»(ref-289225-S42140079472008062700000) .
4. Bleed coolant circuit (connect 2-pin harness connector to pump valve unit only after bleeding coolant circuit --> «Pump/valve unit, removing and installing»(ref-289225-S19938788502008062700000) and). --> «19 - ENGINE - COOLING SYSTEM»(ref-289203-S15357943982008062700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM «19 - ENGINE - COOLING SYSTEM»(ref-289204-S03664241582008062700000) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM «19 - COOLING SYSTEM»(ref-289206-S27114819052008062700000) for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB

1. Before installing drivers storage compartment and glove compartment, check cooling system for leaks, paying particular attention to connection between coolant lines and heater cores --> «Left (drivers side) heater core, removing and installing»(ref-289225-S42140079472008062700000) . --> «19 - ENGINE - COOLING SYSTEM»(ref-289203-S15357943982008062700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM «19 - ENGINE - COOLING SYSTEM»(ref-289204-S03664241582008062700000) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSM «19 - COOLING SYSTEM»(ref-289206-S27114819052008062700000) for 6.0 LITER 12-CYL. 4V ENGINE MECHANICAL, ENGINE CODE(S): BSB
2. Install glove compartment, drivers storage compartment and remaining components removed.
3. Evacuate and re-charge refrigerant circuit. --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000)

Covers in plenum chamber, fresh-air blower and evaporator, removing and installing

Note. A/C unit may only be removed with refrigerant circuit discharged, take vehicle to A/C system service point workshop if necessary. Heating and A/C unit, removing and installing --> Heating and A/C unit, removing and installing

Scheme 186

1 - Oval head self-tapping screw

2 - Cover

3 - Screw

4 - Air Flow Flap Motor V71

1. With Right Center Vent Motor Position Sensor G113
2. Removing and installing --> «Air Flow Flap Motor V71 with Back Pressure Flap Motor Position Sensor G113 , removing and installing»(ref-289225-S28604062512008062700000)

5 - Connecting element

1. Mark before removing (risk of interchange)
2. Heed assignment (code number "063")

6 - Oval head self-tapping screw

7 - Air intake shroud

1. Removing and installing --> «Intake housing with air flow flap, removing and installing»(ref-289225-S35130398122008062700000)
2. Disassembling and assembling «Disassembling and assembling air intake shroud»(ref-289225-S21854330372009021600000)
3. Sealing connections «Sealing connection of covers»(ref-289225-S42223580982009021600000)

8 - Air flow flaps

1. Removing from intake housing «Disassembling and assembling air intake shroud»(ref-289225-S21854330372009021600000)

9 - Bracket

10 - Oval head self-tapping screw

11 - Oval head self-tapping screw

12 - Ring for air guide

1. Left side

13 - Air guide for fresh-air blower

14 - Ring for air guide

1. Right side

15 - Fresh Air Intake Duct Temperature Sensor G89

1. Removing and installing --> «Fresh Air Intake Duct Temperature Sensor G89 removing and installing»(ref-289225-S40864103962008062700000)

16 - Bracket for fresh-air blower

17 - Screw

18 - Cover

1. Seal connection between A/C unit and cover using black silicone adhesive sealant D 176 001 A3 --> «Recirculation Flap Motor V113 removing and installing»(ref-289225-S24887340242008062700000) .
2. As of 12.03, introduction of a modified cover for actuator (with 4 instead of 2 bolt points), a suitably adapted cover with recirculated-air flap and a wiring harness with modified grommet at wiring harness to actuator for recirculated-air flap is planned (gradual introduction).

19 - Recirculation Flap Motor V113

1. With Right Center Vent Motor Position Sensor G143
2. Removing and installing --> «Recirculation Flap Motor V113 removing and installing»(ref-289225-S24887340242008062700000)

20 - Connecting element

1. Mark before removing (risk of interchange)
2. Heed assignment (code number "064")

21 - Cover

1. Removing and installing --> «Cover with recirculated-air flap, removing and installing»(ref-289225-S30509580512008062700000)
2. Disassembling and assembling «Disassembling and assembling cover»(ref-289225-S35255463892009021600000)
3. Sealing connections «Sealing connection of covers»(ref-289225-S42223580982009021600000)
4. Removing recirculated-air flaps from cover «Disassembling and assembling cover»(ref-289225-S35255463892009021600000)

1. As of 12.03, introduction of a modified cover for actuator (with 4 instead of 2 bolt points), a suitably adapted cover with recirculated-air flap and a wiring harness with modified grommet at wiring harness to actuator for recirculated-air flap is planned (gradual introduction).

22 - Recirculated-air flaps

1. Removing from cover «Disassembling and assembling cover»(ref-289225-S35255463892009021600000)

23 - Oval head self-tapping screw

24 - Bracket

25 - Cover

1. For evaporator

26 - Fresh Air Blower V2

1. Removing and installing --> «Fresh Air Blower V2 , removing and installing»(ref-289225-S24370298332008062700000)

27 - Bracket

1. For wiring harness to Fresh Air Blower V2

28 - Fresh Air Blower Control Module J126

1. Removing and installing --> «Fresh Air Blower Control Module J126 , removing and installing»(ref-289225-S30661909472008062700000)

29 - Grommet

1. For sealing refrigerant line openings to evaporator (in A/C unit)

30 - Evaporator

1. Removing and installing --> «Evaporator, removing and installing»(ref-289225-S10206257522008062700000)
2. With refrigerant lines, disconnecting and reconnecting --> «Evaporator, removing and installing»(ref-289225-S10206257522008062700000) .
3. With seal to A/C unit housing

31 - Drip tray

32 - Housing lower part

1. With air distribution housing
2. Disassembling and assembling --> «Bottom section of housing and air distributor housing, disassembly and reassembly»(ref-289225-S42340353562008062700000)
3. Air distribution housing, disassembling and assembling --> «Air distributor housing, disassembly and reassembly»(ref-289225-S28854969932008062700000)

Scheme 187

A - Screw

B - Recirculated air flap

C - Shaft

D - Bracket

E - Screw

F - Connecting element

G - Cover (different versions)

Scheme 188

A - Screw

B - Air flow flap

C - Shaft

D - Bracket

E - Screw

F - Intake with seal (to hood)

Sealing connection of covers

1. Before installing intake housing, seal housing joint in areas - C - and - D - thoroughly with silicone adhesive sealant D 176 001 A3 .
2. Seal grommet through which wiring harness is routed into air conditioner (to Fresh Air Blower Control Module J126) with silicone sealant D 176 001 A3 (to prevent ingress of water into air conditioner through grommet or past grommet).

Note. If there are complaints about humidity (condensation build-up on windshield, odor), a sponge rubber strip 3 mm - A - must be inserted as far as areas - B - in addition to sealing measures described. In the area marked - B - , in which the groove is narrower, there should be no sponge rubber strip. Use commercially available sponge rubber strip, soft type 3 mm.

Scheme 189

1 - Seal

1. Replace

2 - Frame with recirculated-air opening

3 - Wiring harness for heating and A/C unit

1. Different versions on vehicles with or without Rear A/C Control Head (Climatronic) E265 , vehicles manufactured up to and as of 12.03 (different A/C units and grommets, gradual introduction)
2. Electrical connections on heating and A/C unit: --> Electrical Wiring Diagrams, Troubleshooting and Component Locations

Note. Mark all connectors before disconnecting from electrical components (risk of interchange) After assembly, reattach all wiring harness brackets removed. Seal grommets in plenum chamber through which wiring harness is routed into A/C unit (to Fresh Air Blower Control Module J126) or beneath covers (to Air Flow Flap Motor V71 and to Recirculation Flap Motor V113) with silicone adhesive sealant D 176 001 A3 (to prevent ingress of water through or past grommet into A/C unit or actuator).

4 - Housing lower part

5 - Pipe bracket

1. For upper left coolant pipe

6 - Pipe bracket

1. For coolant pipe, lower left

7 - Oval head self-tapping screw

8 - Pipe bracket

1. For right coolant lines

9 - Grommet

1. For coolant pipe, lower left

10 - Grommet

1. For upper left coolant pipe